EPPM 16.1

January/February 2014

Polymer banknotes:

boost for the industry or

publicity minefield?

13

23

head office

27

Carlton House, Sandpiper Way, Chester Business Park, Chester, CH4 9QE. Tel. +44 (0) 1244 680222 Fax. +44 (0) 1244 671074 Web: www.eppm.com C.E.O/publisher mark blezard C.O.O duncan wood

editorial editor david gray david.g@rapidnews.com

production

IN THIS ISSUE MACHINERY REGULARS: Latest news ARTICLE: Two-shot components possible in single-shot process COMMENT: All-electric: What are the Opportunities?

FEATURE: Testing & Inspection FEATURE: Pipe & Profile

MATERIALS

pages 5–15 6–11 5 12 13–14 15

pages 16– 23

REGULARS: Latest news

18–22

ARTICLE: Predicting the Plastics Colour Palette

16–17

FEATURE: Engineering Materials

APPLICATIONS

23

page 24–25

ARTICLE: Polymer Banknotes

INDUSTRY NEWS

pages 26–33

REGULARS: Latest news

28–33

ARTICLE: Chinaplas

26–27

CLASSIFIEDS

pages 34–35

art samantha hamlyn production peter bartley production tracey roberts

advertising advertising manager lucinda nicholls tel: +44 (0) 1244 680222 lucinda.nicholls@rapidnews.com

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European Plastic Product Manufacturer is published by Rapid Plastics Media Ltd. Each issue is distributed in print and digital format to 17,845 buyers and specifiers in the European plastic processing industry.

Volume 16 Issue 1 © February 2014.

While every attempt has been made to ensure that the information contained within European Plastic Product Manufacturer is accurate, the publisher accepts no liability for information published in error, or for views expressed. All rights for European Plastic Product Manufacturer are reserved, and reproduction in part or whole without written permission is strictly prohibited.

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JANUARY/FEBRUARY 2014 • WWW.EPPM.COM • 3

“

FROM THE EDITOR

Ruminations on a shields up approach to muggles

12

24

I’ve written a lot recently about changing perceptions of plastic, about educating the average consumer and about the perils of the national press.

It’s my belief that the PR industry has a huge role to play in disseminating accurate data that doesn’t seek to decry our most valuable resource — plastic.

However, a recent discussion with a friend caused me to analyse a closeddoor approach — or a ‘shields-up’ approach, for the Star Trek fans. The suggestion from said–commentator was that by offering up snippets of data, accurate or otherwise, we leave ourselves vulnerable to attack — even when we think we have nothing to hide.

To me, my friend’s approach is too cynical. It implies that the non-plastics community — muggles, for the Harry Potter fans — are not capable of making informed decisions.

This is wrong, and it’s the reason I don’t accept the closed-door approach. Of course people can make informed decisions. So, again, the responsibility lies with us, and our PR efforts, to make sure we fight our corner.

The article on pages 24-25, which is prominently illustrated on the front cover of this issue, takes as an example the recent announcement here in the UK that we will

soon adopt polymer substrates for our banknotes.

Granted, in the rest of Europe this issue doesn’t present itself as a huge bone of contention. But I’m running the article to draw attention to the issue of publicity in plastics. Do we do enough to support ourselves?

In other, more practical news, over the page you’ll find a technology which has garnered much attention on our website, eppm.com, for its innovative approach to moulding items which would typically be two-shot parts, in a single process.

It’s the most recent and perhaps one of the more refined methods available to moulders who have a need to overmould without over-spending.

In materials and design news, masterbatch giant Clariant offers its predictions for trends to come in packaging and consumer appeal, and we have some major automotive applications in our special feature on engineering plastics.

Finally, on the subject of moulders, Nigel Flowers, MD of Sumitomo Demag UK takes the floor in the first of our processing opinions series - which opens with injection moulding.

Next issue we’ll be hearing from a guest from the arena of film and sheet extrusion.

”

16 4 • WWW.EPPM.COM • JANUARY/FEBRUARY 2014

MACHINERY

Article

TWO-SHOT COMPONENTS POSSIBLE IN

SINGLE-SHOT PROCESS An example of the process in use. This brush handle was previously moulded from black high impact polystyrene (HIPS). With the new Twinshot equipment, the moulder produced a ‘soft-touch’ handle with a TPE skin, while retaining HIPS as the core material.

A new patented technology package has been launched which produces twocomponent parts in a single moulding cycle with a single screw, single shot and single recovery. Nordson Xaloy, the developer of the equipment says that the set-up requires substantially less investment than more complex coinjection moulding systems that use separate injection units.

Called Twinshot, the Nordson Xaloy system replaces a standard screw and barrel with counterparts designed to produce two-component parts. It is available as an option on new injection moulding machines and as a retrofit that can be installed in one or two days.

However, the group says that the Twinshot system is limited to simple ‘A-BA’ sandwich structures and cannot be used for hot-runner moulding or on equipment with L/D ratios less than 20:1.

Within these limitations Nordson Xaloy says it can process ‘a wide range’ of resin and colour combinations and can be switched back to single-material moulding.

“While resin typically accounts for well over half of the cost of producing a part, two-component moulding makes it possible to optimise the trade-off between material function and cost by using two different resins instead of one,” said Anton Hagen, Global Product Manager for screws and multi-material moulding. “The low investment cost of Nordson Xaloy’s Twinshot system and

the ease with which it can be retrofitted make the economic benefits of coinjection moulding accessible to more plastics processors. In addition, the system is simpler to operate than coinjection machines with two injection units, takes up less space, and uses less energy.”

The two-component moulding process allows the user to confine more expensive speciality materials to the outer skin layer, and use general-purpose or recycled materials in the core. Similarly, the moulder can

use it to produce parts with a structural core and a cosmetic exterior, for example, by combining a ‘soft-touch’ TPE skin with a rigid core, or a more aesthetic exterior teamed with a foam core for a reduction in weight and moulded-in stress, bringing elimination of warpage and sink marks.

Mr. Hagen cited the case of an automotive mirror housing that entailed costs of $5.00 for material and $1.00 for energy. “With coinjection, a 15% saving in material costs is easily obtainable, reducing the resin cost per part by $0.75 and cutting the total cost per part by 12.5%.”

The Twinshot system includes

a screw with two independent melting zones and a barrel with two feed ports.

The skin material is fed into the first port from a standard hopper or volumetric feeder. The core material enters via the second port and is metered into the system by an auger feeder with speed control. Other components are a dualpurpose non-return valve and an ‘Eliminator’ nozzle tip. Layer thicknesses are controlled by the speeds of the primary screw and the auger screw.

The mould cavity fills in a single shot.

Injection of the two materials through the same gate (or gates) is generally sequential, though the group says there is ‘some amount’ of simultaneous injection. The skin material cools against the mould walls as the molten second material fills out the core. The result is a three-layer, or A-B-A, sandwich structure with the B, or core, layer completely encapsulated. The ratio of core to skin depends on the relative viscosity of the materials as well as on part geometry.

When using multi-cavity moulds, a balanced fill is a necessary condition for optimal use of the Twinshot system.

Ideally, the melt front should reach all surfaces of the cavity simultaneously.

A video illustrating the Twinshot process is posted on the EPPM website. Visit www.eppm.com and search for Nordson Xaloy.

Nordson Xaloy Web: www.xaloy.com

JANUARY/FEBRUARY 2014 • WWW.EPPM.COM • 5

MACHINERY

News

Filling and discharge frames re-designed “from the ground up” Italian machinery manufacturer Beccaria S.r.l has launched updated models of its big-bag discharge and big-bag filling frames.

The group says that the updated filling frame has had a “ground up” re-design.

The arms for holding the bag have been modified to provide greater strength and can be positioned to accommodate different bag heights by locating a pin in a series of holes in the uprights. The central filling tube is telescopic so can also be set at the appropriate height for the bag being filled.

Beccaria says that ergonomics and safety have also been improved for the operator with the addition of a fixed ladder to access the neck of the bag.

The bag clamping system allows the operator to use one hand to hold the bag in position whilst the other hand remains free to secure the neck of the bag. The filling frames are available with or without a load cell weighing system.

Beccaria’s new big-bag discharge frames are available in two versions: one intended to be loaded using a fork-lift truck, and one for use with pallet trucks.

The pallet truck version has an integrated electric hoist for lifting the bags, with galvanised steel guides for directing the bags into the correct position. The fork lift truck version has a galvanised bag lifting frame which can be set at different heights depending on the size of bag being used.

The bag support funnel is isolated from the main frame using anti-vibration mounts and there is a mounting point on the discharge funnel for a vibrator if it is required for the type of material being processed.

For materials which require a greater level of agitation a bag massaging system is also available. The discharge funnel features a large rubber gasket

to seal the base of the bag against the discharge frame preventing the escape of dust, and beneath the funnel there is an access door to allow the user to untie the bag with a screen for catching any

bag fragments or other large contaminants.

Beccaria Web: www.beccaria.it

Vacuum dryer claims increased moulding productivity Extensive production-scale demonstration runs with a wide range of resins have shown that a new type of vacuum resin dryer introduced by Maguire Products, Inc. less than a year ago exhibits greater throughput than originally specified and achieves required dryness in just 35 minutes after a cold startup, the company has announced.

The Maguire VBD 150 vacuum dryer, originally rated for a throughput of up to 68 kg per hour, has reportedly achieved 90 kg per hour with hygroscopic materials such as ABS, acrylic, nylon, polycarbonate, polyetherimide, and PBT, according to Pat Smith, Maguire Vice President of Marketing and Sales.

Two additional features have now been developed for the dryer: an “EasySlide” mechanism that enables the vacuum vessel to slide out, giving ready access for cleanout; plus, an optional hopper extension whose 0.028 m3 capacity extends the throughput of the dryer by 25%.

“Vacuum drying is six times faster than with desiccant systems, which not only makes possible much shorter cold startups but also reduces the risk of material degradation, since resin is exposed to elevated temperature for 80% less time,” said Mr. Smith. “This remarkable drying speed is attributable to a far more efficient method for extracting moisture from resin pellets — so much more efficient that vacuum dryers reduce energy

consumption by up to 60% in comparison with desiccant dryers.”

The VBD vacuum dryer uses gravity to move material through three vertically arranged vessels, with the discharge of material from one vessel to the next controlled by slide-gate valves. From top to bottom, the vessels include a heating hopper that brings resin to a target temperature; a vacuum vessel in which vacuum reduces the boiling point of water, causing moisture within the pellets to volatilise and be forced out of the pellet into the low-pressure environment surrounding it; and a pressurised retention/take-away hopper that is continually purged by a membrane air dryer to maintain the target level of dryness until the material is discharged. This system eliminates most moving parts, in particular the three-station indexing carousel mechanism of the Maguire LPD vacuum dryer introduced in 2000.

The new EasySlide feature involves the

vacuum vessel, which slides out in the style of a drawer and is held in that position during cleaning. The feature gives access to the retention hopper as well as the vacuum vessel.

Maguire Products, Inc. Web: www.maguire.com

Plastek takes on new product handling set-up

Han Jin underwater pelletizers to be sold in Europe

Plastek UK has taken delivery of a new automation system for its product handling, delivered by UK firm UPM Conveyors. Plastek is a specialist in the design, manufacture and decoration of packaging for the personal care; cosmetics; pharmaceutical and food markets, which uses a range of injection and injection blow moulding machines.

UPM Conveyors installed the first system for Plastek UK in 2005 and has now completed its third additional system. Operation is managed on an HMI touch screen control, allowing finished parts to be transferred from the injection moulding machine, directly to the fully automatic assembly and packaging lines with no manual involvement. This is achieved with the incorporation of multi-way diverters, which are based on a Queen’s Award winning conveyor design from UPM. Under press reversing reject belt

ips Intelligent Pelletizing Solutions of Germany has announced that it has taken over exclusive European sales and service for strand pelletising systems from Han Jin of South Korea.

As a result, ips can now offer complete underwater strand pelletising systems including the matching periphery up to a working width of 1,200 mm and a maximum throughput of 18 t/h. In conventional strand pelletising systems, the ips range of products will now be extended to working widths of up to 800 mm.

The group says it now plans to focus on meeting the requirements of customers with higher throughputs.

Han Jin Ind. Co., Ltd. produces and sells strand pelletising systems. Since 1983, the group has supplied more than 500 strand pelletising systems for the production of virgin polymers (PET, PS, SAN, ABS, PA6/66, engineering plastics, etc.) in the

conveyors operate via the machine control to ensure that only good product is kept. From here, the good parts are transported via swan neck belt conveyors to high level conveyors, minimising floor area occupied. They are then passed through a fire-wall to assembly/filling lines.

UPM Conveyors Web: www.upm.co.uk

6 • WWW.EPPM.COM • JANUARY/FEBRUARY 2014

Gerald Weis, Managing Partner of ips (left), with Young Sool Yoon, President of Han Jin compounding and recycling industry for the South Korean and Asian markets.

Han Jin Ind. Co., Ltd. Web: www.hanjinind.co.kr ips Intelligent Pelletizing Solutions GmbH & Co. KG Web: www.pelletizing.de

MACHINERY

News

“Build-a-part” service launches for hot runner users Fast Heat Inc. has launched an online ‘custom builder’ for hot runner users to purchase new or spare cables and connectors.

The online store at www.fastheat.com features a “Custom Cable & Connector Builder” that allows users of hot runner controllers to find, combine, and order the components they need. As well as making purchases, visitors can use the online store to maintain histories of constructions that they have bought or plan to buy and to communicate with others in their company regarding purchase orders.

The store features a ‘dashboard’ for building customised components. Using drop-down menus with photos keyed to each selection, the user can build a component consisting of cable and controller- and mould-side connectors.

Options span the full range of cable and connector types available from Fast Heat and include the capability for colourcoding. An estimated price is automatically generated for each cable construction.

The site also features a ‘Wishlist’ for cable constructions. After custombuilding a component, the customer can send the design directly to the shopping cart for purchase or store it in a wishlist pending further action. The wishlist can be shared with others via email, allowing the user to refer a design to others in the company for comment or revision, or to secure a purchase order.

“Fast Heat’s new online store makes it easy to specify the cable constructions that exactly meet the requirements of a

particular moulding operation and to streamline the process of authorising and placing an order,” said Deborah Dynako, Marketing Manager, Fast Heat.

“Reordering is easy as well, since the order history maintained on our site for each customer eliminates need for separate records of part numbers and other details.”

Direct access to the Custom Cable & Connector Builder is available at http://fastheat.com/store/index.php/fastheat-custom-cable.html Fast Heat Inc. Web: www.fastheat.com

Spanish screw/barrel firm expands in Europe Husyca, a Spanish manufacturer and repairer of extrusion and intrusion screws and barrels is expanding in Europe with the appointment of a UK representative to service the industry.

Husyca has been providing precision manufactured replacement, refurbished and repaired screws and barrels to companies in Spain, France, Portugal, Mexico and Brazil for over 30 years.

The group says it can build every type of chamber or screw for plastics, thermoplastics, rubber, silicon, etc. Husyca also offers repair services, restoring parts to “the same characteristics and dimensions as the original”.

One of the firm’s offerings is HusycaBernex, a bimetallic treatment used to cover the interior of the chambers. It is said to reduce the impact of wear and tear when using materials with high loads, such as glass fibres, calcium carbonate, talcum powder etc.

Husyca says it seals its screws with powder welding technology, which reduces abrasion, corrosion and the accelerated wear and tear from more resistant materials such as tungstencarbon, colmonoy, stellite, etc.

The company claims it can manufacture or repair the majority of screws and barrels within 15 days from receipt of component, and offers a free collection and delivery service on most orders.

Husyca Web: www.husyca.com JANUARY/FEBRUARY 2014 • WWW.EPPM.COM • 7

MACHINERY

News

Magnetic clamping claims two second changeover

Sepro’s 2013 order books hit new record

Roemheld claims that its M-TECS magnetic clamping plates can reduce set-up and changoever times to as little as two to three seconds and dies of all sizes can reportedly be installed with a single clamp.

The clamping system has no moving parts and Roemheld also claims that it “is basically maintenance-free”. The full metal clamping surface of the elements enables users to avoid standardisation of die sizes and clamping edge heights.

The components are suitable for vertical and horizontal use in machines and can be retrofitted onto most presses and punches. The plate thickness ranges from 47mm to 85mm (with an integral heating system) and the sizes and geometry of shapes can designed to meet a customer’s specific requirements.

The technology is based on the principle of a permanent electric magnet for safety in the event of a power outage. Power is required for one to two seconds to magnetise the system at the start. During operation, the system is independent of the power supply and power is only required again to unclamp the die.

Full-surface magnetic forces of between two and 12 kg/cm² and clamping forces of between 500 and 2,000 kN act on the plates. The square pole magnets of the Roemheld plates mean that even small dies can be clamped without auxilliary devices. In addition, the full-surface clamping force enables the top and bottom die halves to close reliably

Robotics supplier Sepro Robotique has stated that 2013 will enter the record books as the best sales year ever in its 40-year history.

The group states that in the last 12 months it has sold 1650 robots and sprue pickers to customers around the world — a 26% increase on 2012. Jean-Michel Renaudeau, CEO of Sepro, La Roche sur Yon, France, acknowledged the overall strength of the global plastics market, but noted that several other factors played into his company’s success this year.

