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Each issue is distributed in print and digital format to 30,225 buyers and specifiers in the European plastic processing industry. Volume 15 Issue 5 © July 2013. 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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John Ellis, Segment Manager Polycarbonate, Bayer MaterialScience
Clive Maier, Owner and Director, Econology Ltd.
Nigel Brown, Founding MD, Frontier Aerospace
Dr Martin Kay, Chief Consultant, Pira International
Vicki Sayer, Regulatory Manager, Colormatrix
Charmaine Bowers, Operations Manager, Polymer Training & Innovation Centre
Pipe Extrusion Recycling Micro Manufacturing
Jonathon Short, MD, ECO Plastics Ltd.
Home Appliances
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Mark Bonifacio, President, Bonifacio Consulting Services
Andy Bone, Sales Director, Formaplex
Andrew Smith, Head of Manufacturing, Numatic International
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Alex Collins, Director, Vannplastics Ltd.
Regulation & Compliance
Andrew McArthur, Engineering Manager, IKO
Biopolymers/Materials Science
Simon Chidgey, Director, M&H Plastics
General Industry Insight
Paul Maley, Senior Mechanical Engineer, Selex Elsag
James Goddard, Honorary Lifetime Member, Plastics Pipe Institute
Jon Herbert, Director, FS Cables
Dr Terence A. Cooper, CEO, ARGO Group International
Ken Braney, 2010-2011 President, Society of Plastics Engineers
Advisor for the German & Scandinavian Speaking Countries
Film & Sheet Extrusion Recycling
Martin Marron, MD, Biffa Polymers
Graeme Diston, Senior Injection Moulding Engineer, Bausch + Lomb
Education in the UK & Ireland
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Graham Pickwell, Technical Adviser, Polymer Training & Innovation Centre
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John Bunker, Member, Worshipful Company of Horners
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Wood Plastic Composites
A recent study by IT market research firm Vanson Bourne states that nearly a quarter of UK firms in the manufacturing sector do not provide WiFi, even in the office. Half of these firms cite lack of security as the reason for the decision. I don’t know if the figures correlate throughout Europe, but I’ve heard that security fears are an issue for many of our readers where WiFi is involved. It’s absolutely understandable. Process parameters, material recipes, product designs, delivery information, client databases - if these fall into the wrong hands (a competitor, or worse, someone looking to plagiarise your designs) it’s game over. Not just because of the initial threat to intellectual property etc., but because for most small to medium manufacturers, funding a lengthy court battle could swallow up cashflow; add to this the potential interruption in production while the matter is resolved, and it’s a recipe for disaster. Despite this apparent anxiety around connecting manufacturing supply chains to the web, and more recently, the cloud, certain IT firms are now marketing the phrase ‘Big Data’ around the processing sector. It has been described as a so-called ‘revolution in software development’. Is it though? Certainly innovation in recent years has ushered in the ability for processors to mobilise their staff, allowing remote access to machines, delivery implementation and so on. This is undeniably a sign of the times, and has potential to boost productivity (though many are concerned that there may be safety issues, and with good reason). But Big Data in processing? Storing millions of gigabytes of product analyses, machine settings and other critical data in an invisible space may seem unnerving and unnatural to many, but then, is this such a huge leap from ERP? In fact, is it any different? Aside from a new method of storage, and the increase in the sheer volume of information (is that why it’s ‘Big’?) I’m not convinced that the two things are actually two things. So with that in mind, is new software and new connectivity really something to be afraid of? Data stored on a physical hard drive is surely more susceptible to theft and fire than data stored in the cloud? My final question for you, the processing community, is this: if you do choose to embrace it, once you have your Big Data, what do you do with it? This is not a cynic’s question, more a curious enquiry. It’s been said that a gas turbine being monitored with new analytics software produces 500GB of reportable data per day. Twitter, in comparison produces just 80GB per day. I reckon that I view about 0.2KB of the data on Twitter every day (that’s still a lot) so who has time to peruse 500GB? I repeat, I’m not a cynic, but I am interested - please do get in touch with your opinions.
Plastics for the Environment
Manufacturers: why are you scared of your WiFi connection?
General Industry Insight
“
from the editor
Our Editorial Advisory Board is comprised of a cross-section of the plastics industry, including processors, consultants, technicians and key industry figures.
Dr Gerd Schmaucks, Independent Consultant
cover story
Romi Sandretto at
2013 For K 2013 Romi Sandretto is going to present new models of its fully electric- and servo-driven machines, the EL and EN ranges. Romi, the company behind the Sandretto brand, is investing heavily in the development of new equipment, with a view of obtaining the ‘perfect balance’ of performance, efficiency, constructive quality and great value for money. The machines are designed to save energy and material at the same time as keeping productivity at high levels. They aim to increase user productivity whilst cutting down energy bills. Romi uses a vertical production system, starting from the foundry, through to cutting, bending and welding all metallic parts, electrics, and final assembly; all steps take place inhouse, which the company says guarantees a trademark level of quality.
EN Series The new generation of Romi Sandretto machines, the EN Series, relies on smart servo-pumps run by highly dynamic motors that are said to deliver second-to-none response times. Energy savings come from the speed, which allows the machine to revert to idle and save power when not required. Translating this into numbers, Romi says that users can expect savings of 30% compared to variable displacement pumps and 60% against typical fixed displacement pumps. The system is controlled by an inverter connected to the CM10, a user-friendly touch screen interface. All signals operate in closed loop; in other words, the machine is fed by sensors and self-adjusts to compensate any variations; less variation results in more precision. The outcome is more repeatability; this translates to reduced overshooting, and therefore substantial material savings. Compared to a normal hydraulic machine, one case study showed that the EN’s precision resulted in a 4.6g reduction of material consumption per cycle. The EN range comprises 70, 100, 150, 200, 260 tonne machines, as well as the recently added 380 and 450 tonne models, which will be launched during K 2013.
The EL uses dedicated servo-motors for every movement running on ball-screws (a technology widely used in Romi’s other product line, CNC machine tools). All movements are mechanically transmitted, without any of the loss that may be associated with a hydraulic system. The result is improved dosing precision and repeatability to a thousandth of a millimetre, says the group. All elements are controlled by the CM15, the newest control system from Romi. A combination of
functionality and ease-of-use, the EL offers fast movements with low noise emissions and a contamination free area, suitable for cleaning rooms. The EL series comprises 75, 100, 150, 220 and 300 tonne machines. The 75 and the 300 tonne machines are the latest models. During K 2013 Romi will be demonstrating three of the machines — the EL 75, EL 300 and EN 450.
EL Series While the EN brings new technology to the all-purpose moulder, the fully electric machines are said to take precision and productivity to a new level.
Romi Sandretto will be exhibiting at K 2013 in Hall 15, Stand D40. JULY 2013 • WWW.EPPM.COM • 5
MACHINERY
BMW selects Italian drying systems for new site Car manufacturer BMW has recently been supplied with Piovan’s ‘Modula’ drying technology at one of its new German production sites for the BMW i3 and BMW i8. The group specified to all potential suppliers that any of the processes necessary to convey, dry and blend the different polymers in use had to be “energy efficient and selfsustainable”. Outputs claimed by each potential supplier would be tested and compared. The testing period, which lasted for six months saw five major suppliers of auxiliary equipment take part. Modula is an adaptable, energy-efficient drying system with multiple hopper assembly, which Piovan launched to the market in late 2010. Recently Piovan obtained a specific patent in certification of the innovative nature of the Modula system. The two Modula set-ups supplied to BMW were configured to support an expansion to twelve production lines. The materials used by BMW are mainly blends with polypropylene or polycarbonate base (for example, PP/EPDM and PC/SAN). The plastic part is first injection moulded and immediately transferred to the painting lines — a sensitive phase of the production process where silicone particles are banned.