“Over the last five years,” Renaudeau said, “we have invested heavily in the development of new robot technology, expanding our presence in key global markets, and building strong partnerships with automation specialists and injection moulding machine manufacturers. Our product line is almost completely new in the last three years and now includes new 3-, 5- and 6-axis robots as well as specialty robots for inmould labelling, two-material moulding and three-plate moulds. Our Touch and Visual control systems are also evolving so that customers can have the same easy-to-use platform whether they need the simplest 3-axis functionality or complex multi-axis capabilities inside and outside the moulding area. Finally, our close ties to injection-moulding OEMs mean processors can get all the benefits of Sepro technology in a complete and integrated moulding package. No matter what their application, no matter where they are located, no matter what their operating parameters, Sepro has options that can meet their needs. That is what we call ‘Your Free Choice in Robots’ and we think that is why more and more companies are choosing Sepro robots every year.”

Another boost for the group was its participation at K 2013. Exhibiting with a

during the production process with no deformation, true to position and in parallel, says Roemheld. This helps to reduce both wear and maintenance costs.

An additional control system permanently monitors the magnetic power, die position and temperature throughout the working process.

Bill Neal, Joint Managing Director of Roemheld (UK) Limited, said: “In general terms, magnetic clamping systems are the best solution whenever frequent die changes are required, downtimes need to be reduced or it would be impossible or too expensive to standardise clamping edge heights and die sizes.

This technology is also suitable for large die sizes and heavy weights, which require significant levels of power and a great deal of time to be clamped, for instance on large presses and punches in sheet metal forming.”

Roemheld Web: www.roemheld.co.uk

bigger stand than in previous years, Sepro says it has made contact with 65% more customers and prospects than at the previous show in 2010.

In 2008, Sepro Robotique was mainly a European supplier, with nearly three quarters of its sales France, Germany and other European countries. Today, sales outside Europe have increased by almost half. North America has become Sepro’s largest market with more than 20% of global sales, Latin America has jumped to 10% and Asia has doubled its share. At the same time, sales in Germany have held steady while most other European regions have seen significant increases.

The growth in North America and Germany, Sepro’s top two global markets, has been supported by moving these regional daughter companies into new expanded facilities and by adding personnel.

In 2012, Sepro Germany made the move to a new plant in Dietzenbach near Frankfurt. Not only did the new building offer more space for administration and sales, but it also opened about 700m2 of floor space for robot engineering, assembly, testing and training. Sepro Germany also strengthened its sales and service staff. Elsewhere in Europe, daughter companies in the UK, Spain and the Benelux countries are also growing along with Scandinavia and Eastern Europe, where Sepro is represented by independent distributors.

Sepro Robotique Web: www.sepro-robotique.com

‘identiPol’ system upgrades with MFI indicator Plastic quality assurance specialist Lacerta Technology has announced an expansion in its identiPol range of testing equipment (see the testing and inspection feature for more information).

The identiPol QA2 from Lacerta Technology is a tool designed for checking and identifying incoming plastic material into the production area. Lacerta says it has now had its functionality increased by adding the Actual MFI identiPol calculated MFi ability to quickly give an (g.min-1) (g.min-1) indication of the Melt Flow 3.00 3.3 Index of thermoplastics.

7.0 6.6 This new capability has 12.0 12.0 been named Melt Flow Indication (MFi), as MFI is 18.0 19.3 not measured directly.

25.0 23.7 However, for common PE and PP materials (with others to follow) obtained from the identiPol QA2 with the system can be set-up to offer a quick actual MFI results. indication of the MFI. The chart shows some typical results of Lacerta Technology the calculated Melt Flow Indication (MFi) Web: www.identipol.com 8 • WWW.EPPM.COM • JANUARY/FEBRUARY 2014

MACHINERY

News

Samvardhana Motherson Peguform makes €10mil capital investment Samvardhana Motherson Peguform (SMP), a manufacturer of plastic parts for the automotive sector has placed a machinery and systems order with The Frimo Group worth over €10mil.

The installation will be used for back-injecting, laminating, punching and edgefolding natural fibre door panels. The agreement took place following a successful prototype phase with Frimo.

Substrate pressing is carried out using an ‘all-in-one system’ with tools for manufacturing door panels by back-injecting natural fibres, says Frimo. This allows the (previously individual) steps of hot pressing semifinished sheets (e.g. natural fibre mats) and backinjecting to be combined into a single process.

The elements Frimo will install comprise a mat magazine, mat aligner, sizing press, mat transporter, forming press, forming tool, component remover, tool changer and a control system for the entire set-up.

The double design of the mat magazine allows materials to be changed without interruption. Material or job changes are possible without stopping the line. A flexible robot solution is used for mat alignment. Frimo says that the sizing press is designed to ensure that a precise sizing thickness is maintained across the entire product.

Adjustment to the tools, minimal waste and top speed tool changes were key factors in the forming press design, says the group. The system is centrally controlled, with the option of using a mobile unit.

The project also includes complete laminating, punching and edge-folding technology. Frimo sold the package on the basis of its ‘full flex’ laminating system concept, designed for fast tool changes. In addition, the recently developed ‘Frimo advanced cooling system’ (FACS) permits the film to be cooled more, but with no impact on time, which, Frimo says, allows a ‘superior initial adhesive bond’.

SMP opted for a combined edgefolding and punching concept which can also produce different component variants without tool changes. The inline system is also equipped with a ‘smart energy’ heating system.

SMP says that it expects the all-in-one substrate pressing, laminating, punching and edgefolding package to be of benefit in the design of standard tools and systems. This was an important aspect in commissioning the serial equipment. Frimo is responsible for coordinating the interfaces between the tooling and systems technology. In addition to this, the group will also carry out integration and project management for any additional scope included in the

project by SMP, e.g. injection units including material supply and peripherals.

Frimo Group GmbH Web: www.frimo.com

Recycler closes the loop with huge extruder investments VEKA Recycling Ltd claims it is closing the recycling loop with its investment of almost £1 million in its UK facility to produce high-quality recyclate suitable for a wide range of new PVC-U extruded products.

A new compounding line installed at its Kent site enables VEKA Recycling, an accredited Recovinyl recycler, to supply UK and European markets with PVCU pellet derived from post-industrial or post-consumer window frame material. This is in addition to the existing supplies of both pellet and micronised PVC-U (pulver) from its German and French factories.

Tony Cattini, Managing Director of VEKA Recycling, said this investment in UK capacity will help to meet continuing demand for recycled content in new products with all the associated economic and environmental benefits for manufacturers and consumers.

“It also underlines our commitment to progressive growth and development in this sector as well as continuing to offer a sustainable and reliable outlet for PVC window waste,” he said.

Observing ‘encouraging trends’ going into 2014, Tony added: “We have a new string to our bow now we can supply directly from our UK factory, offering a quality

and consistent supply to manufacturers.

“More businesses are recognising the tangible economic and environmental benefits of recycling PVC and we have already had interest from a number of major players in the UK. With our new push into the extrusion market we can now offer a closed loop solution in our home market.”

Simon Scholes, VEKA Recycling’s Business Administration Manager, explained that the approach fits in with Recovinyl’s ‘Pull Market Concept’, involving both the existing recycling network and converters. This concept has been created to support the re-use of as much post-consumer and post-industrial PVC from the market as possible by stimulating the regular use of recycled material in production processes.

“This is becoming more widespread with recycled PVC being used in new window profiles such as VEKA’s Infiniti, as well as other plastic building products,” he said. “We will also continue to focus on maintaining high quality standards of waste PVC frames.

“Quality counts when it comes to recycling waste PVC and feedstock contamination levels impact on the value of goods that can subsequently be made from the recycled material. We want to see old frames going

back into new windows and this is achievable provided the quality is right.”

Simon also added that enquiry levels are rising from building companies seeking a dependable partner to recycle their PVC window waste as the economic recovery in the construction sector gathers pace.

VEKA Recycling Web: www.veka-recycling.com

New efficiency guidelines for extrusion blow moulders Euromap 46 is the second new recommendation to deal with the energy efficiency of plastics machinery. Following publication in January 2013 of the revised Euromap 60 on the energy efficiency of injection moulding machines, the first results of which were shown at K 2013, the new Euromap 46 recommendation is concerned with the energy efficiency of extrusion blow moulding machines. It follows the basic concept of Euromap 60 in distinguishing between machinerelated and product-related energy consumption. Part 1 therefore contains a classification of machinery using a defined test cycle, while Part 2 deals with the measuring methods used to determine the specific energy consumption of products according to customer demands.

Energy efficiency is increasingly important for European plastics and rubber machinery manufacturers. EUROMAP recommendations allow firms to communicate their performance data in this field simply and transparently.

Customers can also use the information to make comparisons.

Further recommendations covering more types of machinery are being prepared.

Euromap Web: www.euromap.org JANUARY/FEBRUARY 2014 • WWW.EPPM.COM • 9

MACHINERY

News

Recycling line tackles plastic-plastic and plasticaluminium laminates

Peugeot subsidiary upgrades to high-tech tool change system

German sorting and recycling processor Saperatec GmbH has commissioned an industrial pilot plant based on a new patented process for the processing of plastic-plastic and plasticaluminium laminates. In addition to processing packaging materials and beverage cartons, the plant is also able to recycle automobile glass or photovoltaic modules.

Based on the group’s work with microemulsions, Saperatec claims to offer “a completely new and unique possibility to separate composite materials and, thus, to recover the individual components as clean secondary raw materials”. The separation process takes place inside the plant: from treating the composite material in the micro-emulsion, via the washing of the separated materials all the way to the recirculation of the microemulsion and sorting of the individual fractions.

“Per year, composite materials with a value of more than a billion Euros are thrown away. With a recycling quota of 100%, our wet-chemical process provides for a sustainable raw materials industry”, said Saperatec’s Managing Director, Jörg Dockendorf. “With this plant, which can process up to 500 tonnes of composite material waste per year, we are proving the industrial readiness of our patented process”, said

Faurecia S.A., which belongs to the French group PSA Peugeot Citroen, uses 40 tonne injection moulds which have to be changed several times per shift. Stäubli’s Connectors division installed a new set-up back in 2012 — in the time since, the transfer of dies is now implemented on a rail trolley. In addition, the controls for the mould change system now manage intelligent tool storage. The results, claim Stäubli, are fully automated workflows, the shortest possible routes and reduced machine downtime.

Applications at Faurecia include complete front-end modules, bumpers, sills and various design elements for the premium segment. For the high-quality plastic parts to be finished, sprayed in the vehicle colour and delivered just-intime to the conveyor belts of the OEM, a three-shift operation is in place at the Rhön factory. Production is characterised by small batches; a standard batch for Faurecia only comprises about 250 to 300 pieces.

“Valuable time was often lost during the transfer of the dies”, said Halil Havan, UAP Manager in the injection moulding department at Faurecia. “That’s why the job for our system partners was to create a new solution adapted to the current situation in order to reduce down-time.”

The high-tech steel moulds are moved from the 70m long tool storage facility, fully automatically, into the injection moulding machine on a rail tool shuttle from Stäubli. In one journey, the trolley can deliver the tool, and at the same time, remove the previous tool.

During the change, both dies are briefly on board together. Then the trolley, which has a load capacity of 110 tonnes moves into the correct position, to the millimeter according to Stäubli, where it pushes the tool into the injection moulding machine using a chain-driven push-pull mechanism.

The numerous quick and multi-couplings for media circuits and electrical energy are still coupled manually with the machine in this application by two employees. Further steps in the tool change, such as centering and clamping, take place automatically using a Stäubli clamping cylinder.

Co-managing Director, Sebastian Kernbaum.

The company has also announced that will begin working on customer-specific projects. For this, Saperatec will license the process for industrial plants at customer’s facilities and provide the appropriate micro-emulsions.

Saperatec GmbH was founded in Bielefeld, Germany in 2010 and specialises in developing innovative recycling technologies based on the use of micro-emulsions. The company has a team of ten, comprised of specialised chemists and process engineers. In August 2011 the company commissioned its first pilot plant for the processing of solar modules and has continued to develop this process using micro-emulsions since that time. The group has also won several awards for its technologies.

Saperatec GmbH Web: www.saperatec.de

Stäubli Project Manager, Stefan Patsch, who has supported the project from the planning phase through to implementation, said: “There are many advanced individual systems which dovetail closely within this system solution, and without which such integrated management of the complex processes would not be possible.”

Stäubli says that these ‘individual systems’ include optical scanning systems for precise detection of the positions for tool and trolley, as well as a push-pull system.

Also taken into account during the installation was the integration of optimised warehouse logistics. Halil Havan said: “The control of the tool change system permanently corresponds to the production planning. Once it is decided which of the 37 stored tools is required next, the trolley puts the tool in the exact position in the storage which is the shortest distance from the injection moulding machine in question. Thus, the tool is waiting in “pole position” with the shortest route to the mould, ready to be used, which allowed us to reduce the setup times even further.”

Stäubli (UK) Ltd. Web: www.staubli.com

EU demand means machinery investment for Welsh packaging group Gwalia Packaging Group, a South Walesbased closure and container manufacturer, has announced a new capital expenditure programme worth £1.8M, which will see the group acquire eleven new all-electric injection and blow moulding lines.

The new capital equipment, which Gwalia says will be delivered and commissioned during the early part of next year, will create a seven day, 24hour working system at the company’s Pontypridd plant. This investment is a result of large increases in demand for the group's products across most of continental Europe.

Gwalia consists of two operating companies, Dragon Plastics Ltd, closure manufacturers; and Gwalia Plastics, 10 • WWW.EPPM.COM • JANUARY/FEBRUARY 2014

which makes injection and extrusion blow moulded containers. The group also includes its own tool making and general engineering division.

“Our new injection, blow moulding and ancillary equipment will increase our capacity and at the same time reduce our energy costs. High quality packaging is in increasing demand throughout Europe and I’m pleased we’re able to invest to meet that demand,” commented Rod Parker, Gwalia’s Managing Director.

The new plant and equipment will be financed by the group’s own resources and will be fully on stream by the end of Q2 2014.

Gwalia Packaging Group Web: www.dragonplastics.com

MACHINERY

News

PET training offers fast-track to processing skills

Seminar Locations and Dates

Plastic Technologies, Inc. (PTI), a specialist in PET packaging technology has announced that it will offer a PET training series for those new to the industry, or who require a refresher course in specific areas.

The training will focus on three areas of interest — PET Technologies and Applications, Plastic Packaging for HotFill/Aseptic Beverages and Design of Experiments Practical Application.

“PTI has a long history of helping companies successfully commercialise new packaging for well-known global brands. Our annual training seminars enable us to deliver the knowledge our professionals have amassed over the past 25 years to a broader audience,” said Ron Puvak, Director of Business Development and Marketing, PTI. European classes will be taught at PTI’s European location in Yverdon-les-Bains, while US classes will take place at the group’s corporate headquarters in Holland, Ohio.

Additionally, the March and November Switzerland dates will have separate oneday add-on training modules for PET barrier materials and PET recycling.

The multi-day PET Technologies and Applications training program will include instruction on material/resin properties, material handling and drying, injection and blow moulding basics, package development fundamentals, heat-set technologies, quality assurance and testing, and the latest recycling information. PTI says that the training targets those professionals seeking fundamental PET knowledge, or those who may benefit from a refresher course.

The two-day Plastic Packaging for HotFill/Aseptic Beverages training module

March 17-18 March 19 March 20 March 25-27 May 20-22 June 10-13 June 17-18 Sept 9-11 Sept 30-Oct 1 Oct 21-22 Nov 11-14 Nov 17-18 Nov 19 Nov 20 Dec 2-4

will include the latest technical information on PET, as well as polypropylene, bioplastics and other materials that are suited for these applications. Also included in this module will be the basics of noncarbonated packages, beverage packaging material compatibility and associated filling technologies. A recommended prerequisite for this course is a basic knowledge of PET, including properties and processing. This is covered in the PET Technologies and Applications training.

Plastic Technologies, Inc. Web: www.plastictechnologies.com

Course: Technology & Application of PET Course: Barrier Technology Course: Recycle PET Technology Course: Technology & Application of PET Course: Technology & Application of PET Seminar: Design of Experiments Practical Application Course: Plastic Packaging for Hot-fill / Aseptic Beverages Course: Technology & Application of PET Course: Plastic Packaging for Hot-fill / Aseptic Beverages Course: Plastic Packaging for Hot-fill / Aseptic Beverages Seminar: Design of Experiments Practical Application Course: Technology & Application of PET Course: Barrier Technology Course: Recycle PET Technology Course: Technology & Application of PET

Europe Europe Europe US US US US US Europe US US Europe Europe Europe US

New paper reveals future of temperature control West Control Solutions has released a new technical white paper that examines the changing face of industrial temperature control technology. The paper looks at how the development of controller technology has reacted to the changing demands of users to create powerful new solutions and predicts how future developments will further boost process performance and efficiency.

Industrial temperature controllers have changed considerably over the last fifty years. The introduction of digital controllers in the 1980s, for example, represented a major step change in temperature control technology. The guesswork that had previously been involved with setting controllers was eliminated as dials were replaced by pushbuttons and digital displays.

As well as examining the historical development of temperature control technology, the new white paper outlines influencing trends of today and how temperature control might change in the future. With the development of increasingly smart technology, modern temperature controllers are highly sophisticated, automated and allow for customisation.