Modula does not use any silicone components/parts within the system, making it suitable for such applications. Two sets of Modula were supplied, each configured with single dry air generator and seven drying hoppers with volumes ranging from 600 to 1000 litres. The purpose of hygroscopic plastic drying is to reduce moisture content to the required levels. This operation is generally performed by circulating hot dry air inside a drying hopper. At BMW, the two Modula systems that Piovan supplied automatically adjust and control all operating parameters for each individual hopper, and hence use only the required energy. This is made possible through control software that interfaces the settings for each hopper with the data collected by the sensors installed on the system. This means that, by using a Piovan patented measuring unit located in the air supply line and under each hopper, the airflow can be adjusted and controlled instantaneously and
Re-processor expands with machine investment
A UK-based material re-processor has ordered a new hydraulic injection moulding machine to its portfolio. RMG Plascomp has purchased the Systec 160 machine from Sumitomo (SHI) Demag UK. The machine reportedly offers a good price/performance ratio and a reduction in energy consumption by up to 45 percent. The Systec 160 is said to boost the capabilities of the company which already says it offers a 24/7 ‘one stop shop’ service for clients who want their products manufactured, packed, stored and distributed by a single provider. RMG organises and reprocesses discarded plastics into manufactureready plastic components and produces a finished item for its 6 • WWW.EPPM.COM • JULY 2013
customers, all from one location. Richard Grainger, Managing Director, said: “Our clients like the idea of their plastic components being regenerated from another source, it ensures transparency with regards to product traceability and reduces their carbon footprint.” Sumitomo Demag’s Central Area Sales Manager, Kevin Heap, added: “It’s incredibly flexible, accommodating any number of injection moulding variations. “The short cycle times and high degrees of precision ensures it delivers maximum efficiency.” Sumitomo Demag Tel: +44 1296 739500 Web: uk.sumitomo-shi-demag.eu
independently hopper by hopper. In addition, the total airflow is modulated automatically and efficiently by the central drying unit, equipped with IE3 class blowers. Modula is currently available for medium and large capacity applications (200 to 2000 kg/h) and, Piovan claims, provides savings of as much as 50% in
comparison to ordinary centralised drying systems of equivalent capacity. Modula is also Winfactory ready. Along with Modula, BMW was supplied with Varyo auto-adjustable vacuum conveying systems, MDW gravimetric blenders and a Winfactory supervisory system. Piovan Email: sales@piovan.com Web: www.piovan.com
New Victor machines for UK moulder
A Leicester-based moulder and toolmaker has announced it has invested in two new all-electric machines for its latest project. Ledwell Plastics has purchased two Valpha injection moulding machines from Victor CNC (UK). The two new machines will produce two separate mouldings and aim to produce 3,000 parts per hour. Ben Simms, Managing Director at Ledwell Plastics said: “We pride ourselves in providing mouldings of the highest quality; the precision of the new Victor machines allow us to
do this consistently and at the right price.” The new machines are equipped with software and control systems that allow for overlapping operations, therefore reportedly reducing cycle time. As well as this, the machines are also said to produce an energy saving of up to 70 percent when compared to a conventional hydraulic machine. Victor CNC Tel: +44 1706 648485 Email: pim@victorcnc.com Web: www.victor-cnc.com
MACHINERY ROUNDUP Polish moulder acquires three new Engels A Polish injection moulder has added three new system solutions to its production capacity. Splast, based in Jedlicze, Poland, has acquired three injection moulding systems from Engel, which includes its new iQ weight control software, for online process control. The machines include the Engel duo 5550/900, the Engel victory 2050H/200V/80L/400 combi and the Engel e victory 440/120 machine, which is equipped with the iQ software. Splast’s services include product design, mould manufacturing, process development, serial production and assembling. Its customers include companies operating in the automobile, white goods, household item, and electronic industries. It mainly outputs materials like glass fibre reinforced polyamide and POM. Tadeusz Sanocki, managing director and owner of Splast, said: “We are at home in challenging and innovative industries. The continuous monitoring of quality-relevant process parameters is an important competition factor to us.” He added: “With iQ weight control, processes now monitor themselves and automatically readjust if necessary. This
means that we have been able to reduce the risk of rejects drastically, because we are producing outstanding quality continuously.” Splast and Engel have worked together since 2005, with 17 machines being provided by the latter. Marek Sanocki, an owner and the technical managing director at Splast, said: “We have dealt with the same contact at Engel since the beginning. Engel is not just a supplier to us, it is also an important development partner, and we particularly value its high levels of system solution competence, which encompass its injection moulding machines, as well as process technology, mould
development, and automation.” Splast says energy efficiency is becoming more and more important to the company. It claims to now only buy hydraulic injection moulding machines with an energy saving option. Sanocki said: “Thanks to the reduction in lost energy we are now using between 30 and 40 percent less energy per machine, depending on its type and use.”
Engel Tel: +43 50 620 0 Email: sales@engel.at Web: www.engel.at
Extensometer claims high accuracy
A test equipment manufacturer has announced a new automatic contacting extensometer, which reportedly supports faster, more reliable and more precise materials testing. Instron’s new machine, named AutoX 750, is said to have a high accuracy of +/- 1 m, with a maximum travel of 750mm and multiple knife edge options. The AutoX 750 meets strain measurement specifications of ASTM E83, ISO 9513 and ISO 527-1. It also complies with ISO 6892-1 Method A and ASTM E8. The data supplied by the new extensometer works in conjunction with Instron’s Bluehill 3 software, which records and stores the data. The extensometer also claims to feature the simultaneous opening and closing of both arms with just one motor, a debris shield to protect it from damage and an ergonomic tensioner to adjust the gripping force of the measurement arms. The automatic nature of the extensometer is said to allow the user to increase throughput while maintaining a high level of repeatability and accuracy throughout the duration of the test. Instron Tel: +44 1494 464646 Web: www.instron.co.uk JULY 2013 • WWW.EPPM.COM • 7
MACHINERY ROUNDUP Specialised foam extrusion line announced
KraussMaffei Berstorff has launched a new foam extrusion line specialised for the production of cap seals. The extrusion line, named Schaumex ISO-PAC, reportedly offers eco-friendly and cost-effective production of the seals, which are made of PE lowexpansion foam. The Schaumex single-screw extruder series produces sheets, film, pipes and profiles. The machines combine all process steps in a single machine - from compounding, blowing agent injection and incorporation up to the final cooling stage. The extruder has a processing section of 40 L/D length with electrical heating and air-heating systems in the compounding and mixing section to melt the plastic material at about 200°C and to mix in the required additives. The CO2 blowing agent is injected through a special injection system in the central section of the extruder barrel. The processing zone downstream from the injection point is equipped with a fluid temperature
control to cool down the melt with the blowing agent to about 130°C. “We are faced with an increasing demand for Schaumex lines at international level. Recently, we have sold two Schaumex 120 lines with an output rate of 210 kg/h and two Schaumex 150 extruders with a lowexpansion film production capacity of up to 320 kg per hour to customers in Asia and Eastern Europe,” said Matthias Reimker, project manager for foam extrusion lines at KraussMaffei Berstorff. All four lines sold feature round-section dies and Teflon-coated die lips and are equipped with an efficient outside aircooling. The cut flat sheet is cooled down on a take-off unit with two watercooled cooling rolls of 600mm in length and subsequently wound up. In addition to the single-stage Schaumex process, KraussMaffei Berstorff offers Schaumtandex solutions composed of a primary extruder for plasticizing and homogenizing and a secondary extruder used for melt cooling.
As this particular market is faced with an increasing demand for eco-friendly solutions, about 75% of low-expansion foam products are produced on the basis of non-polluting physical foaming processes, and only 25% using chemical foaming.