To read the full white paper visit: http://www.west-cs.com/lp/whitepaperthe-changing-face-of-temperature-control/ West Control Solutions Web: www.west-cs.co.uk JANUARY/FEBRUARY 2014 • WWW.EPPM.COM • 11

COMMENT: Injection moulding

Article

ALL-ELECTRIC:

WHAT ARE THE OPPORTUNITIES? Words: Nigel Flowers, Managing Director at Sumitomo (SHI) Demag UK All-electric or hydraulic? In injection moulding, the question may not be a new one, but it is one which is becoming increasingly relevant to greater numbers of processors. Why this interest? Since the beginning of the 1990s, when the first all-electric machines were snapped up by early adopters in European markets, margins have shrunk for many.

Meanwhile, the cost of energy has escalated across the board. And at the same time, companies are looking to improve repeat accuracy in their manufacturing.

Over recent years, sources including Euromap, the European association of plastics and rubber machinery manufacturers, have estimated that while some 80% of injection moulding equipment sales in Japan

were all-electric, and around 50% of US sales (possibly more), the European figure was closer to 20%.

Of course, it could be argued that enduse applications and market conditions are different in Europe. But might it be that many moulding businesses are only now starting to take a closer look at the relative efficiency and profitability of different systems?

In today’s climate, would it make sense for more end users to focus on where their North American and Asian counterparts are benefitting from a shift to all-electric? I think it would.

It is true that the complexity of injection moulding equipment markets is much greater than it was a few years ago, with larger numbers of hybrid systems, more efficient hydraulic machines and specific options and devices for energy saving. It is also true that, for a serious processor willing to put in the research, there is more detailed and accurate data available from manufacturers and organisations than ever before.

Whatever the conclusions of individual processors, the all-electric story remains a compelling one.

Direct drive machines have frequently been shown to offer major improvements in efficiency, giving processors many advantages over conventional hydraulic machines. These advantages include a reduction of up to 75% in energy usage during operation and improved repeatability and fast cycle times.

Electrical drives consume less power for the main movements of plasticising (which typically accounts for around a half of energy consumption), injecting and opening the mould. Because less heat is generated, cooling requirements are reduced, too.

There is much talk about the efficiency of

12 • WWW.EPPM.COM • JANUARY/FEBRUARY 2014

electrical direct drives. But what does this mean in practice? By avoiding the need for gearboxes, they also avoid the friction and loss of energy that these entail. And importantly, kinetic energy can be recovered through the use of multiple frequency drives installed on a common power bus. This means that the braking energy of one drive can be passed on to another via the inverter, rather than being lost. So, for example, while the clamping unit is braking, the energy generated can be used for the energy-intensive step of plasticisation.

Hand-in-hand with electrical drives comes digital control. Delivered via encoders, this fine control ensures that the movements of the machine are more precise. Both machine precision and maintenance requirements are helped by the fact that all-electric systems have fewer moving parts. Additionally, there are fewer variables in the process, with no stretching of hoses, sticking of valves and no hydraulic fluid to heat up or compress.

Once set up correctly, the injection moulding machine runs without the need for any adjustments. So, for instance, the screw position during filling and hold is digitally controlled, allowing just the right amount of material through, optimising resin usage and preventing unnecessary stress to the mould.

Accurate dosing of the mould is doubly important in the production of highprecision plastics, and the non-return valve has often constituted a weak point in the process. Traditionally, systems only closed passively through the pressure applied during the injection phase. In fact, the most advanced all-electric systems, including our own, have addressed this issue through an active closing mechanism on the non-return valve.

This means that, once dosing is complete, the valve can be closed, positively and securely, during the injection and hold stages. In this way, fluctuations in the melt viscosity do not

need to have a knock-on effect on closing behaviour, melt cushion, shot weight or – ultimately – the quality of the final part.

Certain sectors have recognised the specific benefits of an all-electric approach to moulding. For precision industries such as medical appliances, tight tolerance requirements are key, and a combination of electric drives and digital control can turn injection moulding into a predictable and precise operation.

Weight variations in critical parts can be as low as 0.0001g, which means less waste and happier customers.

There are other advantages for hygienesensitive food and medical production environments. Unlike traditional hydraulic machines, all-electric systems have no consumables, such as oil, and no filters requiring regular replacement. There is no risk of fluids leaking, nor of resulting contamination. Consequently, ‘housekeeping’ requirements and downtime on electric equipment can be as little as half those demanded by hydraulic machines. This type of consideration also means it is far easier for producers of all-electric systems such as ourselves to design equipment suitable for clean room operations.

It would be wrong to portray all-electric injection moulding as a universal panacea. Naturally enough, there are types of production which are bettersuited to hydraulic and hybrid systems, notably those higher tonnages typically demanded by the automotive and other heavier engineering sectors.

But although the capital cost of an electric machine may be higher than the hydraulic equivalent, increasing numbers of precision-moulding customers are realising that payback times are not what they used to be. Based on energy consumption alone, savings can easily justify the higher initial investment over a 10-year period, or even less.

FEATURE

Testing & Inspection

Polymer testing gets its own webinar series Smithers Rapra is launching a webinar series focused on helping companies speed up the development cycle for rubber and polymer products with effective testing programs through a variety of stages; from materials science to whole product testing.

“The 2014 series of webinars is designed to show clients how standard and custom testing protocols for rubber, plastics and composites products can benefit the various stages of their product development,” said Todd Hain, Marketing Manager at Smithers Rapra.

“These webinars are designed to be a helpful and educational forum to discuss many common challenges facing product development engineers, chemists and product managers and to connect with Smithers’ experts in these areas.”

The first webinar in the series has already taken place.

“Predicting the service life of polymers in industrial applications” with Dr. Andrew Hulme, Principal Plastics

Consultant, and Jeff Andrasik, Product Testing Supervisor and Senior Test Engineer, was broadcast in January 2014.

The webinar explored the key external factors that affect the performance of polymers; the benefits of independent and complimentary material tests and full product tests and impact the results can have on critical product development decisions. Polymers are inherently variable in their makeup in addition to being time, temperature, environment and stress dependent. Model of life prediction and post-tests can also be applied to get the full picture of performance.

The next topic in the series will cover various tyre testing techniques and will be scheduled for the spring.

Other topics planned for the year will highlight various industry verticals and technologies.

Registration for all 2014 Smithers Rapra webinars and Smithers Rapra additional information can be found at Web: info.smithersrapra.com/webinars info.smithersrapra.com/webinars/.

Data acquisition system improves impact test accuracy Ceast DAS64K and DAS64K-SC, two systems designed

by Instron for high-speed data acquisition within the framework of instrumented materials and components testing, provide a data acquisition rate of 4 MHz, effectively doubling the temporal resolution compared to previous models, the group claims. This development is geared towards testing brittle materials, performing drop weight tests at high speeds, or performing tests at low temperatures. The new data acquisition cards are also available for retrofitting on existing systems without impacting the performance characteristics of these systems, says Instron.

DAS64K-SC provides a single acquisition channel, whereas DAS 64K is designed for simultaneous acquisition of up to four independent channels. Data may originate from a variety of transducers, including standard strain gauged or piezoelectric instrumented tups and hammers, and in the case of the DAS 64K system, from general-purpose transducers supplying a defined voltage or current output. Both models are suitable for use with all current Ceast Series 9000 pendulum impact testers and Ceast 9300 drop towers, as well as with instrumented tups or hammers of legacy models including Instron Dynatup drop towers and nonInstron impact testers. For machine control, data acquisition and storage, and comprehensive data analysis, Instron has also enhanced the Ceast Visual Impact software.

Both data acquisition systems can record and store up to 65,536 data points per test and per channel.

Equipped with 14-bit analogue-to-digital converters, they achieve a bandwidth of up to 700 kHz – depending on the acquisition rate. All relevant parameters such as sample rate, gain, number of data points, trigger mode and trigger level, including the selection of a master channel for triggering data acquisition, may be set from a connected PC.

The Visual Impact software suite used for this purpose is conceived to control Ceast pendulum type and drop weight impact testers and the associated testing procedures, and supports the use of the new data acquisition systems with a user-friendly interface. It saves load and absorbed energy data, and provides features for visualisation and further analysis of acquired data using statistical methods. Recently the software functionality was further expanded with the capability of defining different user profiles for personalised data acquisition and analysis. The introduction of the Ceast DAS 64K and DAS 64K-SC data acquisition systems has resulted in a number of further enhancements. From Visual Impact Version 6, the software is able to manage more comprehensive calibration data sets for instrumented tups and hammers and handle DAS configurations involving a higher number of channels.

Instron Web: www.instron.com

Colour management initiative back by popular demand X-Rite has extended its ‘World of Plastics’ digital initiative due to high volumes of interest and demand for the service. The project aims to give simpler access to colour measurement processes for plastics. Users have access to free eLearning, workflow efficiency checks, and product promotions.

Users can get recommendations based on specification and standardisation. Program registration is available at www.xrite.com/worldofplastics. Upon registering, users have access to all aspects of the program.

“The decision to make use of digital media instead of participating in a major plastics tradeshow enabled us to bring direct benefits to our clients before, during and after the event. As an added benefit, we are able to reach clients without the limitations of distance or time”, said Francesco Tomasello, VP of Sales for EMEA & BIPS. Tomasello added: “Once registered, clients can continue to take advantage of our on-demand program from our colour experts. Like most colour workflows,

controlling colour in plastics is a challenge and tapping into the X-Rite knowledge base gives customers the advantage of our many years of colour measurement, management and communication experience”.

Participants receive a personal promotion code that allows them to use a range of online tools and events, including upcoming webinars and access to the webinar library. They can take part in best practice sessions in managing the plastics workflow, colour formulation and on-line colour measurement. Also on offer as part of the programme is a series of webinars on industry trends. A workflow efficiency check offers a free and individual consulting service associated with the program.

Registration to the program has been extended to 28 February 2014 based on positive feedback and customer requests, says X-Rite.

X-Rite Web: www.xrite.com JANUARY/FEBRUARY 2014 • WWW.EPPM.COM • 13

FEATURE

Testing & Inspection

Polymer training centre chooses ‘identiPol’ system The UK’s Polymer Training and Innovation Centre (PTIC) has added an ‘identiPol’ system to its facility to bring students up to date with the latest plastic testing and conformance technology, says Lacerta Technology, the group behind identiPol. The centre uses identiPol to train individuals starting to work in plastic processing.

Since opening, over a thousand students – both local and international – have passed through the centre to study the production and manufacture of plastic materials.

Darren Vater-Hutchison is a Technical

Trainer at PTIC and has extensive experience in training students both at the college and at customer sites both in the UK and overseas. “We have a wide range of equipment here and we take the students through the entire manufacturing process as part of their studies. From taking a new tool, machine selection and the setting up of the processing parameters, through to the evaluation of the final product. In fact there is very little that we don’t cover in training a process engineer to understand all aspects of plastic manufacturing and production” “Although we have the typical testing

equipment that covers the mechanical and rheological properties, we were very impressed when we first saw the identiPol that it could offer so much more”.

“We were a bit sceptical at first”, VaterHutchison continued.

“The identiPol was so small and yet claimed to do so much. The system hadn’t been on the bench for more than a few moments before we grabbed some material and gave it to Steve Price from Lacerta who was running the machine and said ‘What’s this?’ whilst keeping the bag hidden from him. The identiPol quickly identified the unknown as PA46 and we then started looking more closely at what else it could do for us.”

The identiPol unit can also be used to compare incoming batches of material against known good material before it goes into the production line, as well as comparing different grades from manufacturers for equivalence.

“We think in the design of the identiPol they have got it just right” said VaterHutchison. “It’s not too technical for a new student to pick up and get to grips with during our short courses and apprenticeships. The software is pretty simple and guides them through everything, so there’s no doubt in my mind that it can easily be used on the shop floor and is perfect for ensuring the quality of the manufacturing process” Lacerta Technology Web: www.identipol.com

New device speeds up weatherability tests Atlas Material Testing Technology has released a new weathering instrument suitable for performing accelerated testing on plastic and other materials.

The key features of the mid-sized, aircooled xenon device, which has been named Xenotest 440, are speed and economy of resources.

The system uses lamp operating technology as well as ultrasonic humidifiers to reduce water consumption.

XenoLogic is the name of the group’s twin-lamp operating technology which permits the instrument to reach high irradiance levels of 120 W/m2 of total UV radiation. By testing at higher irradiance levels, test times can be “significantly reduced” compared to standard weathering tests, claims Atlas.

XenoLogic is said to offer an extended lamp service life as it synchronises two 2200 W xenon lamps inside the chamber at the lowest possible stress level, which also leads improved light efficiency. Atlas says that the two xenon lamps combined can last over 4000 hours under standard testing levels of 40-60 W/m2. This increases instrument uptime and reduces lamp operating costs by as much as 30% or more.

Atlas Web: www.atlas-mts.com 14 • WWW.EPPM.COM • JANUARY/FEBRUARY 2014

FEATURE

Pipe & Profile

Product measurement tool designed for pipe extruders Zumbach Electronics has launched a new MSD measuring head series and swivel floor stand for on-line diameter and ovality measurement and control.

The series is designed for applications such as extruded tubes, pipes, hoses, and cables. This new line complements the high-precision laser diameter measuring heads of the group’s ODAC

series. The “Linear Sensor Technology” permits compact and accurate measuring heads.

The MSD features two-coloured LED light sources, allowing simultaneous scanning on each axis (X and Y), thus offering simple measurement accounting for product vibration.

Integrated extraneous light filters prevent

the occurrence of measurement errors often deemed ‘unavoidable’ on previous systems, according to Zumbach.

Reflective surfaces can also be measured thanks to the use of varied coloured lighting for each measurement axis.

Zumbach Electronic AG Web: www.zumbach.com

Extrusions coil faster, with added protection on new machine Conair has launched a new dual-spindle automatic cut-and-transfer coiler designed for high-speed winding of small, flexible extrusions. Nominal line speeds range as high as 243m/min, depending on the size of the extrusion being coiled. Despite high speeds, little or no friction or winding tension is generated, claims Conair, preventing deformities in delicate products. The group is therefore targetting the unit at high-end applications such as medical tubing, small tubes, and small flexible profiles.

“Speed is what sets the Conair ATC coiler apart,” said Chris Weinrich, General Manager, Downstream Extrusion, Conair. “No other coiler in its price range offers these speeds, along with automatic cut-and-transfer. In addition, it is part of a complete line of proven downstream extrusion equipment. From the die to the shipping container, Conair offers multiple

choices for sizing, shaping, cooling, pulling, cutting and handling of extruded products from microbore medical tubing to large pipe and profiles. No other supplier can match our experience or breadth of product line.”

Conair ATC coilers are suitable for tensionless winding of small-diameter flexible tubing. Typical tube diameters are 2.16 to 12.7 mm, while tubes as small as 0.5 mm in diameter can be accommodated with a special minimal tension trim control. Units are available in three different sizes with maximum coil diameters of 61, 91 and 122 cm.

Servo-drive for turret rotation, traverse and spindle speed means high repeatability in speed and positioning control, and minimal product tension during high-speed coiling and cut/transfer. Low tension is ensured by an advanced control algorithm that calculates each successive wrap

diameter to adjust coil speed and traverse relative to the puller speed.

This allows the sonic-loop control to act as a ‘finetuning’ device to ensure error-free lay-on of each wrap. The following circuit allows the winder to automatically ramp up to speed with the line during start-up.

All operating parameters can be saved as a ‘recipe’ for consistency. This includes coil speed changes during cut and transfer.

Automatic turret changeover is completed when a set length of product has been coiled. The system comes complete with collapsible core

assemblies or spools and can also accept customer-supplied spools as an option. All winder components that come into contact with the extruded product are made from stainless steel or are hard-coat anodized.

Conair Web: www.conairgroup.com

Window profile wins bioplastics award A range of spacer profiles for insulating window glazing have won the “Bioplastics Oskar”, an annual award presented by trade publication Bioplastics Magazine. The manufacturer of the profiles is Helmut Lingemann GmbH & Co. KG of Wuppertal, Germany.

The award recognises innovation and achievement from users of bioplastic materials. It was given to Wolfgang Bauer, Head of Quality Management of Helmut Lingemann on December 10th during the 8th European Bioplastics Conference in Berlin. From a list of almost 20 proposals, five judges from academia, the press, and industry associations from America, Europa and Asia selected the five finalists and the winner.

The new spacer system is called Nirotec Evo, and is applied in windows and facades for a high level of insulation to reduce energy losses by using double and triple glazing.

Technical requirements are high strength and structural reinforcement (e.g. tensile modulus), low thermal conductivity, no

fogging when used in insulating glass, and no incompatibility with other components in the insulation of windows and facades.

Together with a partner company, a tailormade blend of different biopolymers based on PLA, biopolyester and further additives were developed.

The group says that Wolfgang Bauer, Head of Quality Management of Helmut about two million Lingemann receives the award metres of Nirotec Evo have been processed into insulating areas that do not come to ones mind glass units to date. The biopolymer ratio immediately. And even though it offers a is approximately 40 tonnes. If Nirotec potential for high volumes of a bioplastic Evo were used for the total annual material,” said Michael Thielen, Publisher production of insulating glass units in of Bioplastics Magazine and member of Europe, about 18,000 tonnes of the jury. “And the application makes use bioplastic material could be applied. of the biopolymers very special “The judges decided for Helmut properties, in this case the mechanical Lingemann’s spacer profiles, because and thermal properties combined with this is an example which shows that the very important feature of ‘no fogging’ potential applications can be found in which is essential for this application.

The Nirotec Evo window profile In addition the chosen biopolymer blend features very special adhesion properties and allows high speed bending procedures of the profiles. Modern thermal insulation technology meets modern materials; this is how ecological development should look like in todays technology age”, said Thielen.