Aside from environmental aspects, this is also due to the fact that reaction products of chemical foaming processes may affect odour and taste, which must be avoided in the food sector. KraussMaffei Berstorff Web: www.kraussmaffeiberstorff.com
PET system said to offer energy savings A German-based supplier claims it has developed a system that can lower energy costs for PET production. BKG Bruckmann & Kreyenborg says its CrystallCut pelletising system can reduce production costs by up to €3.2million a year (approximately £2.7million). The company says its system saves up to 15 EUR (approximately £13) per tonne and with an average throughput of 600 tonnes per day; an average of 9,000 EUR (approximately 7,600) per day can be saved. CrystallCut uses the thermal energy of
New pellet drying oven revealed Grieve Corporation has announced a new electric oven for the drying of pellets in pans. The oven, the No. 1027, is a 287˚C cabinet oven featuring 6 inch insulated walls, aluminised steel exterior, stainless steel interior and four doors. In each of its openings, the oven has eight 20" by 30" loading pans with c hannel supports. The No. 1027 can be controlled via a digital indicating temperature controller and also has a manual reset temperature controller. Grieve Corporation Tel: +1 847 546 8225 Email: sales@grievecorp.com Web: www.grievecorp.com 8 • WWW.EPPM.COM • JULY 2013
the melt for crystallisation. The melt is granulated by means of an underwater pelletiser, and the outlet temperature of the pellets after the dryer is already at the required temperature of 160-180ºC. Therefore, according BKG Bruckmann & Kreyenborg, the PET is pelletised and crystallised in the same single step, resulting in ‘enormous energy cost savings’. BKG Bruckmann & Kreyenborg Tel: +49 251 26501 0 Email: info@bkg.de Web: www.bkg.de
MACHINERY
SHOWCASE PRINTING & DECORATING Sheet extrusion line allows great scope for printing In recent months, KraussMaffei Berstorff says it has recorded increased demand for extrusion lines for the production of photosensitive sheets for offset printing. “Photosensitive sheets made of styreneisoprene-styrene block copolymer (SIS) with a thickness of 1 to 7 mm are produced for offset printing,” said Marco Schönekäß, Sales Engineer for Film and Sheet Extrusion Lines at KraussMaffei
Berstorff. “These sheets are covered with a printing film that is provided with a cut-out in the area of the pattern to be printed. Cross-linking of the material is then produced by ultraviolet light applied to the area in question. After the non-crosslinked material has been chemically washed in a final step, the printing sheet with the desired printing pattern is finished. This printing sheet can be used for wide variety of products.” Throughout the entire production process up to cross-linking, the sheets are susceptible to deformation. To prevent this they are covered with protective film on both sides after extrusion. “The processing of lowviscosity, sticky and temperature-sensitive melts involves high
demands on the entire extrusion line – in particular in view of the wide thickness range required in offset printing with a tolerance of +/- 1%,” said Marco Schönekäß. Offering a range of single-screw extruders and counter-rotating or corotating twin-screw extruders helps the supplier to meet more criteria. The group’s portfolio of customised polishing calenders comprises horizontal, vertical and inclined versions,
which come with a number of different polishing and cooling rolls and in various dimensions. Depending on customer requirements, KraussMaffei Berstorff says it can develop and manufacture complete production lines – starting from material feeding up to the wound-up, stacked or packed final product. KraussMaffei Berstorff Web: www.kraussmaffeigroup.com
Surface printing industry strengthened with investment in academia Members of the academic printing community and the gravure printing sector recently gathered at the Hochschule der Medien (HdM) — Stuttgart Media University — for the inaugural print run of the university’s new BOBST Rotomec MW 60 gravure printing press. The institute trains students in all fields of print and media technologies and is the only university in Europe with a dedicated Chair for gravure printing studies. HdM’s new machine — which replaces a
57 year old press — is a 4-colour machine set-up for production runs. The press is fitted with an insetting system enabling production of 8-colour jobs, two metre long dryers, and BOBST Registron register control. The machine is also equipped with an ESA electrostatic print assist system from Enulec (three units with top loading and one unit with direct charge) and a 100% web inspection system from BST. Thomas Reckert, BOBST Area Sales Manager, presented a technical overview of the MW 60 press and its efficiency in
short run printing. This was followed by other technical presentations providing an overview of the gravure printing industry. Using the machine, HdM now offers a facility that businesses can access for a range of activities, such as trial runs for testing substrates, inks, ESA tests for direct-indirect current, etcetera.
BOBST Tel: +39 0523 493 236 Web: www.bobst.com
New Berlin Plastics Tel: +1 262 784 3120 Email: info@newberlinplastics.com Web: www.nbplastics.com
RTP Company Tel: +1 507 454 6900 Email: rtp@rtpcompany.com Web: www.rtpcompany.com
New compound to offer printing capabilities Two companies have engineered a new compound that allows laser marking and reportedly has increased tensile strength. New Berlin Plastics worked with custom compounder RTP Company to custom – create the compound, to be used as a cable tie tool. “We've both worked with RTP Company most of our professional lives, and knew of their ability to create laser-markable plastics that would also meet the strength and other requirements that this application demanded,” said Dave Sansone, New Berlin Business Development Manager. After careful testing and evaluation, RTP Company furnished a custom glass fibre-reinforced RTP 600 Series ABS compound that provided the required tensile strength for the cable tie tool’s tension knob. A matched RTP 6042 Series thermoplastic elastomer (TPE) was then overmoulded on the knob to 10 • WWW.EPPM.COM • JULY 2013
provide an ergonomic gripping surface. The TPE compound was formulated to bond with the rigid ABS substrate for optimum product integrity. RTP Company colourists added lasermarking additives and colourants chosen for their compatibility with the compound and the operational range of the laser being used. This allowed the laser to clearly “write” an indelible, high contrast white mark on the black plastic surface. “The laser-marked numbers are very durable and will hold up for the life of the product,” said Director of Engineering, Mike Miller. Commenting on the supplier/processor partnership that New Berlin enjoys with RTP Company, Sansone said: “They're not an ‘off the shelf’ commodity kind of supplier; RTP Company has excellent engineering capabilities. When we need to solve a customer challenge by using a custom-engineered compound, we go to RTP Company.”