Helmut Lingemann GmbH & Co. KG Web: www.helima.de

Profile extrusion offers strength and aesthetics in construction project A series of extruded profiles made entirely from recycled plastic films and bottles has been used to construct a new walkway suspended across the lake at Watermead in Buckinghamshire, UK. The profiles are part of the Duraplas range from Centriforce Products. They are intended to have the appearance of wood but Centriforce says they are expected to last for at least 40 years.

“The construction solution we developed demonstrated the integral strength of

Duraplas profiles which comes from Centriforce’s extrusion manufacturing process, making it capable of withstanding stresses that other types of recycled plastic profiles could not withstand,” said Ronnie Doctor, Marketing Manager, Centriforce products.

Hugh Roberts, Environmental Consultant at Environments for People, the specialist contractor chosen for the project, said: “The recycled plastic profiles are so versatile to use. They arrive in hundreds

of pieces just like a giant Meccano set ready to be built. The profiles can be drilled, sawn and bolted just like wood and also have a degree of flexibility to be shaped around curves in the structure. On this project we had the added advantage of being able to float the profiles on the lake to transport them to where we needed them.”

Centriforce Products Web: www.centriforce.com JANUARY/FEBRUARY 2014 • WWW.EPPM.COM • 15

MATERIALS

Article

Predicting the plastics

COLOUR PALETTE Clariant has launched its ninth annual colour forecasting guide for the plastics industry – ColorForward 2015. Although not specific to the actual colours, we’ve tried to deduce what some of the ‘trends’ may mean for plastic product design in 2015.

The annual tool from Clariant’s ColorWorks team is designed to identify the trends that will attract consumer attention and pave the hue palette for 2015.

Essentially, Clariant sees it as offering a ‘head-start’ on harnessing colour in design in order to influence and guide consumer purchasing decisions.

It does incorporate a lot of marketing lingo, but nonetheless, the ColorForward guide has been shown to offer a genuine and thought-provoking look ahead at what’s to come. Added to which, its previous predictions have been shown to come to fruition.

“As a natural element, colour has the power to transcend and translate cultural, political, religious and social influences.

As a tool, it has the power to communicate emotions and stories as succinctly as possible.

And in the world of plastics, it acts as the ideal marketing driver to steer consumers’ purchasing choices for the future,” said Judith van Vliet, Designer at ColorWorks Europe/IMEA. The group says that its ColorForward ‘colour predictions’ are based on intensive research of the most influential societal trends around the world. The process includes in-depth presentations from ColorWorks centers all over the world, where regional trends and influences are explored.

Experts from the world’s major trend-watching organisations, and colour experts from diverse creative industries contribute to the process.

16 • WWW.EPPM.COM • JANUARY/FEBRUARY 2014

For ColorForward 2015, colour, design, marketing and polymer specialists congregated at Clariant’s new ColorWorks center in West-Chicago, Illinois, USA to identify the trends and to develop colours that best reflect each trend. The palette selected for 2015 is inspired by four societal trends expected to have the most influential global impact in the near future. Although not specific to the actual colours, we’ve tried to explore what some of the ‘trends’ may mean for plastic product design in 2015 and beyond.

Tune In, Space Out This perceived trend has been formulated based on the rise of digital technology and devices, and the requirement for ‘shutting the world off’. In 2015, Clariant predicts that there will be an emphasis on privacy, silence and switching off digital connections. This trend also appears to incorporate an inter-planetary element, based on the use of the earth’s resources.

Live2Live The second trend is based on the idea that the next generation of workers are motivated by more than just work heralding the end of the ‘live to work’ concept. This - admittedly idealistic notion hones in on the profitability of creative thinkers. Technology is referenced in this capacity - perhaps a hint towards the recent surge in 3D printing on a personal level.

In addition, work is referred to in terms of a ‘game’ - with Clariant picking up on the fact that motivation is often incentivised. This competitive thinking is set to be reflected in consumer design,

Article

“

We’ve tried to deduce what some of the ‘trends’ may mean for plastic product design in 2015 and beyond.

even in applications which may not necessarily be inherently competitive, according to Clariant.

Redefining Eden Essentially, this trend is based on gender and orientation. Clariant’s description identifies the movement towards “a human being who should be considered as an individual that excels beyond the limits created by prevailing and selfish man-made cultures, which have been artificially built over the centuries and are detached from freedom-pervading nature.” The reference to ‘Eden’ and ‘nature’ gives a

hint at the decorative motifs that Clariant anticipates. The group asks the question “Does it really benefit human beings to expect each and every one of us to fit into a preconceived and conventional scheme, rejecting the acceptance of human nature as a collection of infinite shades within the concept of a person?”

The phrase ‘infinite shades’ is another clue, hinting at more diversity, variety and choice.

Raw The final trend looks at the (already noticeable) return in taste to natural,

”

un-refined items, materials and even food. This is perhaps the most observable movement, as demand for applications with natural elements increases. Clariant doesn’t reference bio-materials specifically, but it’s likely that more work will be done to explore the use of bio-materials in a decorative, rather than just functional sense.

Also referenced are ‘blood and bruises’ which Clariant believes ‘are the new badges of courage’. Naturally this implies dark hues of red and crimson.

Finally, the ColorWorks prediction looks back on the rise of ‘extreme’ branding, as is often seen on beverage packaging

(presumably Clariant is referring to energy/sports drinks). The description says that the colours involved here will see greater prominance in 2015.

To read more about what the ColorForward predictions could mean, readers can visit the dedicated microsite www.colorworks.clariant.com. Clariant also offers seminars at its four ColorWorks locations as well as at selected conferences and at customer sites.

Clariant Colorworks Web: www.colorworks.clariant.com

JANUARY/FEBRUARY 2014 • WWW.EPPM.COM • 17

MATERIALS

News

Waste gases put to good use in polymer manufacture

Müller Kunststoffe announces Germany investment

Chemical group Evonik Industries and gas fermentation specialist Lanzatech have signed an agreement to develop a method of producing ‘bioprocessed’ precursors for specialty plastics from waste synthesis gas.

The three-year agreement will combine research from both companies, with a goal to manufacture the precursors by placing microorganisms in fermenters with synthesis gas, converting it into useful chemical commodities. The synthesis gases used comprise mainly of either carbon monoxide or carbon dioxide and hydrogen and can come from a variety of gasified biomass waste streams including forestry and agricultural residues and gasified municipal solid waste.

“Industrial biotechnology is one of the core competences of Evonik. It enables new approaches to specialty chemicals and processes,” said Professor Stefan Buchholz, Head of Creavis, Evonik’s strategic innovation arm. Creavis’ function is to develop alternative bio-based methods for the production of specialty chemicals. “The use of renewables and

Müller Kunststoffe, the German arm of the HEXPOL TPE group, will grow its TPE production with an additional line early in 2014. The group also announced plans to grow its technical centre with a new building at Lichtenfels for developing customised TPEs. The new line is forecast to increase TPE production by around 4,800 tonnes per annum. Specifically, it will increase capacity for the group’s Lifoflex and Dryflex TPE compounds. The range includes properties for halogen-free flame retardancy, conductivity, adhesion grades for multi-component applications, food contact grades and compounds offering improved compression set performance.

In addition to the new production line, the investment also includes plans for the construction of a new 600m2 building to expand the technical centre at Müller Kunststoffe’s main Lichtenfels site. The technical centre will be used for the development of customised thermoplastic elastomers including TPS, TPO, TPU and polymer blends. It will house the R&D, product safety, analytics and process technology departments for Müller Kunststoffe.

Construction of the new building is forecast to be completed by September 2014. The centre will include profile extruders, film extruders and various

specific waste streams is one of the main focuses of our research and development work, and LanzaTech offers an additional interesting approach,” said Buchholz.

“Synthetic biology is changing the face of the chemicals industry enabling production of ‘green’ chemicals that play a valuable part in our daily lives,” said Dr. Jennifer Holmgren, CEO of LanzaTech.

“We have developed the knowledge and capability to use waste resources to produce these chemicals and our partnership with Evonik plays an important part in bringing these technologies to the world.”

LanzaTech uses proprietary microorganisms to capture waste gas streams, including synthesis gas for the production of low carbon fuels and chemical intermediates.

Evonik Web: corporate.evonik.com LanzaTech Web: www.lanzatech.com

Comment In the December 2013 issue, EPPM published a piece from the nova-Institut, in which the research body stated that waste CO2 is “ready to go” as a feedstock for use in polymer structures, namely polyurethane foam, with others being explored. With the likes of Bayer MaterialScience already on-track to commercialise the process in 2015, it seems other giants like Evonik are also backing the technology. This year could see the formation of a marketplace for polymers derived from waste gases.

injection moulding machines, as well as polymer testing and analytical equipment.

Georg Ender, Managing Director at Müller Kunststoffe said: “Our speciality is tailored solutions delivered efficiently and quickly. We create bespoke products for our customers, they come to us with a problem and we solve it. We also place a strong importance on product safety and reliability, the new technical centre and its specialist equipment will increase our capacity to perform diagnostic, processing and quality assurance testing. The production expansion and investment in technical resources is a result of our growth over recent years and will ensure continued fast and responsive customer support, as well as the development of new polymer combinations and compounds.”

Müller Kunststoffe Web: www.mueller-kunststoffe.com

‘Gobie’ filter water bottle means double order for PolyOne The creator of the ‘Gobie’ filtered water bottle, Gobie H2O, has selected a PolyOne specialty GLS TPE formulation and FDA-compliant OnColor colorants for its reusable filtered water bottles.

“Our ultimate goal for the Gobie water bottle is to help reduce plastic waste from single-use water bottles while promoting consumer health,” said Ari Hoffman, Chief Operating Officer and Cofounder of Gobie H2O. “However, with several reusable water bottles already on the market, we turned to PolyOne for a high-performing material that would provide competitive advantages and differentiation.”

In collaboration with Gobie designers, PolyOne says it helped develop a recyclable, dishwasher-safe, and FDAcompliant TPE material that avoids leaching into the bottle’s contents. The material also provides an attractive matte

finish that maintains appearance after prolonged use. Gobie overmoulds GLS Versaflex TPE material on the bottle’s patented FlexFlo squeeze grip, non-slip base and finger-loop for non-slip grip properties, as well as attractive aesthetics and a strong bond for durability.

Hoffman says that before selecting the Versaflex material, Gobie evaluated more than 40 different materials, including rubber, along with methods such as bonding and ultrasonic welding.

“PolyOne provided incredible support, from trialing and testing services to onsite consultations. We are a small company, but PolyOne provided excellent support, spending time and effort to help make this project a success.”

In addition, Gobie chose OnColor colorants to differentiate its creative and sustainable product line. The FDA-

compliant colorants were used to produce fresh, bright hues, pairing with the TPE material to avoid bonding problems that Gobie had experienced previously with other materials.

“Products like the Gobie H2O bottle play an important role in increasing sustainability,” said Charles Page, Marketing Director for PolyOne GLS. “We

COC moulding grade launched with internal mould release Topas Advanced Polymers has expanded its line of Topas 5013 cyclic olefin copolymer (COC) resins for injection moulding of high-performance components for the optical, diagnostic, and microfluidic markets. The new grade, Topas 5013L-10, features an internal mould release designed for easy processing.

“The boost in processability from the internal mould release has made this new grade the go-to choice for components with high aspect ratios, precision details, and other moulding challenges,” said Timothy Kneale, President of Topas Advanced Polymers, Inc. The new grade has been designed for clarity, high flow, and a heat deflection

temperature of 127°C. Topas says it features a high level of flowability for a transparent resin, without loss of material strength or optical characteristics. The material’s low melt viscosity permits the production of ultrathin light guide plates, as may be used for displays in tablet and smartphone devices.

Topas 5013L-10 also delivers low birefringence and high moulding accuracy (submicron detail replication) for optical parts such as lenses, optical storage media, as well as for medical and diagnostic applications, claims Topas. The heat resistance and purity are said to be suitable for DNA analysis, including typical 95°C PCR protocols.

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The internal mould release can permit a reduction in the use of spool runners, along with easier demoulding. Other features include light transmission of 91%, low water absorption resulting in reduced warpage, and reduced discolouration properties over time.

Topas 5013L-10 resin is available globally and has found commercial use in microfluidics, diagnostics, and optics, including automotive and mobile device displays.

Topas Advanced Polymers Web: www.topas.com

are pleased that our materials are contributing to a unique product that has received wide recognition in its first year on the market. This design showcases our ability to collaborate with customers to address multiple challenges.”

PolyOne Web: www.polyone.com

Injection Moulding Rotational Moulding Extrusion Blow Moulding Thermoforming Vacuum Forming Film Extrusion Recycling Materials Design

30 September-2 October 2014

NEC, BIRMINGHAM, UK

www.interplasuk.com

MATERIALS

News

Medical cable assemblies switch to styrenic TPE Minnesota Wire, a specialist in the custom design and production of cable assemblies for medical devices, has replaced the thermoplastic vulcanizate (TPV) elastomers that are standard in such applications with new styrenic thermoplastic elastomer (TPE-S) compounds from Teknor Apex Company, citing better performance initially and after autoclaving, superior processing, and an enhanced look and feel in the end product.

The TPE-S compounds, Medalist MD8421, MD-8431, and MD-8451, comprise a series within Teknor Apex’s Medalist product range of high-purity medical elastomers that also includes other TPE types. Teknor Apex will publish new data on the compounds in a white paper soon to be available.

“We’ve tested the new Medalist compounds and found them to have better tensile and elongation properties than TPVs before autoclaving and to retain more of these properties after multiple autoclave cycles — an important advantage in the many medical devices intended for reuse,” said Jeff Lewison,

Design Engineer at Minnesota Wire. “In addition, the Medalist compounds are more stable in extrusion, and in injection moulding their improved processability means that we can lower the pressures to reduce the likelihood of defects when we’re molding over delicate circuitry.

Customers will like the fact that our product just looks and feels better.”

Enhanced electrical properties are another advantage of the new Medalist compounds cited by Mr. Lewison. “We can run cables with thinner walls, which enables them to coil better, and the improved electricals enable us to use these compounds in insulation as well as jacketing.”

The white paper by Teknor Apex will provide test data comparing the three new Medalist compounds with a standard medical-grade TPV used in wire and cable. In tests measuring tensile strength and elongation, all three Medalist grades exhibited greater values for these properties prior to autoclaving and greater property retention after as many as 15 autoclave cycles.

“The new Medalist compounds address

the issue of limited resistance to multiple autoclave cycles that has been a problem for the TPVs that are currently the standard materials for medical wire and cable jacketing,” said Ross Van Royen, Senior Medical Market Manager for the TPE Division of Teknor Apex and a co-author of the white paper. “And while standard TPVs are restricted in colour to natural and black, TPE-S compounds are available in a variety of custom-matched colours that have important functional value in complex cable assemblies.”

Medalist MD-8421, MD-8431, and MD8451 elastomers can be used for insulation, jacketing, and moulded fittings and connectors. They have Shore A hardness levels of 92, 69, and 82, respectively, a flammability classification of HB (UL-94), and a maximum continuous operating temperature rating of 105ºC (UL-1581). The three compounds also retain high levels of tensile strength, tensile modulus, and

elongation after gamma irradiation and EtO sterilization, according to Teknor Apex. They are resistant to the cleaning and antimicrobial solutions commonly used in medical facilities.

The new TPEs are manufactured in an ISO-13485 facility dedicated to Medalist medical elastomers. Medalist 8421, 8431, and 8451 compounds pass ISO-10993-5 cytotoxicity testing, are RoHS- and REACH- compliant, and are free of animal-derived materials, phthalates, and latex proteins, states the group.

Teknor Apex Web: www.teknorapex.com

Evonik ramps up structural foam supply responsible for the Rohacell Business Segment. The polymerisation process has been largely automated with the use of robot technology. This has led to shorter cycle times and significantly increased capacity.

Stefan Plaß, Head of the Growth Line Advanced Technologies, said: “Rohacell is expanding into ever larger serial applications. Our customers expect highly efficient and economic production processes from us. Only in this way can we make lightweight construction with Rohacell attractive for large quantities and new applications. We’re making an

Evonik Industries has started operation at its new production facility for Rohacell structural foam at the Darmstadt, Germany site. The work has started following a construction project costing approximately six million euros. The new facility will increase the polymerisation capacity at the site by 50%, says Evonik.

Due to extensive automation of the polymerisation process, cycle times have reportedly dropped by almost half.

“The facility enables us to account for the increasing demand and growth strategy for Rohacell,” said Dr. Andreas Hoff, Head of Performance Foams and

important step in this direction with automating the polymerisation, but we are also planning further automations and optimisations in the production process.”

Rohacell is a structural foam based on polymethacrylimide, which is used in fibre-reinforced composite parts in lightweight applications. The key market segments are aerospace and lifestyle, as well as automotive engineering and wind energy.

Evonik Industries Web: corporate.evonik.com

UK firm lays claim to “biodegradable AND recyclable solution” Following the recent announcement that a 5p levy will be charged from October 2015 in England on all single use PE carrier bags obtained from retailers with over 250 employees, UK firm Enzymoplast has submitted evidence to the Environmental Audit Committee for what it claims is a “biodegradable and recyclable solution for plastic carrier bags”. The group claims that with its technology, “plastic carrier bags do not have to be either biodegradable or recyclable but can be both”. ISO14855 and EN13432 are the accepted industry standards for biodegradable and

compostable plastic packaging.

One of the Government’s proposals is that the levy will not apply to biodegradable carrier bags, which is a concern for the recycling industry in the UK as such materials may contaminate the recycling stream. Enzymoplast says that its product is based on an enzymatic reaction in which the enzymes remain inert until they come into contact with a microbial source. The firm’s claim is that the product is recyclable with standard PE waste streams without contamination.

Enzymoplast has recently been certified according to ASTM D 7209 – 2006, the

Standard Guide for Waste Reduction, Resource Recovery and Use of Recycled Polymeric Materials and Products.

Wayne Dobson, Sales and Marketing Director, said

“Once reprocessed, the PE containing the enzyme pack will be diluted to such an extent that the enzymatic reaction simply will not start. The consequence of this is that the recyclate will retain all of the inherent mechanical properties of standard plastic recyclate. If the product containing Enzymoplast does not enter the recycling stream, then the material can be reintroduced into the carbon cycle, whatever the End of Life of the material”.

Stock image

Enzymoplast Web: www.enzymoplast.com

Clariant to acquire Plastichemix Clariant has it announced that it plans to acquire Plastichemix Industries, a masterbatch business in India.

Plastichemix is a supplier of black, white, filler and colour masterbatches, additive masterbatches, flushed pigments and mono-concentrates as well as engineering plastics compounds. The group has facilities in Vadodara with production facilities in Rania, Kalol and Nandesari in Gujarat.

The group’s Indian division, Clariant Chemicals (India) Limited (CCIL) will gain

access to new territories with the acquisition, expanding its customer base significantly.

The group also announced that a new Technical Service Laboratory will be opened to develop customised products.

“This acquisition is part of our global strategy to explore business opportunities in our Masterbatches business and to focus on emerging markets like India. The strong growth perspective of the plastics industry results in a bright future for the

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masterbatches business in India”, said Hariolf Kottmann, CEO of Clariant.

Hans Bohnen, Head of Clariant’s Business Unit (BU) Masterbatches, said: “Clariant and Plastichemix Industries have a complementary product portfolio that will enable us to cater to a larger customer base. This synergy will help us to develop our business. We aspire to double our sales in the next five years.

The global set-up of the BU Masterbatches will allow the exports of Plastichemix Industries to grow even

stronger and to give products like highly loaded and very well dispersed single pigment concentrates a global platform.”

Clariant’s masterbatch business has more than 50 manufacturing plants around the world, supplying colour and additive concentrates for plastics.

Clariant Web: www.clariant.com Plastichemix Web: www.spectramix.com

MATERIALS

News

Value could “leak out” of European nylon supply chain PCI Nylon, a market research and consultancy firm based in Germany has raised major concerns over the future of the polyamide (nylon) sector in Europe.

The firm says that the global polyamide industry is currently undergoing a massive wave of investment which is set to continue in 2014. This new capacity is forcing the rest of the industry to rethink its plans and consider its options. For the last decade, European producers have been able to grow their polyamide businesses by selling increasing quantities of intermediates and polymers to Asia in general and China specifically. As China becomes selfsufficient in all these materials, these export opportunities are fading fast and producers are turning back to their domestic markets in search of alternatives. But with the majority of suppliers in the same situation, the result is over-capacity and increasing competition.

PCI Nylon will be hosting the 8th annual European Nylon Symposium in Frankfurt on 26-27 February 2014. One key theme will be an examination of the effect that this will have on the European polyamide supply base.

Although the actual market situation should be a benefit to polyamide buyers, in reality over-capacity further down in polyamide supply will cause value to leak out of the chain, says PCI. For example, the price of PA6 polymer is now back to where it was in 2006/2007, but the build-up of the cost structure is entirely different (see illustration). Back in 2006 the crude oil price was USD 61 per barrel and it represented around 18% of the total cost of PA6 polymer. Currently oil is at USD 108 per barrel and it now represents 28% of the cost. While some stages in the chain have been able to pass these increased costs on, others

have been less successful and have had to give up some of their margins. The worst affected have been the caprolactam producers who, after a record year in 2011, have now been pushed all the way back to breakeven.

PCI says that “European caprolactam producers are now in a very precarious position indeed”. Over-capacity in PA6 polymer and many downstream markets is also leading to increased price pressure.

PCI Nylon Web: www.pcinylon.com

Poppies overmoulded for Kenzo perfume DuPont’s ‘Surlyn’ PC range for ‘glasslike’ cosmetic packaging applications has recently been highlighted for its use in a high-profile perfume bottle.

The perfume, ‘Kenzo Flower in the Air’, is made by luxury French brand Kenzo.

Inside the bottle’s large cap, which is manufactured by French packaging company SAF, is a perfect poppy corolla, visible from both sides as a result of a special laying and overmoulding process developed by SAF. DuPont says that encapsulation (overmoulding) technology using Surlyn grades allows objects, images, design elements and textiles to appear suspended in the clear resin. Despite the injection moulding process, overmoulded decorations reportedly maintain fine details and show no distortion.

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MATERIALS

News

Fiat chooses Styrolution for ‘premium’ exterior aesthetics Italian car maker Fiat has partnered with Styrolution to source a high-performance styrenic for exterior parts which need to retain ‘premium’ aesthetics over the course of time.

Styrolution’s ‘Luran S’ grade will replace all unpainted exterior ABS applications in Fiat Group models. Typical applications range from rear view mirrors, emblems and front grills to b-pillars and roof rack bars.

Luran S can replace the need for paint, as it features a high gloss surface quality in Fiat Nero 831, a custom-made colour developed by Styrolution at its Color Excellence Center in Cologne, Germany.

Luran S also helps Fiat to improve UV resistance to weather and ageing. This is because the Luran S grades and their blends (ASA and ASA+PC) are impactmodified with acrylic ester rubber, making them suitable for components that are

exposed to rain, wind and weather.

Maurizio Servetti, Manager at Fiat Center Research – Group Materials Labs said: “Luran S is one of the best materials of choice, as it allows us to create external parts that retain the premium surface quality our customers expect while reducing total costs. This is the kind of material innovation that helps Fiat deliver true value to our customers.”

Pierre Juan, Global Industry Lead, Automotive, Styrolution said: “Fiat is launching an increasing number of new models that are truly built on plastic design innovation,” said Juan.

“Styrolution has been a proud partner of Fiat for a number of years. We are very pleased we could work side-by-side with Fiat to co-create a customised styrenic solution that can now be found in literally every external application on every new Fiat model worldwide.”

Styrolution Group GmbH Web: www.styrolution.com

PET Annual now available on request

Protect profit margins with new processing aids

The 6th edition of the annual PET guide, named ‘connecting comPETence 2013’ is now available on demand for those involved in the PET sector.

Published by the specialist conference organiser PETnology, the book explores market trends and technical developments, with opinions and views from the PET industry. Key topics include materials and additives, PET packaging and machinery, recycling, and closures.

The PET Yearbook is now ready for shipment, on demand, and is available with a CD which contains all presentations given at PETnology Europe 2013, held in September last year. The conference also has an app, called ‘PET to go’ which offers access to all conference contents, including the lists of speakers and participants.

The book alone is available for €59.00, or €210.00 for the book and CD. A third

Grafe Advanced Polymers of Germany has developed a process aid additive, nicknamed ‘flow improver’ to make more efficient use of resources and boost profitability.

Through the positive effect that the additive has on crystallisation properties, temperatures and cycle times can be substantially reduced, Grafe claims.

The group states that reductions in machine temperature of around 30% are possible, which naturally cuts direct energy costs. In addition, less external heat is generated, which improves working conditions around the machine.

Grafe is saying that this is a benefit because it means that the machine can be re-started more quickly after downtime or set-up. The accelerated crystallisation ensures faster cooling of the component and so permits cycle time to be optimised.

The additive masterbatch can be used on all current machines and is suitable for injection moulding, extrusion, and blow moulding. It is added during the process, generally at a rate of about 35%. It can also be combined with dyes in

option offers the book, CD and app for €420.00. Orders can be made online at www.petnology.com Features of this year’s book include: • Special: PET Innovations 2013 • Market Overview: Growth Trends and Market Opportunities of the PET Bottle • PET@Drinktec 2013: • PET@K 2013 • Main theme: PET recycling - quality and quantity still have room for improvement • PETnology Europe 2013: ready-todrink products stimulate growth in the PET market • Interviews with Participants: challenges are there to be overcome - there is still a lot of work to be done!

• Summaries of the presentations • Exhibitors at PETnology Europe 2013 • New services à la PETnology: Seminars & Training • PETnology in 2014: Seminars, conferences, connecting comPETence at BrauBeviale PETnology Web: www.petnology.com

Victorinox Hunter Pro uses ‘self-healing’ plastic Victorinox, the brand behind the iconic Swiss Army Knife, has launched a new exclusive knife named the Hunter Pro. The knife has been developed from scratch and a major focus has been to analyse the material used in the handle, to bring the knife up-to-date with current technologies. Polykemi AB has announced that its POLYfill PP Touch grade has been selected for the project.

Mr Mattias Persson, Sales Manager of Polykemi AB (apparently a passionate huntsman himself) stated: “The knife feels very solid and sturdy with a good weight and a comfortable grip. Our POLYfill PP Touch-material gives the sensation that the handle is both soft and hard at the same time. In addition the good grip remains – even with the handle being moist or even wet.”

Henrik Eriksson, Development Manager at Polykemi AB said of the PP grade: “Initially the material was developed with

interior automotive parts in mind. The idea was to combine mechanical properties with a surface that both visually and when touching it gives you the luxurious feeling associated with soft lacquered – or over-moulded materials.

“A target application was for instance is door panels for mid-price class cars and trucks. Many trials involving POLYfill PP Touch were carried out over a four year period and during this development – the concept found usages in many different projects.”

The high scratch and wear resistance properties have also come to find homes on the surface of cutting boards. Polykemi says its grade was chosen in this instance as a result of its “self-healing” attributes.

Polykemi AB Web: www.polykemi.se

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The sample shows the different effects of the additive with specific machine parameters. a masterbatch. The product can be tailored to meet the specification of the end product.

Lower energy consumption and faster cycles have a direct influence on the cost structure and contribution margin for packaging applications. Grafe believes that the resulting unit cost optimisation allows producers to adjust their price policy individually to meet the requirements of the market, adding a competitive advantage.

Grafe Advanced Polymers Web: http://www.grafe.com/en/

FEATURE

Engineering Materials

Ford engines switch to plastic for coolant component The new Ford 3.5 and 3.7 engine manifold uses a crossover coolant component which will now be made of DuPont’s Zytel HTN PPA resin instead of brazed metal, reducing weight by one pound to improve fuel economy.

The cross-over coolant component is a hollow part that allows engine coolant to bypass the manifold as it circulates through the engine. Traditional nylon 6 polymer doesn’t withstand long-term exposure to heat and long-life coolant, so the component had previously been made of brazed metal.

While DuPont Zytel HTN PPA is frequently used in engine cooling components because it can withstand the long term exposure to heat and long life coolant, the intense pressure of the overmoulding process needed to integrate the component into the manifold system was damaging the hollow component.

The cross-functional team looked at the design, material and processing, and made modifications using advanced computer models. ITW invested in cavitypressure sensing technology from RJG,

Inc. to examine pressures inside the moulding cavity. The data was used to pinpoint where design changes could add structure and to control the process so the prototype could scale into production quickly.

“Getting accurate data about pressures and conditions inside the moulding cavity significantly improved our ability to evaluate the material, iterate more efficiently on design and shorten the development cycle,” said Tyler Terrell, ITW Project Manager. “This was a really tough challenge and we used every technology we could to get this part into production. The collaboration between the members of this team really made the difference.”

“There’s a growing trend toward using high-performance materials only where

POM to replace HDPE in small fuel tanks

Celanese Corporation has launched Hostaform LPT POM, a low-permeation and toughened polymer specifically designed for demanding small off-road engine applications, jerrycans and other containers.

The company celebrated 50 years of the Celcon/Hostaform acetal copolymer (POM) product line at K 2013, and launched the new line to coincide with the anniversary.

A low permeation toughened POM, the grades deliver a “balance of impact and durability performance”, claimed the group.

“Celanese specifically designed its Hostaform S 9364 LPI for injection moulding and S 9364 LPB for blow moulding to perform in fuel systems that use ‘advanced fuels’,” said George Zollos, Celanese Market Development Manager, POM. Traditionally, SORE fuel tanks have been moulded from HDPE, but new regulations in the US require manufacturers to find a cost-competitive alternative material.

Celanese used a proprietary hybrid POM technology to create the new grades, which feature barrier properties inherent to POM resin — i.e. they do not degrade, scratch or wear.

The group claims its new line can offer up to a 25% reduction in manufacturing time compared with other gas tank materials.

Crucially, for the target application, the material exhibits strength and impact properties suitable for tank durability at 40˚C, as well as long-term fuel resistance.

“In addition, the Hostaform LPT POM property profile can help customers increase their productivity via faster cycle times, which can save energy and lower their unit per tank costs,” Zollos said.

Celanese Web: www.celanese.com

DSM increases engineering plastics prices DSM has announced Akulon and Novamid polyamide 6 polymer price increases for Europe and the Americas.

As a result of increasing raw material prices, the group will increase the price for its Akulon and Novamid polyamide 6 lines by €100/t in Europe, and by $0.10/lb in North and South America.

These increases will take effect for all orders shipped on or after February 1, 2014 where contracts allow.

DSM Web: www.dsm.com

they are needed,” said Pat Granowicz, Powertrain Segment Leader, DuPont Automotive Performance Polymers. “This can lead to challenging designs and demand innovative processing solutions.

Modelling based on how a material behaves in processing and in use is critical.”

In addition to significant weight savings, the switch has eliminated several steps in the value chain associated with processing and machining powdercoated metal. Ford and the team from ITW and DuPont were named finalists in the Society of Plastics Engineers Most Innovative Use of Plastics Award in the

Process/Assemby/Enabling Technology category.

It was one of two 2013 finalists. The other – an acoustic shield mounted on the 2013 Hyundai Elantra and Forte cylinder block – was developed by a team from Hyundai Motor Company, NVH Korea Co., Ltd. and DuPont. The application relies on heat and flame resistant DuPont Nomex brand fibre to withstand the demanding engine environment.

DuPont Web: www.dupont.com

Oyster-shell filled PP can achieve flame-retardancy

Clariant flame retardants are being used in the development of commercially viable, flame retarded thermoplastic composites based on renewable oyster shell fillers.

Research led by the Unité Matériaux et Transformations (UMET) at the University of Lille in France has shown that it is possible to achieve effective flame retardancy for oyster shell reinforced polypropylene (PP) composites using Clariant’s Exolit AP non-halogenated flame retardants.

Results indicated a significant increase in the thermal stability of the PP compound with phosphate-based Exolit AP760 added to the high performance compound.

Eurostar Engineering Plastics, developer of the ‘green’ PP compound, has chosen oyster shells as a renewable source of mineral filler.

In addition, the Exolit AP flame retardant displays no toxic effects, and is biodegradable, breaking down to naturally occurring phosphate, according to Clariant.

“The project results herald a breakthrough in the feasibility of using bio-based materials in high-end application areas, such as the automotive and building and construction industries, where effective flame retardancy is required,” said Professor Sophie Duquesne, who is leading the research group from Unité Matériaux et Transformations (UMET).

“In addition to oyster shells we are also actively researching the viability of achieving flame retardancy when vegetal fillers such as flax are used, to further extend possibilities for more environmentally-friendly materials in demanding environments.”

Clariant Web: www.clariant.com Unité Matériaux et Transformations Web: umet.univ-lille1.fr Eurostar Engineering Plastics Web: www.eurostar-ep.com

JANUARY/FEBRUARY 2014 • WWW.EPPM.COM • 23

APPLICATIONS: Polymer Banknotes

Article

POLYMER BANKNOTES: A BOOST FOR THE INDUSTRY, OR PUBLICITY MINEFIELD? Will the growing use of polymer substrates for banknotes around the world bring with it an unwelcome media frenzy?

The Bank of England has announced its decision to join many other nations and adopt polymer bank notes following the completion of its UK wide consultation process. This is great news: polymer supply, machinery investments, employment, skills and training are all set to reap the benefits in the plastics industry.

But as with all innovations that impact the public at large, it may just come with a price. Just as the reported side-effects of BPA have been held in reserve for slow news days in the national press, polymer banknotes will, undoubtedly, hit the headlines in the run-up to the 2016 launch. Once again, this will turn the spotlight onto the plastics sector itself, with the general public forming opinions based, in some cases, on questionable sources.

Whilst some surveys in the UK have demonstrated strong public support for the move, those in the industry have seen how quickly the tide of opinion can change.

Innovia Security, a division of the Innovia Group, has been selected to manufacture the polymer substrate destined to produce the new notes. Innovia says it has been identified as the preferred supplier because its ‘Guardian’ polymer substrate is “already well established, being used by over 20 other countries, including Canada.”

Innovia announced that it intends to build a opacification plant at its Wigton site, which will require an investment of over £20 million.

The new opacification plant has been forecast to be fully operational in early 2016 and is destined to produce the polymer substrate required for the 24 • WWW.EPPM.COM • JANUARY/FEBRUARY 2014

new Winston Churchill £5 note, which will be launched in 2016. The Jane Austen £10 note will follow around a year later.

The investment will also “create 70 to 80 additional jobs” said Innovia Security.