MACHINERY
SHOWCASE PRINTING & DECORATING Lenticular printing effects possible on new sheet grade extension to our product range, and believe that our new portfolio of Quinn Lenticular perfectly suits the demands of this exciting market,” said Charles Shaw, Managing Director of Quinn Plastics and Packaging. “We also offer our customers
in-depth technical support, based on our experience and expertise in lenticular printing materials and processes. This will lead to creative collaborations where our specialized expertise and know-how can help develop innovative niche
applications for lenticular printing.” Quinn Plastics Tel: +32 14 576 772 Email: info@quinn-plastics.com Web: www.quinn-plastics.com
Plastic sheet extruder Quinn Plastics has announced an extension to its range of lenticular products. Quinn Lenticular is a range of polyethyleneterephthalate glycol (PETG) sheets specially created for printing lenticular special effects. This technology is said to offer opportunities for multi-imaging visual printing effects including real 3D, animation, zoom, flip, and morphing. It is available in three LPI (lenses per inch) grades. Quinn Plastics already offered a 75LPI grade; this is now supplemented by 60LPI and 100LPI grades, as well as a 60LPI-3D grade. The extended range is suitable for all kinds of standard and special format applications. The key applications for Quinn Lenticular are in advertising and marketing communications, on items such as displays, postcards, posters, POS material, magazine covers, DVD boxes, promotional gifts etc. Features of Quinn Lenticular which make it so attractive for these applications include its brilliant clarity; excellent ink adhesion; high impact strength; good chemical resistance; and recyclability. It is also environmentally safe, and meets current food contact legislation. “We are delighted to be introducing this
German printing machinery gets UK sales channel
Kammann Maschinenbau GmbH, a German manufacturer of silk screen printing machinery, has announced the appointment of the Cheltenham-based Industrial Resource Management Ltd (IRM) as its UK agent. IRM Ltd has been involved in selling container decorating machinery for some years and will now represent Kammann in the United Kingdom. IRM Ltd. Tel: +44 1242 690154 Email: dcp@irm.uk.com Web: www.irm.uk.com JULY 2013 • WWW.EPPM.COM • 11
MACHINERY SPOTLIGHT eppm
SOFTWARE
A new piece of software, which is now available with Dynsico’s LMI series melt-flow indexers aims to simplify the gathering, storing and management of data collected by the system. The LaVA Suite software is a proprietary development of Dynisco, a group that offers measurement and control technology for plastics processing. The name “LaVA” stands for Laboratory Viscosity Analysis. Since their introduction, LMI melt flow indexers have been recognised for advanced features that are said to make them ideal for the modern testing lab. Developments include an ergonomic weight-handling system, automated resin-sample packing, and improved digital piston-
SOFTWARE LAUNCHED TO SIMPLIFY TEST DATA MANAGEMENT
displacement measurement and a touch-screen user interface. “The LMI is Dynisco’s approach to reinventing one of the most common pieces of equipment in any polymer laboratory,” said Joe DiOrio, Product Manager. “Along with its ergonomic features, our new software turns a standard piece of laboratory equipment into a 21st-century test operator’s dream come true.” The LaVA Suite software for the LMI is reportedly capable of delivering a wider range of data, simplifying analysis, reporting and archiving. It captures not only melt index values, but also shear stress, shear rate, viscosity and apparent melt density, while also recording testing conditions. Dynsico claims the LaVA Suite software has the look and feel of applications for the latest PCs or mobile devices. Borrowing an ergonomic feature from gym equipment, Dynisco has stored all weights in the unit itself, and changing the weight load is as simple
HOT RUNNER PROGRAM
controller with the ‘Mold Wizard’ software. When a new mould is put into service, the software is said to identify and analyse the individual zones of the hot runner system in only seven process steps. The ‘Mold Wizard’ overview monitor screen is divided into four groups: menus, ‘Mold Wizard’, ‘Mold Doctor’ and ‘Main Screen’. The software then goes through its seven process steps, which include selecting nozzles and manifold zones; setting temperature set
New hot runner mould software FOR THE has been released, NOVICE reportedly capable of USER being operated quickly and reliably, even by inexperienced operators. Gammaflux Europe has equipped its G24 hot runner temperature
Compuplast has announced a new version of its Virtual IMPROVE Extrusion Laboratory – EASE OF USE version 6.7. The company claims the new version offers significant improvements, which aim to increase capability of the programs and the comfort for the user. A full 3D Solution for some mixing elements in the extruder module has also been incorporated. Chill roll and multi-layer modules have been converted to the new environment, reportedly giving the programs many new features.
EXTRUSION SOFTWARE UPDATE TO
12 • WWW.EPPM.COM • JULY 2013
as moving a pin from one slot to the next. To avoid inconsistent packing of resin samples, which can cause data inconsistency, Dynisco says it has developed an adjustable force packer that delivers a constant force regardless of the operator. Replacing the vacuum fluorescent display, the larger, backlit colour touch-screen allows for easier programming and viewing of testing status and results. Three USB ports are standard with the LMI. One master and two slave ports provide all the communication necessary for networking LMI’s, storing data on a USB stick or communicating to a weigh scale or printer. Other features include optional automatic cut-off of samples during Method A and A/B testing, and correlation of data to determine PET intrinsic viscosity.
The spiral die and flat spiral die modules have full 3D capability with a possibility to see results in in full 3D mode due to a new 3D visualization option. The cooling module contains new variable shrinkage indicating the product’s potential tendency to be damaged or bend. For K 2013, the Profile Die program has been especially converted into the new environment. This aims to reduce the necessary number of clicks and make the program easier to operate overall.
Compuplast Tel: +420 57 722 0451 Web: www.compuplast.com
COPA-DATA has released a new iteration of its WINDOWS 8 automation software, COMPATIBLE and has confirmed the new version is compatible with Windows 8. Microsoft confirmed the software, named zenon 7.10, can run smoothly under Windows 8 and meets their quality and security requirements. Reinhard Mayr, product manager at COPA-DATA said: “Being a Gold Application Development Partner, we have been able to profit from the strategic partnership with Microsoft for many years now.” He added: “The confirmed
Dynisco Tel: +49 7131 297 0 Web: www.dynisco.com
points; ensuring throughputs are safely monitored; selecting heating and cooling processes; recognising melt leakage and defective heating zones; heating to working temperature and finally storing the mould data. This mould data can then be retrieved through the controller menu whenever it is to be used again. Gammaflux Tel: +49 611 973430 Email: info@gammaflux.de Web: www.gammaflux.de
NEW AUTOMATION SUITE IS
compatibility of zenon 7.10 with Windows 8 once again underlines our continued technological leadership in the industrial automation software market. COPA-DATA recommends that for full performance with Windows 8, customers use zenon 7.10 only. COPA-DATA Tel: +43 662 43 10 02-0 Email: sales@copadata.com Web: www.copadata.com
MATERIALS
FEATURE: CONSUMER TRENDS DRIVING PLASTICISER INNOVATION For years now, phthalate-based plasticisers have hit the mainstream headlines for their reported side effects. The debate still rages on. Certain product lines have already been banned across Europe for use in specific applications. To respond to consumer demand for ‘phthalate-free’ plasticisers, especially in applications aimed at children or food contact, many major chemical groups are introducing new product lines with more stringent criteria. One such group is Eastman Chemical Company. EPPM’s Mark Wynne caught up with Martin Stimpson, Global Market Development and Key Account Manager, Adhesives and Plasticisers Business Unit, to find out what needs to change, and why.
Phthalates have been used in consumer products for the past 50 years and are primarily used to make vinyl plastics soft and flexible. They are said to improve the performance and durability of many consumer products and play an important role in medical devices. In terms of Eastman’s plasticisers, they are found in flexible PVC applications and in adhesives and sealants. Flexible PVC, according to Stimpson, covers flooring and wall coverings, medical bags and tubing, garden hoses, food contact caps and wraps, children’s toys, flexible film, vinyl gloves and more. It is two of the aforementioned applications – food contact and children’s toys – that have garnered the most criticism for their use of phthalatebased plasticisers. Of Eastman’s new phthalate-free plasticisers, Stimpson said: “Eastman is confident that Eastman DOP (DEHP) is safe for its intended use and is committed to the continued research and development of plasticisers as the industry and regulatory landscapes evolve. Eastman conducts its own toxicology testing and reviews and is responsive to
our customers’ desire to have alternatives for traditional phthalates.” Regulations surrounding phthalates are changing, with products using phthalate-based plasticisers being phased out of production in North America and Europe. Consequently, companies are now adapting to this change in trend by using alternatives, which Stimpson discussed: “There are many alternatives to phthalates and each alternative has is pluses and minuses. In flexible PVC, the primary alternatives include DOTP, citrates including ATBC and others, and trimellitates such as TOTM and DINCH. “Non-phthalate plasticisers generally command a slight premium compared to phthalate-based plasticisers but that is not always the case. Actual pricing is dependent upon many factors, therefore generalisations regarding market pricing are impossible.” When asked if there are any potential disadvantages to not using phthalates, Stimpson argued otherwise: “On the contrary, there are many potential advantages to using non-phthalate plasticisers. As consumer preferences
shift, many manufacturers are finding that switching to a non-phthalate plasticiser is easier than they thought. “Once switched, they no longer have to worry about adapting to the changing regulatory environment related to phthalates. By making the switch now,
manufacturers can be assured that any new restrictions on the use of phthalates will not negatively impact their business.” Eastman Chemical Company Web: www.eastman.com
Masterbatch supplier releases antimicrobials research PCC (Plastics Color Corporation), a supplier of colour concentrates, compounds, additive masterbatches and other polymer technologies, has released a paper on antimicrobials in polymers. The paper aims to explain the development and use of antimicrobials in medical, consumer and other applications and examines the application of antimicrobial plastic resins. The new white paper, available by request on PCC’s website, reportedly provides an in-depth look at the various chemical and biological methods used to inhibit microbe growth, the spread of disease and the deterioration of materials.
In explaining the need for antimicrobials in plastic the paper states: “The sheer ubiquity of plastics in modern society makes them a logical candidate for antimicrobial use. It would be difficult in a developed nation to go through an average day without contacting a plastic surface in your car, home, work or virtually any other public or private setting. To the extent that contact with plastic is practically unavoidable, efforts to minimise the spread of pathogens via that contact are clearly worthwhile.” The proliferation of plastic items in virtually all settings subject to human
contact provides an opportunity to address many concerns by engaging microbes proactively on product surfaces where they colonise and are spread via contact. Using select antimicrobial formulations matched to appropriate resins, the plastics industry is producing a wide variety of antimicrobial polymers for use in medical, industrial, commercial, marine and home applications. Plastics Color Corporation Tel: +440 670 8802 Email: tworkman@plasticscolor.com Web: www.plasticscolor.com
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MATERIALS ROUNDUP Specialist grades eliminate warpage and offer conductivity In order to overcome warpage and rough surface issues for moulders, engineering plastics specialist Eurotec has developed Tecomid NAX0 GD50 NL CA (PA 6.6, 50% GRF, heat and UV stabilised). This grade is said to eliminate warpage issues whilst retaining the surface finish of PARA (polyarylamide) resins at mould temperatures as high as 80˚C. The grade is said to have a higher heat deformation temperature then PARA resins and shows better mechanical properties than standard PA6.6 GF50
grades, according to Eurotec. It features the same density as a standard PA6.6 GF50 grade which is 4% lower than a standard PARA GF50 resin. The group is also making strides in the conductive electronics market. Tecolen OE00 BK EC can be used in film and fibre applications where conductivity is required. While achieving high conductivity with surface resistivity lower than 1cm, flexibility is not compromised, says the group. The grade has a tensile modulus of 500 MPa and a strain at break higher than 100%. Moreover
Tecolen OE00 BK EC can be used either by itself or as a masterbatch for PP, PE and EVA resins. When used as a masterbatch Tecolen OE00 BK EC can modify base resins from permanent antistatic to high conductivities. It can also be used in woven antistatic big bags to create conductive fibres and films or as an electrically conductive masterbatch for PP, PE and EVA based fibres and films. Eurotec also offers Tecolen OE10 RD018 EC 0B (electrically conductive LDPE) a non-sloughing, transparent grade
developed for ESD packaging applications. It also supplies conductive grades compounded with a variety of base resins from engineering to high performance thermoplastics, using assorted formulations to achieve the required electrical conductivity. Nonsloughing, FDA compliant, transparent, electrostatic and paintable grades have all been developed to meet specific customer requirements. Eurotec Web: www.eurotec-ep.com
ELASTO and MGS Technical Plastics collaborate on bicycle Wrap ELASTO UK, the UK arm of the HEXPOL TPE group and MGS Technical Plastics a specialist in technical injection moulding and product development have collaborated on the latest innovation from Cycloc – the bike Wrap. The Wrap can be used in combination with the award winning Cycloc bike storage system or on its own to fix jackets and belongings to the bike frame. The Wrap is produced from a special grade of Dryflex TPE developed by ELASTO. The material needs to be elastic, with very good recovery. It has high tear strength and needs to be easy to colour as MGS Technical Plastics manufactures the product in a range of colours. The TPE also has good UV and weather resistance and is 100% recyclable.
MGS Technical Plastics produces the Wrap via an insert moulding process; the TPE is used for the Wrap and polypropylene for the fastener. Speaking about the project John Sturgess, director at MGS Technical Plastics said, “We are very happy with the support from ELASTO UK. Their materials expertise combined with our tooling and injection moulding knowledge allowed us to develop a grade that gave us the exact properties and performance we wanted. It also means that the Cycloc bike Wrap has been designed, developed and manufactured in the UK, showcasing the best of British manufacturing”. Another innovation from the HEXPOL TPE group, which brings together the ELASTO and Müller Kunststoffe businesses, has developed a range of
TPE compounds with optimised compression set performance. The range of thermoplastic elastomers (TPE), known as Dryflex CS, are based on SEBS and have been engineered to deliver low compression set values. Compression set is the measure of permanent deformation remaining when an applied force is removed. A TPE sample is compressed to a specific deformation, for a specified time and at a specific temperature. The compression set value is the percentage of the sample that fails to recover to its original height and is an important performance indicator for applications such as seals, flexible connectors and gaskets. For a 40 shore A hardness TPE, typical compression set values are 65 to 70 percent, with the Dryflex CS range this is reduced to 40 percent (22 hours at 100 degree). Dryflex CS TPE compounds are
also compliant with FDA and 10/2011 EC regulations, with improved organoleptic performance, making them suitable for food packaging applications. The range includes hardnesses from 40 to 90 shore A with a service temperature range from -40 to 100 degree centigrade. The compounds are suitable for injection moulding and extrusion and adhere to PP and PE for 2K applications. Elasto Web: www.elastotpe.com
Compostable grade now for thermoformers and moulders
European Sales Manager - Vacancy Prisma Colour Ltd are an expanding UK based manufacturer of colour masterbatches for the plastic and rubber industry and are seeking to appoint a European Sales Manager to help us further develop our diverse product portfolio in Europe. We are a leading manufacturer of coloured rubber and silicone concentrates and produce a wide range of Thermoplastic masterbatches with a well equipped laboratory to help meet customers requirements.
www.prismacolour.com We already have established distributors in many European Countries and the European Sales Manager will be expected to support these distributors as well as developing direct sales to new accounts. The successful applicant will be based in Northern Europe and fluent in German and English and a good knowledge of plastic/rubber processing would be an advantage. The remuneration package will be commensurate with the responsibility of this position. Please send all applications to the Managing Director Mr Tim Johnson by emailing tim@prismacolour.com Prisma Colour Limited. Hole House Mill, Marple Road, Chisworth, Glossop, Derbyshire SK13 5DH t: +44 (0)1457 856505 f: +44 (0)1457 851055 www.prismacolour.com
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BASF has added variants to its range of compostable and partially bio-based plastics, named ecovio. The ecovio T2308 is now available for thermoforming work. For injection moulding, the company offers the new ecovio IS1335 grade. Until now, the available ecovio grades have been for the extrusion sector – for producing films that can then be converted into bags and mulch film. Both of these products are available in commercial quantities and consist of renewable raw materials and are said to lend themselves well for being dyed. Ecovio T2308 exhibits similar mechanical properties to those of amorphous PET, but claims to differ from PET by virtue of its compostability and its high content of renewable resources (polylactic acid). BASF says the material is not too stiff or too brittle and as a result, thermoformed trays and cups are not damaged during transportation and storage. The processing window for ecovio T, between 80°C and 120°C, is very broad in comparison to other plastics. Processing can be carried out on conventional flat-film installations and at
the processing speeds that are typical for thermoforming. The second new release in the ecovio product line, the injection-moulding grade ecovio IS1335, also appears to offer good stiffness. It can be processed using single-cavity or multi-cavity moulds that are equipped with or without hot runners. This material is said to exhibit moderate flowing characteristics and is dimensionally stable under heat up to 55°C. This variant lends itself for thinwalled, complex and high-quality packaging, which should preferably be manufactured by injection moulding and should be compostable and can also be decorated through in-mould labelling. BASF Tel: +49 621 60 43348 Web: www.basf.com
MATERIALS ROUNDUP Recycler launches toy grade A UK-based recycler has released a new variant of its recycled products. Axion Polymers has produced Axpoly r-PS01, a 100%-recycled polymer that meets British Standard testing for toy safety. The BS EN 71 Toy Safety standard deals with many aspects of toy safety from flammability and toxicity to their potential to trap clothing or cause physical harm to a child. Axion Director Keith Freegard said: “Proving the EN 71 standard had been met was the key order-winning aspect for the ultimate customer of the moulder, a large supermarket chain in central Europe.”