David Beeby, CEO, Innovia Group said: “We are very proud to have been selected as the preferred supplier of the polymer substrate for the new £5 and £10 bank notes. This decision not only recognises the benefits that polymer notes have to offer but also Innovia’s expertise in this field.”

However, one firm (which also works in the plastics sector) has warned that the switch may create health and safety concerns. Symphony Environmental, a firm which supplies anti-microbial additives recently issued a statement which cites an initial report from the UK’s ‘The Independent’ newspaper, that “A study of the survival rates of microbes such as E.coli and the MRSA superbug, when placed on seven different currencies has found that they thrive best on money printed on the plastic banknotes earmarked to be introduced in Britain” (13 September 2013).

For Symphony of course, these findings could help to open up a potential market, and also bring new revenue streams to speciality additives suppliers in the UK and Europe. Symphony’s CEO Michael Laurier said: “Some of these bacteria can be extremely dangerous and have proved resistant to antibiotics, so we need to deal with them before they get into our bodies. Following years of R&D, Symphony can now supply an antimicrobial and anti-fungal formulation called d2p, which can be added to most types of plastic, and it should be introduced as quickly as possible,” said Laurier. “Not just for banknotes, but for bank cards, driving licences, bus passes, retail cards, shopping bags, computer keyboards, steering-wheels, telephones, door handles, and many other applications. “d2p has been independently tested by recognised laboratories and is effective against over 50 dangerous organisms, including MRSA, E.Coli, salmonella, listeria, pseudomanas and aspergillus niger. These are germs which lurk

Article

“

If the mainstream media want to find an angle to decry the benefits of polymer substrates, they certainly will.

”

everywhere, in hospitals, schools, homes and offices, as well as inside long-life shopping bags.”

On the other side of the coin, in a video posted on the Innovia Security website, Managing Director Philippe Etienne refers to a different piece of research: “There was a study in 2010 where researchers in 10 different countries around the world took banknotes out of circulation, and they then examined the bacterial loading on those banknotes.

They compared paper banknotes with polymer banknotes. That study showed

conclusively that there was a dramatically lower loading of bacteria on polymer notes versus paper.

“Intuitively I think that’s what you’d expect when you compare a smooth, non-porous material with a porous material.”

Andreas Voss, Professor of Infection Control at Radboud University Nijmegen Medical Centre in the Netherlands was a co-author of the first study (mentioned in The Independent) and suggests that the findings are not necessarily evidence that polymer banknotes would provide a major source of transmission. Quoted on the webmd.boots.com website, Voss

says: “I don't believe in them [polymer banknotes] being a major source of transmission. In addition, all other objects around us are ‘contaminated”.

Though this rationale may align with some opinions in the plastics sector, the reality is that physical money is the ultimate consumer commodity. If the mainstream media want to find an angle to decry the benefits of polymer substrates, they certainly will. Before 2016, the plastics sector needs to be prepared for that prospect — thoughtleaders, suppliers and processors could all be challenged with yet more negative publicity.

Anti-microbial technologies may offer a solution. Others in the industry may argue they are unnecessary — no doubt further studies in coming years will provide more knowledge on this.

The good news is that other countries have managed to successfully ride the storm — indeed for many years — and have embraced polymer money with open arms. Posting on the UK’s ‘The Guardian’ website, business blogger Bridie Jabour writes a short but celebratory piece entitled “Plastic pound notes: a message from the enlightened future…Australia”. It’s an encouraging read.

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CHINAPLAS A GLOBAL STAGE FOR THE PLASTICS COMMUNITY

Chinaplas 2014 will be held from 23-26 April, 2014 at the Shanghai New International Expo Centre, PR China. The organiser says that exhibition space is expected to exceed 220,000m2 with more than 2,900 exhibitors and 120,000 visitors coming from 130 countries and regions.

China is an important market for European processors, with strong potential for trade links and collaborative technologies.

What follows is a run-down of the event and its significance for those considering making the trip to Shanghai.

China as a marketplace It’s no secret that China is undergoing rapid industrialisation and urbanisation.

The country’s five-year plan sets out a direction for the plastics and rubber industries, including lowering pollution and energy consumption, adding highvalue and improving technology.

The good news is that the domestic market is showing increasing demand for cutting-edge plastic and rubber technologies. A steady increase in demand for high-quality plastic and rubber solutions is expected in China.

Eastern China is one of the leading regions of economic and industrial development, but it’s also experiencing growth as a base for raw chemicals supply. In 2012, around 25 million tonnes of plastic products were manufactured in the region, accounting for 44% of the country's production capacity. With wellequipped infrastructure and a strong industrial cluster effect, Eastern China has become an appealing prospect for some of the world’s biggest multinationals.

The Chinese government is set to invest 400 billion yuen each year, in order to improve the country’s water infrastructure. This, coupled with rapid urbanisation, should bring with it growing demand for plastic piping and contruction materials. Extrusion and 26 • WWW.EPPM.COM • JANUARY/FEBRUARY 2014

injection moulding machinery sales are also set to rise as a consequence.

Like the rest of the world, China is also placing an emphasis on fuel efficiency in the automotive sector — a trend in which plastics will, of course, have a major part to play.

Moreover, showing continued environmental commitment, the five year plan aims to explore renewable energy, while solar technology is also on the rise.

China’s environmental policies have also accelerated the development of the rubber recycling industry.

Finally, the market is preparing itself for further developments in plastic for medical devices. The emphasis here is on the basic equipment which is in the highest demand.

Ada Leung, Assistant General Manager of Adsale Exhibition Services Ltd, the organiser of the show, said: “As global economic focus shifts eastwards, more and more global buyers pay greater attention to China’s market. Chinaplas, with over 30 years of history, has become a high quality sourcing platform of both domestic and overseas technology for plastics and rubber industries as well as the downstream sectors, such as automotive, building and constructing, E&E, packaging, etcetera.”

Article Sustainability at Chinaplas Reflecting the continued demand for more sustainable business practices, Chinaplas will promote sustainability under the theme of "Greenovation Solution to Sustainability", with "The City of Tomorrow" and a "Green Conference" as two featured events.

"The City of Tomorrow" will feature a circular structure at Central Square of the exhibition centre to showcase a comprehensive sustainability model which covers four aspects, namely Green and Alternative Raw Materials, Energyefficient Machinery, Plastics and Rubber Applications, and Recycling. Visitors will be able to explore the latest green messages and trends from manufacturing till the end of the life of the products through interactive displays and even games.

Also taking place during the show is the Green Conference, a two-day conference co-hosted by Adsale Exhibition Services Ltd, Plastics Information Europe (PIE) and the Association of Green Molding Solutions (AGMS). It will be held on the second and third day of the event (April 24-25), and sessions will include "Innovative Solutions for Plastic Recycling" and "Green Molding to Halve the Cost and Double the Wealth". The conference will highlight a range of topics, inclduding ‘green’ moulding, 3D printing, plastics recycling as well as various solutions for end-of-life plastic waste, and will see international brand names share their experiences and insights.

More information on the activities surrounding sustainability can be found at www.chinaplasonline.com/event.

Technological diversification The organiser of Chinaplas says that this year’s event is moving with the times.

Sophisticated, high-tech and diverse solutions and applications will be a key focus at the show. Specific technologies have been identified for highly relevant purposes, including safety, lightweighting, aesthetic appeal, multi-purpose functionality, heat retention, and water resistance to name a few.

Roughly speaking, the exhibitors break down as follows: over 1,000 will display machinery and raw materials specifically for the automotive industry; more than 600 will target the building and construction industries; over 700 will focus on electricals, IT and telecommunications; and finally, over 1,100 exhibitors will cater for the packaging industry.

Stanley Chu, Chairman of Adsale Exhibition Services Ltd, said: “Since the global financial crisis in 2008, the rapid development of the plastics raw materials and machineries in China have accelerated the upgrading of industries.

Many companies understand that using low-end technology to operate cannot sustain their development. Technological and management breakthrough, quality upgrade and following government policies like energy saving, high efficiency and environmental protection are the best solutions. Corporations are suggested to change their marketing strategies according to the market variation, to concentrate the resources on the highgrowth industries and areas, for example, increasing needs on the automation equipment resulting from the recent problems of rising salaries and labour shortage,”

Themes for an easy visit Some aspects of this year’s show have been divided up by process, making for a straightforward visit.

These technical zones will include: • Extrusion Machinery • Injection Moulding Machinery • Chemicals and Raw Materials • Auxiliary and Testing Equipment • Mould and Die • Film Technology • Plastic Packaging and Blow Moulding Machinery • Rubber Machinery and Equipment • Chinese Export Machinery and Materials • Bioplastics • Semi-finished Products A global event Of the predicted 120,000 visitors to the show, the organisers suggest that 25% will come from overseas. Many will be looking to establish new trade partnerships, renew existing contracts or explore the technology on offer in China itself.

At the same time, the exhibitors themselves will come from all around the world. Many of the major European and American players are confirmed to exhibit. Providing a base for foreign trade will be the international pavilions, which will include Austria, Canada, France, Germany, Hong Kong, Italy, Japan, Korea, Switzerland, Turkey, UK, USA, PR China and Taiwan.

Exhibitor turnout So, who’s going? Chinaplas always tends to attract the major names — and they do send their leading delegates to talk shop with clients and prospective customers, no matter where they fly from. This year, the exhibitor profile represents a combination of western and eastern technology. So far, a few of the familiar processing equipment brands include Haitian, Chen Hsong, Husky, Engel, Demag, SHI, Jwell, Jinhu, Liansu, Fangli, Mold-Masters, Yudo, ACS and Conair.

In the field of chemicals and raw materials, expect to see brands like BASF, Exxonmobil, Teijin Kasei, DSM, Mitsubishi, Polyone, DuPont, DOW, SABIC and Lanxess on site.

What’s new?

The organisers have continued to invest in the event, with specific ‘upgrades’ taking place for 2014. To attract the larger names in the business, new ‘exhibition suites’ have been introduced.

These standalone booths are located in a prime location in the central square of both the North wing and East wing of the exhibition grounds.

The sizes of the suites range from 150m2 to 300m2, and will act as both display areas for products and services, and meeting points for trade discussion. And it seems that the new strategy has paid off: currently, Bayer MaterialScience, Dow, Kolon Plastics, and Uniplas are among the names that have confirmed to exhibit in these exhibition suites.

The “Chinaplas Elite Club Lounge” has also been introduced outside hall E4, as a premium service for taking a break from a busy day at the show.

Free services in the lounge include WiFi and computer stations for internet access, magazines and newspapers, refreshments and power supplies for charging devices.

Ms Leung said: “We always aim at enhancing and improving our services for the exhibitors and visitors. The Exhibition Suite and the Elite Club Lounge are two of the major upgraded services. We hope that visitors not only find the right suppliers and acquire the latest technology here, but also visit this mega show more comfortably and easily.

Since the show scale is large, visitors are encouraged to plan their visit earlier and stay the whole four days in order to grasp the most and best of the information here.”

Getting to the show If you’re hoping to visit, it’s worth making contact with the major trade associations in your country first, as they may be offering assistance to members.

There is a wide variety of options for flying from Europe into Shanghai, many with stops at Dubai. The exhibition centre is located 33 km away from Pudong International Airport to the east, and 32 km away from Hongqiao Airport to the west. Getting there from Pudong is simple, about 35 minutes by taxi or about 40 minutes via the airport bus line (take lines No. 3 and No. 6). By Metro, take Line 2 to get off at Longyang Road Station where you can walk or change to Line 7 which goes direct to the centre.

Alternatively, if you’re coming from Hongqiao Airport, it’s about 35 minutes by taxi, or on the metro, take Line 2 again as above.

Naturally Shanghai has plenty of hotels, and around the centre there’s plenty of choice for accommodation with suitable business facilities. If you’re staying in Shanghai, there are several modes of transport available for travelling to and from the show.

Chinaplas 2014 Web: www.chinaplasonline.com

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INDUSTRY

News

Bioplastic production to jump in coming years The bioplastics market is predicted to grow from around 1.4 million tonnes (annual production capacity) in 2012 to approximately 6.2 million tonnes in 2017.

The actual land used for sourcing renewable feedstock for bioplastics will amount to approximately 0.02% of the global agricultural area.

This forecast comes from a recent statement issued by the industry body European Bioplastics. It is published annually in cooperation with the Institute for Bioplastics and Biocomposites of the University of Applied Sciences and Arts Hannover in Germany.

“Our market data update once more affirms above average growth in the bioplastics industry around the world”, said François de Bie, Chairman of the Board of European Bioplastics.

“Continuous growth can be expected with regard to all bioplastic material types and in a range of very diverse market segments – from packaging to fibres to consumer electronics.”

According to the report, the strongest growth is expected in the biobased, nonbiodegradable bioplastics group.

Biobased versions of bulk plastics like PE and PET in particular are project to grow significantly. Biodegradable plastic production is expected to grow by around 60% by 2017.

The packaging market will remain the leading segment for bioplastics applications. However, other segments are moving forward in the trend for bioplastics use, in particular consumer electronics, automotive, and the fibre market.

European Bioplastics believe that the market growth will lead to economic improvements in Europe’s rural areas, leading to increasing employment opportunities. The group is pushing for a European knowledge base to help provide skills and employment opportunities European Bioplastics’ current data shows that Europe and North America remain key locations for research and development and also as sales markets.

However, the establishment of new production capacities is seen to be stronger in South America and Asia. “In order to stay competitive along the complete bioplastics value chain, Europe needs to step up its game. We call upon the European Commission to establish a level-playing field for the biobased industries in Europe and a clear cut policy framework for promising markets such as bioplastics”, said de Bie in light of the current forecast.

European Bioplastics Web: en.european-bioplastics.org

New Chairman for Lanxess

Italy’s machinery exports take a dip for 2013

The Supervisory Board of Lanxess AG has announced that it will end, by mutual agreement, the appointment of Axel C. Heitmann as Member and Chairman of the Board of Management of Lanxess AG, effective the end of February 28, 2014.

The Board has appointed Matthias Zachert, former Chief Financial Officer of Lanxess and currently Axel C. Heitmann will leave his post as Chairman of the Board Chief Financial Officer at of Management at the end of February 2014.

Merck KGaA, as Mr. Heitmann’s successor, effective no later high regard for Mr. Heitmann, also on than May 15, 2014. behalf of all employees.”

Until Mr. Zachert joins the Board of “Lanxess is facing significant challenges, Management, Lanxess Chief Financial for example in terms of market capacities Officer Bernhard Duettmann will assume and business portfolio. Therefore, the the responsibilities of the Chairman of the Supervisory Board believes it is the right Board of Management. time to hand over responsibility to a new “Mr. Heitmann has played a key role in leadership in order to overcome these shaping the company since its creation challenges,” said Stomberg. “Mr. Zachert through consistent restructuring and performed excellent work as Chief strategic portfolio measures. He has Financial Officer at Lanxess and has an formed LANXESS into a leading global outstanding reputation among specialty chemicals company, achieving employees as well as in the capital many noticeable successes,” said Rolf market.”

Stomberg, Chairman of the Supervisory Board of Lanxess AG. “The Supervisory Lanxess Board expresses its sincere gratitude and Web: www.lanxess.com

Assocomaplast, the Italian trade association for plastics and rubber machinery has produced its 2013 final report based on ISTAT foreign trade data for the first nine months of the year. The most notable trend was the downturn in exports (down 2.8% across JanuarySeptember). The report states however that growth “could be recovered” in the final quarter thanks to the expected economic recovery, early signals of which have been noted recently by the Confindustria Research Center. Exports have historically formed the bulk of Italy’s machinery industry, with a market share exceeding 65% of production, so the downturn is significant for the market.

With “caution while awaiting final data for the year”, Assocomaplast projects that production value for the sector will reach just under 4 billion euros, and forecasts that the threshold will be surpassed in

Repsol resumes ethylene production During its recent shutdown, chemicals giant Repsol has undergone an investment of 95 million euros in maintenance and technical improvements to its Tarragona ethylene cracker. The cracker start-up operations took longer than expected due to “technical challenges”, said the group.

Repsol Web: www.chemicals.repsol 28 • WWW.EPPM.COM • JANUARY/FEBRUARY 2014

2014 if signs of recovery continue.

The continued downturn in imports (down by 5.4%) reflects the continuing sluggishness of the domestic market, according to Assocomaplast.

More optimistic are the results of the recent survey conducted by Assocomaplast among its members, where half the sample sees recovery in their revenues in the second half of the year with respect to the first half; over 40% of respondents reported a positive trend in orders in November, compared both to October 2013 and to November 2012. The recent K in Düsseldorf has probably had a positive impact here: most of those interviewed confirmed that they had had a high number of quality contacts at the German fair.

Assocomaplast Web: www.assocomaplast.org

Biesterfeld adds chemicals group to UK operation Biesterfeld Spezialchemie GmbH, part of the Biesterfeld group has announced that as of 2014, it will team up with Biesterfeld Petroplas Ltd. in the UK and Ireland.

Biesterfeld Petroplas Ltd. distributes thermoplastic resins from several major suppliers to the polymer industry in the UK and Ireland. In 2006 Biesterfeld Petroplas Ltd. was integrated into the Biesterfeld Group as a joint venture of Petroplas Ltd. and Biesterfeld Plastic GmbH, which today holds a majority stake.