“They had insisted the moulder used a plastic that was both recycled and able to meet European toy standards. Ours was the only material available that ‘hit the spot on both counts’,” he added. He concluded: “As a result, we have high hopes that our recycled white polymer will gain wider acceptance in the toy or promotional gift market.” Axion states it is now working to satisfy the revised Toy Safety standard, which are due to be announced in July. Steve Bell, Commercial Operation Manager said: “When we supplied Axpoly r-PS01 to a global stationery product manufacturer for its range of sustainable pencils, we had to satisfy
the toy standards because people would chew on them.” “It was also important to meet this specification for Marks & Spencer as PS01 was used in their new Solutions gift range. The polymer is sourced from fridge linings that came into contact with food so it would never have contained any potential harmful metals from the outset,” he added. “Therefore it is ideal for re-use in new items such as toys, gifts and gadgets."
Axion Polymers Tel: +44 161 737 6124 Web: www.axionpolymers.com
‘Velvet’ to break into confectionery packaging
A new premium packaging film has been launched, claimed by its manufacturer to have a ‘unique’ feel and texture. KM Packaging Services has launched the film, targeted towards the luxury confectionary and high-end boxed goods markets. KM Velvet aims to help brands to achieve shelf differentiation, meeting demand for standout flexible packaging that is suitable for many different treatments. KM Velvet is available as a reverse printed heat-sealable film laminate for use on form-fill-seal or flow-wrap equipment. Alternatively KM Velvet can be laminated to board to provide the ideal solution for suppliers of luxury boxed products such as premium confectionery - and even perfumes and cosmetics. Charles Smithson, KM Packaging Services managing director, said of the coated polypropylene: “Confectionery brands are constantly searching for that elusive USP that will make their products stand out among the hundreds of others in the same display. Shiny gloss sleeves are giving way to matt finishes that convey an element of discreet quality, and the next stage is enhancing the visual impact with an unbeatable feel of luxury that tempts consumers to touch and pick up a particular product. “This is a very competitive market and we expect that such a sophisticated development as KM Velvet will provide a winning point of difference to confectionery and packaging manufacturers in our existing and new markets worldwide,” he added. KM Packaging Services Tel: +44 1832 274944 Email: contact@kmpack.co.uk Web: www.kmpack.co.uk JULY 2013 • WWW.EPPM.COM • 15
MATERIALS
SHOWCASE TPEs Outlook: the TPE market Elasto is one of the world’s leading suppliers of thermoplastic elastomers (TPEs). To gain an outlook on this evolving market, EPPM spoke with Dominic Philpot, Managing Director, ELASTO UK… Elasto has always been strong in the consumer, medical and automotive sectors. What other areas are you seeing growth in? One of the reasons we are inspired by TPEs is their tailorability and adaptability, we continue to see new material combinations and compounds being developed which are opening up further markets and design possibilities. We work primarily with custom formulated solutions, so in essence every day we are creating new materials. We’re constantly testing polymers, additives, stabilisers and other ingredients, to advance the properties and performance of our compounds, driving growth potential. We’re partnering OEMs, moulders and designers across a wide spectrum of industries including construction, consumer, sports, electronics, automotive, medical and caps and closures. We may also want to consider growth in terms of the different classes of TPE. Each class offers properties related to their base chemistry, which in turn determines their performance and suitability for the end-use application. As part of the HEXPOL TPE family we’ve been developing our portfolio to cover a comprehensive range of Styrenic Block Copolymers (TPS), Thermoplastic Olefins (TPO), Thermoplastic Vulcanisate (TPV), Thermoplastic Polyurethane (TPU) and soft PVC compounds. This means we can offer our customers the best solution for each application or indeed supply multiple compounds from different classes – making us a single source for flexible polymer solutions. If we look at the different market sectors, we believe the automotive sector will continue to be a dominant force for TPEs, in particular high-
ELASTO are developing a comprehensive portfolio of TPE solutions for a wide spectrum of industries including construction, consumer, sports, electronics, automotive, medical and caps and closures.
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performance TPS and TPV compounds. The development in these technologies can be seen as a direct correlation with the growth in the automotive market, which has well documented forecasts for future expansion. In several automotive applications, such as underbonnet, hose, cable, glazing seals and encapsulation, the higher chemical and heat resistance offered by TPV is a pre-requisite. The growth in SBC based TPEs can be said to be driven from several directions. We continue to work on the advancement of properties; be it temperature resistance, compression set or new processing techniques. Growth is also being driven by novel design, consumer demand and end-use application performance, for example we are experiencing increased use of TPEs in packaging caps and closures applications, where manufacturers are looking to differentiate by including softtouch areas to their packaging. The tactile feel of TPE adds to the appeal for the consumer, helping to enhance the perceived value and quality of the product. The medical market is another area where we’re seeing increased demand for SBC based TPEs. Here the demand for PVC free compounds continues to be a factor. The industry itself is also growing, as we face aging populations and global government spending increases in healthcare provision. What are the current market challenges for your products? Our customers are looking for suppliers with a balanced product portfolio and expertise in specific application areas. We are seeing that some applications for TPE are maturing and moving towards commodity status. This combined with the growing number of entrants to the market and increasing competition will mean you have to have a certain size to leverage synergies or have specialized market knowledge and expertise that makes you dominant in a particular sector.
This is our strategy for the HEXPOL TPE group, where we’re developing both global capacities as well as market specific products. Key technical drivers for TPEs in the future will include performance and tailor-made properties for special applications. The ability for quick and flexible adjustments and the engineering of smart properties by using polymers and materials from the latest raw material developments will differentiate the TPE suppliers into active drivers or participants. Cost improvement will also be a driver in mature applications. The influence of national laws or legal requirements and industry specific regulatory requirements, can influence future product development in a way which has not been known in the past. The TPE compounder will need a deep understanding of these requirements as they develop solutions. What does the future hold for Elasto and for the TPE sector as a whole? ELASTO has had an exciting few years since we joined HEXPOL in 2010. Our TPE family of businesses has grown with the acquisition of Müller Kunststoffe in 2012 and in parallel HEXPOL have started up TPE production in China. With the integration of ELASTO (with sites in UK, Sweden and China) and Müller Kunststoffe (with two sites in Germany) we have established a global organisation for TPE and polymer compounding. With progressive solutions come, a very high level of technical expertise, advanced production capabilities and an international footprint. Growing does not mean that we have distanced ourselves from our original philosophy; we have kept the heart of a small, down to earth company whose main goal is solving customer problems. As we continue to expand, our focus will remain on the engineering of intelligent flexible polymer compounds which precisely match application requirements, but also the creation of solutions that meet gaps in the market. Take two recent examples; ELASTO UK worked with MGS Technical Plastics on a customised TPE solution for their bike Wrap project (see full story on page 14). As a group, our product engineers have also developed a range of TPE compounds (Dryflex CS) that have been optimised for compression set performance – they can be used in a variety of applications such as seals, flexible connectors and gaskets. The Dryflex CS range was
Dominic Philpot, MD of Elasto UK. developed to address market demand for TPE compounds with low compression set values. Our customers are an inspiration for this product engineering, be it a large multinational OEM, design-house, subcontractor or trade moulder. Our partnerships with these companies help drive some of our most interesting product development. Their demands can be varied and specific as they challenge us to deliver TPEs with enhanced adhesion, conductivity, wider service temperature, chemical resistance or high-flow for improved processing. We can consider the TPE market from various angles; geographical, application and TPE chemistry. There are well documented high growth forecasts for Asia-Pacific, Russia and NAFTA, while the more mature economies such as EU are forecasting lower growth. The demands can vary significantly from region to region, with EU pushing for advancement in mechanical properties, 2K capabilities and high performance TPEs, whereas the demand we are seeing from other regions has been more general, but with an increasingly sophisticated consumer market, demand is rising for TPE compounds that provide the right combination of functional performance attributes as well as soft-touch aesthetics. From an application perspective, we are continuing to see the adoption of TPE in new markets and industries; driven by trends in design, consumer demand and legislation requirements. Finally, as we continue to work with the advancement of properties and the development of new material combinations we’ll see growth of new classes of TPE. For example, we predict that POE / Polyolefin Elastomers will be another fast growing material, where there is potential for them to enter markets which have become commodity for SBC. One thing is for sure, for us, TPE continues to be an exciting and dynamic market and one that offers many opportunities for further development.
MATERIALS
SHOWCASE TPEs Medical-grade TPEs launched for calendering A technology from three suppliers to the medical device sector has been developed to create the potential for film products that combine the properties of TPE with the ability for calendering, and sealability via radio frequency (RF) welding. In collaboration with O’Sullivan Films and Genesis Plastics Welding, Teknor Apex Company claims that its Medalist MD-500 Series elastomers eliminate the traditional disadvantages of TPEs in certain applications including fluid drainage and storage bags, cushioning bladders, and surgical pouches, exhibiting performance that is comparable to PVC in processing, bonding, assembly, and clinical handling. While calendered PVC film is widely used in medical applications, traditionally TPEs have not performed well in calendering, a process which typically provides better thickness uniformity, more consistent physical properties, and greater thermal stability than film extrusion. Working with Teknor Apex, O’Sullivan Films is reported to have demonstrated that Medalist MD-500 Series medical elastomers can be formulated for successful calendering. “Our company has attempted to calender a wide range of plastics besides PVC and concluded that most are simply not calenderable,� noted Chuck Stronach, O’Sullivan Films Commercial Manager for Healthcare Products. “We were intrigued to discover that Medalist 500 Series compounds can be adapted for this process, and together with Teknor Apex we carried out a lot of R&D work to optimiSe the production and properties of Medalist calendered films.� Film and bag applications for Medalist MD-500 Series TPEs include cushioning bladders (for mattresses, wheel chairs, and gurneys); IV and saline bags; medicine storage and delivery pouches; bags for enteral and parenteral nutrition storage and delivery; dialysis bags; and surgical pouches. “While there is pressure on medical device companies to replace PVC in a number of applications, the track record and excellent cost-performance profile of PVC have in the past made it difficult to replace,� said Elliott Pritikin, Global Medical Market Manager for the Thermoplastic Elastomer Division of Teknor Apex. “Recently, however, Medalist MD-500 Series elastomers have been commercially successful as alternatives to PVC in medical tubing,
TPE 2013 comes to Dßsseldorf during K build-up mithers Rapra’s TPE conference will return in 2013 for its sixteenth edition. The group has decided to hold the 2013 event to coincide with the build-up to and opening of K 2013 Taking place in Dßsseldorf on 15-16 October 2013 and featuring a range of highly topical papers, the focus for this year's event will be end-use applications. The conference will take place at the Hotel Nikko, Dßsseldorf, just a short distance from the Messe enabling delegates to combine both events. Whatever tier of the supply chain they may occupy, whether TPE processor, medical grade supplier, sports goods designer or an automotive parts manufacturer, Smithers believes that the last few years are likely to have been tough for business. However, the group predicts that the expanding automotive production industry of Eastern Europe, increased
S
and now they are proving to offer clearcut advantages over PVC in film products.� Film made from Medalist MD-500 Series TPEs is reported by Teknor Apex to exhibit the same degree of strength as PVC film that is twice as thick. Because the Medalist compounds are 30% less dense than flexible PVC and can be down-gauged without compromising strength, finished products can be 66 to 70% lighter, claims the group. “Teknor Apex started off by listening to the voice of the customer, consulting with manufacturers of medical devices to identify all of the regulatory and performance considerations that may arise in film applications and to learn how traditional TPEs and PVC compare,� said Richard Faulkner, Teknor Apex Medical Market Manager. “As in our development of compounds for tubing, we partnered with companies that have longstanding expertise in the target applications.� Teknor Apex also collaborated with Genesis Plastics Welding, an ISO 13485:2003 certified medical device contract manufacturer. Genesis' proprietary radio frequency (RF) welding technology, ecoGenesis, enables sealing of polar and non-polar plastics, including film produced from a Medalist elastomer. While the alternative technique of heat sealing produces only a straight-line bond, RF welding with ecoGenesis makes it possible to form strong permanent bonds in complex geometric patterns, including sealing two mono-layered film to tubing producing traditional infusion bags. Teknor Apex Email: medalist@teknorapex.com Web: www.teknorapex.com
use of TPEs in the emerging markets of India, China and Brazil and the ongoing push for the use lighter materials in the automotive sector are playing a part to boost demand and there is optimism for new materials, technologies and applications. With representation from some major TPE suppliers and compounders from across the world, the event aims to offer application-driven papers from market leaders, unparalleled networking opportunities and access to Europe's key industry players�. For end-users of TPE, the event is a forum to achieve the multi-tier capabilities and information needed to influence the performance of the materials of the future. Representatives from GLS PolyOne, Dow, Robert Eller Associates and Ford Motor Company will be amongst the speaking panel. TPE 2013 Web: www.tpe-conference.com
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APPLICATION FOCUS THE 2014 WORLD CUP
Plastics set to score at
THE WORLD CUP Words by Mark Wynne
The World Cup is now just a year away, with the first game set to kick off in Sao Paulo at 5pm local time (1pm UK time). The tournament will take place across 32 days in 12 different Brazilian cities. A recent EPPM blog highlighted some of the uses of ETFE in stadia around the world, and it is looking as though some of the World Cup’s arenas will use this material for their roofs and facades, as well as some other similar plastics. But that isn’t where plastic’s involvement comes to an end. Here, EPPM takes a look at the different types of plastic and their uses at the World Cup, from the seats that will be graced by fans, to the shirts their heroes will pull on and stadium roofs to the balls that will be kicked around them. We will start with what is arguably the most important stadium of them all, the Maracana. This is where the decisive match of the 2014 World Cup will take place. The stadium was originally built for the 1950 World Cup and hosted the final then too. However, it has been in need of rejuvenation and refurbishment, which started in 2010 and was only finished in April this year. The stadium has a capacity of 76,935, which makes it Brazil’s biggest stadium. The biggest part of the stadium’s renovation was 18 • WWW.EPPM.COM • JULY 2013
The "Maracana, Brazil. Copyright: Celso Pupo
arguably the installation of a new roof. Hightex Group, in collaboration with its Brazilian construction partner Sepa won the contract to engineer and install the inner liner membrane of the Maracana’s roof. The new roof, which according to Hightex uses eco-friendly materials, is comprised of an area of 46,000m2 built on a cable rope construction. The resulting structure resembles the spokes of a bicycle, with a PFTEcoated glass fabric over it. Bayer MaterialScience have had a hand in the roof of the Estadio Nacional, the second largest stadium by capacity at the World Cup. The stadium will play host to seven games, including the third place match, the day before the final. Bayer’s Makrolon UV2099 sheets will form the roof, reportedly offering high weather resistance and a UV coating on both sides that can stand up to many years of weathering. The sheets are also said to have a light transmission of 82%, which aims to ensure
optimum natural light for healthy turf growth. This polycarbonate has been used in other stadiums around the world. For example, two stadiums for Beijing’s Summer Olympics in 2008, the Arena Legia in Warsaw and the PGE Arena Gdansk, which were both Euro 2012 stadia. Hightex and Sepa have the contract to two more stadiums for the World Cup. The Beira-Rio Stadium is the southernmost stadium for the championship and is expected to have a capacity of 50,000. The BeiraRio will host five matches, four in the group stage and one in the first knockout round. This particular stadium features PTFE-coated glass fabric and PTFE laminated glass mesh with high translucency. Hightex says this offers a ‘unique visual appearance in daylight and when illuminated at night’. The support for the membrane is comprised of three
APPLICATION FOCUS steel supports, which form a section reminiscent of a half-closed leaf. Some 65 of these ‘leaves’ are placed around the periphery of the stadium and are lined with the PTFE membrane, stretched over the aforementioned steel structures by ropes. The space between the ‘leaves’ is covered with the PTFE laminate which can be illuminated at night to match the colours of the teams playing in the stadium. All in all, approximately 57,000m2 of PTFE-based material will be used for the Beira-Rio. Arena das Dunas, in Natal is named after, and reportedly takes design principles from the sand dunes that form its backdrop. The 45,000-seater stadium contains approximately 18,000m2 of a PVC/PES membrane over the ‘shells’, accompanied by ETFE louvers between these ‘shells’. The stadium’s structure reportedly protects visiting fans from direct sunlight, while the ETFE louvers aim to allow for onshore breezes to flow into the stadium naturally. The Arena Pernambuco in Recife draws comparison to the Allianz Arena, which is home to German league champions Bayern Munich through both stadiums’ use of ETFE. The German stadium was a venue for six games at the World Cup 2006, including the semi final. This stadium will host five games and accommodate 46,154 football fans during the tournament as well as three games in the ‘warm up’ to the World Cup – the 2013 Confederations Cup. The initial exterior for this stadium was reportedly supposed to be an aluminium structure with an outer layer of glass. However, this façade was scrapped and made way for the plastic film, which is already an established material in sports arenas worldwide.