“Biesterfeld Spezialchemie is looking forward to further expand its specialty chemical business in the UK and Ireland together with Biesterfeld Petroplas. The successful joint venture of Biesterfeld Petroplas is a guarantee for a prosperous development of our specialty chemical

business. With this cooperation we will continue to pursue our focus on further growth into the Western European regions,” said Thomas Arnold, Managing Director, Biesterfeld Spezialchemie GmbH. Biesterfeld Spezialchemie GmbH is a European distributor of specialty chemicals in the fields of life science (pharmaceuticals, cosmetics, household cleaning products, organic synthesis), food Ingredients, CASE (coatings, adhesives, sealants and elastomers) and performance products (silicone elastomers and products for automotive, composites, construction, electronics, power, and photovoltaics industries).

Biesterfeld Petroplas Ltd. Web: www.biesterfeld-petroplas.com

INDUSTRY

News

Massive growth forecast for fillers/reinforcements Market research organisation Ceresana has released its third annual market report on the fillers industry – and the outlook is positive. The group forecasts revenues generated on the global market for fillers to rise to approximately $27.7 billion by 2021.

For 2013, Ceresana has identified AsiaPacific was the largest worldwide sales market for fillers, accounting for 48% of total demand, followed by Western Europe and North America. The two key applications for fillers are plastics and elastomers. A trend towards the use highly filled compounds, containing up to 85% of fillers, has been identified in the study. The growing use of ‘nanofillers’ is another trend, presumably due to the fact

that they can increase the share of fillers in a product and improve the product's characteristics at the same time.

The most commonly used filler on the global market is ground calcium carbonate (GCC), followed by precipitated calcium carbonate (PCC) and carbon black, says Ceresana. Other fillers used in significant quantities are kaolin and talc. All other types of fillers reached an aggregated market share of only 9%. Demand for almost all types will increase steadily, claims the report, with the highest growth rates of more than 3% p.a. being forecast for carbon black and talc. The use of carbon black as a filler in the tyre industry in particular will continue to increase considerably, due to

BPA ‘low-risk to consumers’ assessment open to public consultation In a move that opens up the BPA debate even further, the European Food Safety Authority (EFSA) has announced that it is opening a public consultation on its assessment that exposure to bisphenol A (BPA) is of ‘low-risk to consumers’.

EFSA reviewed over 450 studies relating to potential health hazards associated with BPA and identified likely adverse effects on the liver and kidney and effects on the mammary gland as being linked to exposure to the chemical. It therefore recommends that the current tolerable daily intake (TDI) be lowered.

However, the findings concluded that BPA poses a low health risk to consumers as exposure to the chemical is well-below the recommended temporary TDI. The Authority has undertaken a comprehensive review of scientific literature and previous risk assessments from expert bodies on BPA. All stakeholders and interested parties are now invited to comment on the document through an online public consultation that runs until 13 March

2014. EFSA said that it particularly welcomes input from national risk assessment bodies that have previously evaluated BPA. Specifically, EFSA recommended that the tolerable daily intake (TDI) for BPA be lowered from its current level of 50 µg/kg bw/ day (or 0.05 mg/kg/bw/day) to 5 µg/kg bw/day (0.005 mg/kg/bw/day) and be set on a temporary basis.

Despite this call, the authority elaborated to say that the health risk for all population groups is low – including for fetuses, infants, young children and adults. This is because the highest estimates for combined oral and nonoral exposure to BPA are 3-5 times lower than the proposed temporary TDI, depending on the age group. For all population groups, oral exposure on its own is more than 5-fold below the proposed temporary TDI. EFSA Web: www.efsa.europa.eu

the massive expansion of the automotive industries in China and India.

As fillers can be used in applications in various industrial sectors, the development of the market for fillers largely follows the macroeconomic development of a country. As such, Ceresana noted that the sales markets for fillers in China and India are developing very rapidly. China singlehandedly accounts for increases in demand of almost one million tonnes per year, which is likely to result in AsiaPacific accounting for more than half of total global output of fillers by 2016.

Ceresana Web: www.ceresana.com

TPE distribution growing in the CIS and Baltics Hexpol TPE, which brings together the Elasto and Müller Kunststoffe businesses, has grown its reach in the CIS and Baltic states with the appointment of Telko (Helsinki, Finland) and Forplast (Riga, Latvia) as distribution partners. The announcement comes just two weeks after Müller Kunststoffe announced capacity expansions and a new technical centre, signalling a period of strong allround growth for the brand.

The Elasto and Müller Kunststoffe businesses have worked with Telko and Forplast respectively for a number of years. Under the terms of the new agreement, Telko and Forplast will now be supporting the market expansion of Hexpol TPE’s full range of Dryflex and Lifoflex TPE products, throughout the CIS and Baltic States.

Dryflex and Lifoflex TPE compounds include grades based on TPS (SBS and SEBS), TPO and TPV technologies. They are used extensively in the consumer, industrial, automotive, electronics and construction markets. The portfolio includes several fully customisable series

including halogen-free flame retardant, conductive, extrusion profiles, automotive mats, adhesion grades for 2K applications and compounds offering improved compression set performance.

Forplast will also continue to work with the group's range of complimentary flexible polymer compounds including Lifolit soft PVC, Lifocork cork compounds, Lifoprene TPU and Lifobatch colour and additive masterbatches.

Sven-M Druwen, European sales coordinator for Hexpol TPE said: “The CIS and Baltic States are a growing market for us. We want to give our expanding customer base in this region the best in terms of product offering and customisation with fast local support and logistics. That is why we will be working with both Telko and Forplast in these regions. Telko and Forplast are strong partners for us, with in-depth technical knowledge and a commercial understanding of their home markets.”

Hexpol TPE Web: www.hexpoltpe.com

Turkish compounder opens Germany site

Teknor Apex talks phthalate replacement

Turkish polyamide compounder Epsan is expanding its presence in the German market with a new office located in Dortmund, which will provide customer training, sales operations, technical support, product demonstrations and customer events.

"The new office shows our commitment to grow our business in the Automotive Industry and Germany through direct communication, technical support and sales," said Arda Efe, Epsan Global Sales Manager.

The office, which opened 1st January 2014, is being managed by Adrian Kaminski who previously managed a US nylon resin manufacturer’s Business & Market Development operation in Europe. A key focus for the new site will

In a seminar during the MD&M West show, Teknor Apex Company provided systematic information for medical manufacturers facing the issues involving the replacement of phthalate plasticisers in PVC compounds.

The presentation by Vinyl Division Industry Manager Peter M. Galland took place on 12 February 2014 in Room 201A of the Anaheim Convention Center, the site of MD&M West.

Mr. Galland covered the full range of phthalate and non-phthalate plasticisers for PVC compounds in medical devices, along with certain non-PVC materials.

His presentation addressed key considerations for evaluating these alternatives, including chemical structure, toxicology, solubility, migration, crazing, sterilisation, mechanical properties, processing, design, economics, and current market penetration.

“Teknor Apex has prepared comprehensive data on plasticiser alternatives as a way to help device manufacturers make informed decisions in addressing marketplace issues concerning phthalates,” said Mr.

be on developing automotive applications with OEMs. Founded in 1976, Epsan is an independent compounder which is specialised in the production of high performance polyamide compounds. The company has two plants located in Turkey with a total capacity of 23.000 tonnes a year.

Epsan Web: www.epsan.com.tr

Vinyl Division Industry Manager Peter M. Galland Galland. “As a diversified producer of both plasticisers and medical-grade compounds, our company is prepared to work with designers and processors no matter which alternatives they select.”

The Vinyl and Thermoplastic Elastomer Divisions of Teknor Apex will exhibit at MD&M West in Booth 2532.

Teknor Apex Web: www.teknorapex.com

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Plastic closures officially ‘more popular’ than metal Plastic beverage caps and closures are now more popular than metal closures, according to a new report from Canadean.

According to the report, plastic closures (49%) overtook metal closures (48%) last year, gaining the largest share of the global market for beverage closures. In comparison, metal closures held 51% of the market in 2007. The advance of plastic closures is primarily associated with a shift towards more innovative, lightweight, cost saving packaging.

Over recent years, the economic downturn has encouraged a focus on cost and material savings in the beverage industry, with the aim of delivering cheaper closures that require minimal adaptation of installed technology. Plastic

closures have benefitted from this with their intrinsically lightweight properties and strong potential for innovation.

There have been a number of new innovations for plastic closures in the last two years, with more resistant, technologically advanced lightweight caps providing greater potential for energy reduction and material savings.

Lightweight packaging in general has been a strong trend in the beverage industry, as suppliers continue to strive to develop products which satisfy both environment and cost concerns.

In May 2013, can2closure launched a resealable end. The closure consists of a tamper-evident lever that opens the can when turned 180 degrees in either direction. This simple mechanism is

designed to be easier to open than the standard stay-on tab opening of beverage cans, and can be repeatedly sealed.

Innovation in plastic closures continues to be of growing interest, holding great potential for development in the future.

As a result, the gap between plastic and metal closures is expected to widen, with 52% of the market expected to be held by plastic closures in 2017.

“Plastics closures crossed a critical threshold last year in overtaking the share of their metal counterparts across all CPG end-markets,” said Dominic Cakebread, Director of Packaging Services at Canadean.

According to Cakebread, the recent growth of plastic closures has been

driven partly by the associated gain in share of plastics containers and partly by further advances in closure design, materials and systems.

“These have been focusing on reducing polymer weight and cost, while maintaining or improving technical performance and convenience features. It is the greater flexibility of plastics to adapt to the changing demands of the closure market that give them their ongoing advantage.”

This information is based on findings from the Canadean report ‘Innovation in Caps and Closures’ published in November 2013.

Canadean Web: www.canadean.com

DB-Automation adds a new division Injection moulding automation specialist, DB-Automation, has announced the acquisition of feeding systems and automation equipment manufacturer, Premier Bowl Feeders.

This development sees UK-based DBAutomation acquire the rights to manufacture bowl feeders and associated feeding elements previously made by Premier. Key team members from Premier Bowl Feeders will join the DB-Automation team.

“When DB-Automation approached Premier Bowl feeders it was evident that

the quality and workmanship displayed in the equipment manufactured at Premier was exceptional, this aligned perfectly with the beliefs of DB-Automation, that all equipment should be manufactured to the highest possible standards in order for it satisfy completely,” commented Nick Parker, Operations Director at DBAutomation.

DB-Automation says this new division provides the company with a product range that immediately extends the expertise on offer. Now, along with the high speed de-mould and take-out robots

it says it can fully integrate equipment for bowl feeding components both for pre- or post- moulding operations, as well as stand-alone feeding systems for all industries including end users and OEMs alike.

The company says plans over the next 12 months for the re-development of the bowl feeding products will see the addition of far more units into the currently strong range.

DB Automation Web: www.db-automation.co.uk

Funding backs research into recycled compounds for cars

Plasticiser growth predicted to reach $19.5bn by 2020

Funding from local authorities has enabled UK recycler Luxus to embark on a three year project that will enable R&D into recycled compounds for the automotive industry. The funding has come from East Lindsey District Council's Rural Development Fund, and will see 14 skilled posts created: 10 machine operators, two polymer technicians and two polymer technologists all working at its Louthbased business, situated on the Fairfield Industrial Estate.

The Council's Portfolio Holder for Economic Development, Councillor Craig Leyland, said: “We are pleased to be able to support Luxus in what will be a cutting edge project creating at least 14 jobs over three years.

“This is what the Rural Development Fund is all about - supporting local

The global market value of plasticisers is expected to increase to more than US$19.5 billion in 2020, with Asia-Pacific and Eastern Europe predicted to be major growth markets, according to the latest study by market research firm, Ceresana.

The use of plasticisers in plastics, PVC in particular, dominates demand, with Ceresana forecasting that the production of phthalate-free plasticisers will be a key driver for growth.

"In 2012, about 87 percent of global plasticisers consumption was processed in plastic products, the majority being films and cables,” commented Oliver Kutsch, CEO of Ceresana.

Demand for plasticisers in the production of rubber products, paints and varnishes, as well as adhesives, is considerably lower.

The highest growth rates are expected for the BRIC countries (Brazil, Russia, India, China), but Ceresana predicts the USA is also likely to increase demand for plasticisers during the next eight years. Demand in Western Europe is anticipated to hardly exceed stagnation; however, the study suggests an increasing demand for phthalate-free plasticisers will stimulate the market.

Health concerns of consumers and possible further bans on the use of phthalates lead to an increased demand for phthalate-free and biobased plasticizers. Ceresana expects

businesses, enabling them to survive and expand and creating jobs in our community.”

Peter Atterby, Managing Director at Luxus added: “We are pleased to achieve grant funding to support the future development of our technical plastics recycling business and therefore the local community through future job creation.

“In making this decision the East Lindsey District Council has recognised the importance of local, well established manufacturers and the contribution they can make to its future economic plans.”

The funding has also acted as a catalyst attracting a further £134,925 of funding for the project.

Luxus Web: www.luxus.co.uk

Spanish engineering plastics group gets UK distribution UK-based polymer distributor, Longfield Chemicals, has announced a new partnership with Spain’s Ferro Engineered Polymer Products that will see it market and distribute the company’s range of products in the UK. Ferro Engineered Polymer Products’ operation in Castellón, Spain, is a major supplier of high quality masterbatches and concentrates. The company, which is part of Ferro Corporation, headquartered in Ohio, USA, produces a range of coloured, white, black and additive masterbatches and

concentrates designed for use in processes including injection and blow moulding, film, sheet and profile extrusion and compounding.

“Ferro and Longfield are confident that Ferro's innovative and rapidly growing product portfolio and Longfield's dynamic approach to polymer distribution are well matched,” said the companies in a joint statement announcing the partnership.

Longfield Web: www.longchem.co.uk

30 • WWW.EPPM.COM • JANUARY/FEBRUARY 2014

phthalate plasticizers, especially DEHP, to lose even higher market shares at the favour of phthalate-free products than they did in the past.

Where new production capacities are created in Western Europe, these will be almost exclusively dedicated to the production of phthalate-free plasticizers; even China is exhibiting excess capacities for DEHP now, whereas so far DEHP had accounted for about 60 percent of the AsianPacific market.

Ceresana Web: www.ceresana.com

INDUSTRY

News

Coca-Cola’s PlantBottle Technology applied in automotive sector The Coca-Cola Company and Ford Motor Company are collaborating on an interior vehicle fabric made from the same renewable material used to produce Coca-Cola's PlantBottle Technology for its plastic packaging.

The two companies recently unveiled a Ford Fusion Energi plug-in hybrid research vehicle which uses the first-ever fibre that can be woven into durable, automotive-grade PET fabric from PlantBottle material for interior fabric surfaces covering seat cushions, seat backs, head restraints, door panel inserts and headliners.

The vehicle marks the first time PlantBottle Technology has been applied beyond packaging and is part of a commitment by the two companies to develop innovative new products produced from renewable materials.

“By using PlantBottle Technology in a plug-in hybrid, Ford and Coca-Cola are showing the broad potential to leverage renewable materials that help replace petroleum and other fossil fuels,

reducing the overall environmental impact of future vehicles,” said John Viera, Global Director of Sustainability and Vehicle Environmental Matters at Ford.

Both companies use PET in a variety of products including plastic bottles, fabrics and carpets. This, they say, provided a natural opportunity to bring together both recyclable and renewable technologies.

“This collaboration with Ford demonstrates that PlantBottle Technology can be applied anywhere PET plastic is traditionally used, but with a lighter footprint on the planet,” said

Scott Vitters, General Manager, PlantBottle Packaging Platform, The Coca-Cola Company. “We are pleased to share this technology with Ford, and look forward to continuing to expand the application of PlantBottle Technology.”

Ford Web: www.ford.com Coca-Cola Web: www.coca-colacompany.com

Plastic voted “sixth most important invention” In a new survey, published by the Institution of Chemical Engineers (IChemE), chemical engineers have voted plastics as the sixth most important chemically engineered inventions and solutions of the modern era.

From a shortlist of over 40 inventions, chemical engineers voted for their most important chemically engineered solutions over the past century, with plastics’ “relatively low cost, ease of manufacture, versatility and imperviousness to water,” being cited as major benefits in their use for an “enormous and expanding” range of products.

“It is difficult to conceive of modern living without plastics. Versatile, lightweight and tough it is no surprise that worldwide demand for plastic has risen from 1.7 million tonnes in 1950 to 280 million tonnes in 2011. That trend is expected to continue,” commented IChemE Media Envoy, Thaddeus Anim-Somuah, a Process Engineer based in The Netherlands.

“Innovations in plastics have also supported improvements for many other products and industries. In particular, the construction, automobile and textile industries have been able to develop new products,” he continued.

“Health has benefited - the simple task of storing and supplying clean water in plastic bottles or down lightweight pipes has saved many lives.

“The food industry has been transformed by plastic packaging.

Manufacturers, retailers and consumers have benefited from extended shelf lives. Even the environment has benefited from plastics by helping to reduce the amount of materials needed for packaging and the energy required to transport goods.”

The full list of solutions that made the top 10 in the survey were: 1) Drinking or potable water; 2) Petrol or gasoline (and

other fuels including diesel); 3) Antibiotics; 4) Electricity generation (from fossil fuels); 5) Vaccines; 6) Plastics 7) Fertilizer; 8) Sanitation; 9) Electricity generation (from non-fossil fuels); 10) Dosed medications (such as tablets, pills and capsules) “Plastics fully deserve to be in the top ten of chemically engineered products and they will continue to evolve and change especially in relation to sustainability,” Anim-Somuah concluded.

strategic fit with RPC. It operates in our core geographic and product markets and complements the Group’s existing market positions very well.

RPC says M&H’s growing business in the US offers the Group a stronger platform from which to invest in profitable growth going forward, as well as extending the Group’s product ranges to include flexible tubes and a range of personal care packaging for short production runs and over-the-counter healthcare container designs.

The second acquisition is Bosnia and

Herzegovina-based supplier of injection moulded rigid plastic packaging, Helioplast. Generating circa £7m of annual sales, Helioplast manufacturers a range of packaging for consumer food segments.

RPC has funded both acquisitions from existing debt facilities and expects them to be earnings enhancing for the Group in the next financial year ending 31 March 2015.

Since 2012, three new members joined EPRO from the Netherlands, Canada and South Africa. EPRO now includes 19 members (including Recoup) from 16 countries and there is a global appetite for EPRO support and international cooperation.

“Membership growth in 2013 for two key plastic recycling associations demonstrates growing importance of plastic recycling and continued commitment from leading stakeholders,” commented Stuart Foster, CEO at

Recoup. “In 2014, Recoup will continue to deliver a range of strategic, research and practical activities and projects across the plastics supply and recycling chain in partnership with its members and other stakeholders to improve the plastic recycling opportunity.”

Institution of Chemical Engineers (IChemE) Web: www.icheme.org

RPC Group makes packaging acquisitions RPC Group has made recent acquisitions designed to boost its position in the rigid plastic packaging markets.

The first acquisition is UK-based Maynard & Harris Group Limited (M&H), a major supplier of rigid plastic packaging to the personal care, healthcare and selected food segments, across all blow moulding and injection moulding conversion processes, for £103.5m.

M&H will operate as an independent business within RPC’s Bramlage cluster

and RPC says it will enhance the Group’s leading personal care product offering in the UK, mainland Europe and the US. Pim Vervaat, Chief Executive of RPC, commented: “Following the announcement of ‘Vision 2020’ in November, the acquisition of M&H represents an important step in realising RPC’s strategy of selective consolidation in Europe and the creation of a meaningful presence outside of Europe.

“M&H is a well-established and highly respected business, which has a good

RPC Group Web: www.rpc-group.com

Strength in numbers for plastic recycling associations Two plastics recycling associations have seen an increase in membership numbers in 2013 as the industry strives to improve the awareness and understanding of recycling and recyclability.

UK-based Recoup, has seen 12 new members join its ranks in 2013 which it says demonstrates the increasing focus on plastics and its role in working and motivating the supply chain to meet the challenges and targets which the industry faces.

The new members include SITA UK, RPC Group, Viridor, Machinex, Kent Resource Partnership, Centriforce Products, PlasRecycle, Ellen MacArthur Foundation, Ashortwalk Ltd, Brunel University London, Campden BRI and Milton Keynes Council.

2013 was also a positive year for EPRO, an association of national organisations charged with organising, managing, researching and promoting recycling and recovery of plastics throughout Europe.

Recoup Web: www.recoup.org EPRO Web: www.epro-plasticsrecycling.org

JANUARY/FEBRUARY 2014 • WWW.EPPM.COM • 31

INDUSTRY

News

Milacron makes further acquisitions Milacron LLC has completed the acquisition of Industrial Machine Sales, Inc. (IMSI) and its sister company, Precise Plastics Machinery (PPM). The move follows last year’s announcement that the Mold-Masters firm was to be acquired by Milacron, joining other established brands DME and CIMCOOL already part of the umbrella.

IMSI specialises in the application engineering of primary plastics processing and support systems for many operations, including injection moulding, extrusion and blow moulding.

PPM was established in 1994 as a full service support company for the plastics industry, offering pre-owned equipment and turnkey services.

Based in Southlake, Texas, IMSI and PPM’s staff will join the Milacron team and will remain at the current location.

The location will serve as a High Impact Technical (H.I.T.) center in the region providing a full spectrum of plastics machinery support, including training and aftermarket parts and service.

Larry Burchett, President and Owner of IMSI and PPM, will serve as Vice President of Sales and General Manager of the Milacron Certified Pre-Owned Machinery division. Burchett began his career at Milacron and assumed increasing levels of responsibility throughout his tenure. His purchase of IMSI in 1991 ended his direct employment at Milacron, but kept him

KUKA to open new robotics facility in North-East England Kuka Robotics has announced plans to open a new new office and unit space in the in Newton Aycliff, County Durham in the first quarter of 2014.

The company says the unit will allow it to offer improved services to customers in the North; including physical robot demonstrations and trials, as well as the ability to access local training. The offices will also hold spare parts and have dedicated engineer resource, which Kuka says will mean local customers will benefit from quicker response times should problems arise.

Gary Hughes, Kuka Finance Manager, said “This is an exciting time for Kuka and the new offices represent an important first step towards offering our customers improved local support across the UK.”

The new site will be located on the Aycliffe Industrial Estate, directly adjacent to the A1(M).

Kuka Robotics Web: www.kuka-robotics.com

Swappage scheme promotes automation upgrades A swappage scheme currently being undertaken by ABB Robotics is seeking to promote greater use of the latest robotic automation technology amongst UK manufacturers.

Subject to the payload of the robot, the Robot Swappage Scheme enables operators to get up to £4,000 off the purchase cost of a new ABB robot when they trade in an existing robot, from any manufacturer, installed 12 or more years ago.

Open until 8th April 2014, the scheme is part of ABB’s drive to encourage the greater take-up of robotic automation in the UK manufacturing sector.

The scheme is aimed particularly at small and medium sized businesses that have a current working robot, which may be nearing the end of its useful economical working life.

“A large number of robots in use in the UK are now at the point where they are becoming increasingly more difficult and costly to maintain,” said Dean Phipps, ABB Robotics’ Service Sales Manager for the UK and Ireland.

“Difficulties in obtaining spares for obsolete models, the absence of any warranties and finding technicians qualified to work on older models are just

some of the problems that can add to the heartache, expense and inconvenience of using older robots when issues inevitably occur. In such cases, replacing the robot with a new model can present the most sensible option.”

“New developments in robotic technology may also mean that companies using older models may be missing out on a raft of new productivity enhancing features. The enhanced efficiency, flexibility and reliability delivered by the latest generation of robots could help these companies to dramatically transform their production operations.”

ABB Web: www.abb.com

32 • WWW.EPPM.COM • JANUARY/FEBRUARY 2014

connected through a 20-year agent association developed among IMSI, PPM and Milacron.

“We are excited to bring IMSI and PPM into the Milacron organisation. As a leading Independent Representative for over 20 years, Larry and his team have contributed significantly to the overall success of Milacron. Now, as a permanent part of our company, we plan to work closely together to improve our customer experience through increased coordination, communication and a single-minded focus to support the customer throughout their asset lifecycle.

This move continues to build on our objective to provide unparalleled aftermarket service and support to help

fuel our customers’ success. We want to offer a clear total lifecycle advantage in a competitive global landscape,” said Shawn Reilley, Group VP of Sales & Marketing, Global Plastics Machinery.

“I have had a long relationship with Milacron and am excited about how the joining of these companies will benefit our customers,” said Burchett. “The strong engineering services approach of IMSI and PPM combined with the technologies of Milacron allows us to be a partner from the purchase of a new machine all the way to when it is time to upgrade or buy new again.”

Milacron Web: www.milacron.com

Viridor enters closed-loop recycling contract Plastic bottle recycler, ECO Plastics, and waste management firm, Viridor, have announced a twelvemonth contract that they say will to help close the loop in soft drinks packaging.

The multi-million pound agreement will see Viridor supply 10,000 tonnes of plastic bottles throughout 2014 – almost eight percent of ECO Plastics’ total Image: From Left to Right – Nick Brown (Coca-Cola Enterprises), capacity.

Jonathan Short (ECO Plastics) and Herman van der Meij (Viridor The announcement is Resource Management). the latest in a trend revenue levels. Crucially that makes it which has seen a growing portion of the difficult to raise the finance necessary to industry move away from spot trading invest in new technology, which in turn and instead develop long-term means that there are still valuable collaborations. ECO Plastics say the resources which can’t currently be additional surety provided by such recycled domestically. agreements has allowed it and others to “As it becomes more and more difficult invest in the creation of new technology, to export our waste material overseas, further developing the UK’s waste we’re left with a choice between building infrastructure. new infrastructure and going back to Commenting on the announcement, landfill. We see an industry wide move to Jonathan Short, Deputy Chairman of longer agreements as the fundamental ECO Plastics, said: “Obviously a to resolving that dilemma.” contract of this size is important for us, Herman van der Meij, Director of Viridor and we’re delighted to be partnering Resource Management, said: “Viridor with one of the UK’s leading waste has led the way in UK recycling through management companies in Viridor. the development and operation of “But today’s announcement is also advanced technology recovery facilities. strategically significant for ECO Plastics, Practical partnerships and cross-sector marking the latest phase in our plan to collaborations are essential if we are to offer more strategic, long term move towards a real circular economy.” partnerships to our key suppliers.

“Buying material on the spot market can ECO Plastics at times deliver robust prices, but it Web: www.ecoplasticsltd.com provides very little certainty over future

European Commission continues to evaluate proposed joint venture The European Commission is continuing with its evaluation of the 50/50 Joint Venture proposal in European chlorvinyls activities from Solvay and INEOS, following the original notification in September 2013.

During this Phase II review, Solvay and INEOS have both confirmed that they will continue to work with the Commission and remain confident that the proposed Joint Venture will receive

clearance, which could be in the first half of 2014.

Both companies say this would create a “competitive and sustainable business that would continue to benefit customers in Europe's rapidly changing markets and highly challenging economic environment.”

Ineos Web: www.ineos.com

INDUSTRY

News

Award winners highlight PVC innovation

Evonik invests in FRX Polymers

PVC water pipes with increased dimension, conveyor belts made from renewable plastics and flax fabrics from nanotechnology, were some of the innovations awarded prizes at the recent SolVin Awards.

The awards, which aim to recognise innovative solutions in the PVC sector, saw Spanish pipe manufacturer, Molecor take the Gold prize for its large size PVC-O pipe. The pipe, which can now measure up to 630 mm in diameter opens a new market for PVC pipes, being 50 percent larger than previous versions and corrosion free.

“The competitors and the winners of the SolVin Award show that the PVC industry is responding with innovative solutions to global megatrends, including the growing demand for water, energy and resource efficiency amid difficult economic times,” said SolVin Managing Director Filipe Constant. “They also demonstrate how our industry is meeting those needs in a safe and sustainable way.”

German-based Forbo Siegling took Silver for its BioBelt and AmpMiser conveyor belts, which are made using renewable materials and the French-based Depestele Group won Bronze for NanoVin flax reinforcements using nanotechnology. Spain’s Plasticos Escanero won the Recycling award for

Speciality chemicals company, Evonik, has led a $12million series C financing round in FRX Polymers of the USA, with its corporate venture capital fund, Evonik Venture Capital, investing $2.5 million in the round.

FRX is the manufacturer and marketer of a new family of inherently flame retardant plastics and oligomers, trade named Nofia. The closing coincided with the opening of FRX’s first industrial scale flame retardant polymer plant in Antwerp, Belgium.

Nofia products are a family of halogenfree, phosphorus-containing oligomers and polymers that are inherently flame retardant and have applications in consumer electronic, building and construction and transportation markets.

“We are delighted to have become an investor in FRX. This is an exciting company with a unique product offering that has come a very long way and is strategically well positioned to carve out an important market share in the years to come,” said Dr Bernhard Mohr,

processing PVC industrial waste, and Italy’s FIP won the Industrial Design award for their Easyfit PVC-U ball valves for water distribution.

The Special Prize went to a team effort

by BASF, Renolit and Sanquin that developed plastic materials for medical applications, including a blood bag for pediatric use.

The 78 projects in competition came from sectors ranging from construction to electronics, gardening to road safety, health care to autos and other manufacturing. The ceremony also included a panel discussion, a first for the SolVin Award, on innovation and sustainability.

Solvay Web: www.solvayplastics.com

Managing Director of Evonik Venture Capital.

Marc Lebel, President and CEO of FRX Polymers, said: “With Evonik, we have added an important strategic partner who shares the same vision as we do for the growth of the company to our shareholder base.”

Joining Evonik in this financing round are FRX’s current shareholders, Capricorn Venture Partners, DB Masdar, SAM Private Equity, BASF Venture Capital, Israel Cleantech Ventures, a Western Canadian Syndicate and many of the company’s founders and employees.

Evonik Web: www.evonik.com

Dieffenbacher adds preform center to Fraunhofer collaboration Dieffenbacher, based in Eppingen, Germany, is continuing its partnership with the Fraunhofer Project Center (FPC).

The Dieffenbacher Preform Center sees the FPC expand its range of applications to include those involving carbon fibre reinforced plastics.

Research at the Fraunhofer Project Center (FPC) in London, Ontario, is focused on the area of fibre composites in lightweight construction. The FPC works in close collaboration with both Western University and the Fraunhofer Institute for Chemical Technology (ICT), and is operated as an independent institute that undertakes applied research into materials development and the processing of fibre-composite materials.

The existing Dieffenbacher plants in North America have used glass-fibre reinforced thermosets (SMC) and longfibre reinforced thermoplastics (LFT) to enable the development and production of semi-structural components. The addition of the Preform Center, which is currently under construction, is set to expand the range of applications now offered by the FPC to include processes related to high-pressure resin transfer molding (HP-RTM). Preform technology forms part of the innovative HP-RTM process, which is primarily used to produce components using carbon fiber reinforced polymers (CFRP). Previously, CFRP preforms could only be produced

by hand via a cost-intensive process. At the Preform Center, production will be fully automatic — allowing the institute to continue to implement the systematic strategy of introducing series-production processes.

This technology is planned to be commissioned at the end of March, after which companies will use the research

center to further develop and test the use of CFRP during the production stage. The expansion of the HP-RTM process is based on an increasing need for procedures in the production of structural components.

Dieffenbacher Web: www.dieffenbacher.de

PVC recycling promoted at Pollutec Fair Plastics Recyclers Europe’s PVC recyclers recently exhibited at the Pollutec Fair in Paris from 3-6 December, as a part of the VinylPlus Communication Project to promote PVC plastics recycling and raise visibility for rPVC products and materials.

The stand, which featured eight PRE members, was located in the ‘Waste and Recycling’ sector at Pollutec, an

event which was visited by around 30, 000 people.

The PVC working group members involved in the project presented videos, samples and products made of recycled PVC and say the fair was a successful event in raising awareness of PVC recycling in France.

Plastics Recyclers Europe Web: www.plasticsrecyclers.eu JANUARY/FEBRUARY 2014 • WWW.EPPM.COM • 33

ADVERTISERS’ INDEX

EPPM Classifieds RE-PROCESSING EQUIPMENT Cont’d

MATERIALS

Company

Page

Abbey Masterbatch

34

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ACS/Cumberland

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DISTRIBUTORS REQUIRED For a number of key areas

Chinaplas

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Engel

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PROCESSING EQUIPMENT ANCILLARIES, AUTOMATION & TESTING EQUIPMENT

Krauss Maffei

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To Advertise Here...

Renmar Ltd

Contact Lucinda Nicholls Tel: +44 (0) 1244 680222 Email: lucinda.nicholls@rapidnews.com

Plastico Trading Plastrep

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Tappex

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Tinius Olsen

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TransXL

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Vinyl GB

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34 • WWW.EPPM.COM • JANUARY/FEBRUARY 2014

For further information: T: +44 (0) 1789 206600 F: +44 (0) 1789 206651 E: sales@enquires.co.uk Or scan the QR code below:

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Granulators Shredders Pulverisers Blowers-cyclones All spares Contact: Dick Monkhouse Tel: 01928 734724 Email: sales@zerma.co.uk

eppm

To advertise here please contact Lucinda Nicholls: Tel: +44 (0) 1244 680222 Email: lucinda.nicholls@rapidnews.com USED MACHINERY Cont’d

MATERIALS HANDLING

OTHER

Extruder and Extrusion Lines

Maschinenhandel Borowski Used plastic processing machines Injection moulding, blow moulding and accessories

Tel: +49-2244-83041 email : pmh.gmbh@t-online.de www.pmh-extruder.com

Over 35 Years of Service

130mm + 63mm Davis Std coextrusion sheet line Upstream ; Comprising extruders, continuous s/changer, g/pumps, Cloeren Coex block & 1100 die, 2002!!

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®

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Prime Reprocessed Regrind Pulverised As well as composition raw materials For all of your PVC requirements please call +44(0)1691 664256 / fax +44(0)1691 664235 Email: enquiries@vinylgb.co.uk The Fort Offices, Artillery Business Park, Oswestry, SY11 4AD ® The Vinyl GB logo is a registered trade mark

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Web: www.transxl.co.uk

1120mm wide EDI close approach PET sheet die model H100 with Flex lip and decals. Lip heater. Lip gap up to 2.5mm 1996.

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50mm Welex extruder 1700mm Line for ABS and PMMA

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Conair Dehumidifying Dryer Model CD300 With Insulated Hopper, And Hopper Loaders.

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500mm wide Illig RDM 50/3 lid thermoformer, Double heaters, Motor Indexing. Auto Rail Spreading, Counter/ Stacker, 1982 very good condition.

32mm Corelco EC25LLV corrugator

1500mm wide Covema 2 Station Winder with variable speed control. 76mm air shafts.

Boschaert chucks.Max roll diameter 1000mm. Dc motor control 2.2kw.

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JANUARY/FEBRUARY 2014 • WWW.EPPM.COM • 35