The Estadio Nacional. Image courtesy of Bayer MaterialScience.
It is lighter and stronger than glass and offers aesthetic benefits, primarily the use of LED lights to illuminate the stadium to match the playing teams’ colours or to coincide with the non-sporting events the arena will cater for beyond the World Cup. A quicker installation time was reportedly also a factor in the switch to ETFE. As the Arena Pernambuco is scheduled to host matches of the Confederations Cup, a whole year earlier than the World Cup, the consortium behind the stadium decided the new exterior would be quicker to construct. The recently finished stadium now boasts an ETFE exterior similar to those of the Allianz Arena and Beijing’s Water Cube.
Image courtesy of Nike.
The majority of seats in the World Cup’s stadia will be manufactured by way of injection-moulded plastic,
Image credit: Bucchi Francesco / Shutterstock.com mainly polypropylene, and with two stadiums capable of holding almost 80,000 fans, that’s a lot of plastic. To make the production of plastic seats at the tournament a bit greener, Coca-Cola announced the installation of recycling bins across the country. The soft drink maker’s PET bottles can be recycled at these bins with the end goal being that they will make up 6,700 seats at the Maracana, five percent of seats at the Estadio Nacional and 3,000 at the Mineirao stadium. On average, Coca-Cola say it takes 100, 600ml bottles to make a PET seat but they maintain bottles of any capacity can and should be recycled at the bins. The hosts of the World Cup, Brazil, as well as England and several other nations at next year’s tournament will wear shirts manufactured by sportswear giant Nike. Since the 2010 World Cup in South Africa, Nike has been producing its national team kits as part of a ‘Better World’ program to be more environmentally friendly. As a result, Nike now uses recycled polyester from plastic bottles to manufacture their kits. This is done in the traditional process through which plastic becomes polyester – bottles are melted down to form yarn that is spun into recycled polyester. Nike says it takes on average 13 plastic bottles to make a
single kit. Seven of these bottles comprise the 96 percent recycled polyester shirt; with the other six making the 100 percent recycled shorts. According to the company, 272 million plastic bottles were used in the production of their shirts in 2012 alone. Although the official ball of the 2014 World Cup is yet to be unveiled (FIFA usually do so when they draw the teams for the group stage in December), Bayer MaterialScience has worked with Adidas for over 25 years developing footballs for championship tournaments. The pair has produced footballs for other World Cups and European Championships including The Tango12 ball used at Euro 2012. The Tango consisted of five polyurethane layers with three more layers of varying thickness with the aim of making the surface resistant to external factors and abrasion. With Adidas the official sponsor of the World cup, and official ball provider, there could be another collaboration between the two German companies to create the ball of the 2014 World Cup, named Brazuca. Plastics are set, then, to be heavily involved at the 2014 World Cup with a variety of different uses in a variety of scenarios. JULY 2013 • WWW.EPPM.COM • 19
2013: THE PREVIEW 16-23 October 2013, Düsseldorf, Germany
Positive outlook on the future of the industry he European plastics industry remains strong despite the many challenges it faces, according to a report from K 2013. The report asserts that there is a state of uncertainty on the continent with austerity measures affecting building and construction projects, consumers buying less cars and best-selling products like smartphones and tablets being made elsewhere. However, performance plastics is just one of the areas where development, production and use is strong. An example given is that of Victrex in Thornton Cleveleys in England, which has said it will increase its capacity for polyaryletherketone (PAEK) by around 70%. PAEK polymers are used across a wide range of applications in the transport, industrial and electronics sectors. Despite the current automotive woes that can affect processors of plastic components – automotive production in Europe could fall by up to 8.5% this year
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– the German plastics processing sector is growing too, according to trade association GKV. The association’s managing director Oliver Möllenstädt, said: “The converting industry in Germany in 2012 had nearly the same turnover as in the year before but the raw material input decreased.” Although sales of packaging and films fell in Germany last year, by 0.4%, the IK trade association for plastics packaging believes growth should return this year. This comes as the bioplastics sector, one that occupies a niche in Europe, is noticing growth. Non-biodegradable plastic bags are being phased out in Italy by law, with biodegradable bags taking their place. Other European nations could also follow suit, the report says. The Dutch government apparently has a target of being ‘the land of green chemistry’ and Italian energy firm Eni has formed a ‘green chemistry’ joint venture with Novamont to produce biobased monomers, intermediates for elastomers and plastics, and fillers. Machine makers in Europe are also
continuing to invest. Engel is set to spend 12 million euros to expand its assembly and shipping area for injection moulding machines. Sumitomo has also reportedly set aside 20 million euros for the modernisation of production at plants in Germany.
High recycling rates are achievable n a second encouraging piece from Messe Düsseldorf, the trade show organiser references surveys from PlasticsEurope, which maintain that in 2011, 47 million tonnes of plastics were consumed in the 27 EU countries plus Switzerland and Norway, with 25 million tonnes of waste plastics collected. 60% of the plastics recovered were from collection systems, and the report commends Switzerland, Germany, Austria, Belgium, Sweden, Denmark, Norway, the Netherlands and Luxembourg for their exemplary collection rates ranging from Swizterland’s 99%, to Luxembourg’s 92%. Six of the aforementioned nations,
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Norway, Sweden, Germany, the Netherlands, Belgium and Austria have the highest recycling rates in Europe, from 35 to 26%. PET bottles are regarded as the most amenable products for recycling, as they lend themselves to a large field of products from fibres and films to simply becoming new bottles. There are also closed-circuit systems such as PETcycle, which turn old bottles into new ones. The report states PET recycling achieves a market volume of 1 million tonnes per year in Europe, and asserts it does work. However, there are some problems facing recycling. There are plastic items of different materials and when they cannot be sensibly separated, that causes obstacles for recycling. Also, certain products have residues that are difficult to entirely remove. Many processes have established themselves, but recycling still has plenty of potential for improvement, according to the report. One opinion is that recyclable design should be examined, so that products can be made with a view to later recovery.
Erema promises “new dimension” with K Show technology launch Erema, a specialist in plastic recycling systems has announced that it will be launching a new core technology at the K 2013 trade fair. The group is celebrating its 30th anniversary as a business this year. Erema is describing its development as a “new dimension” in plastic recycling system engineering. The presentation will take place during the show. Erema’s systems are based around a large patented cutter/compactor and extruder combination which can be used for a wide variety of recycling jobs
according to the configuration in both inhouse production waste recycling and severely contaminated post-consumer waste applications. The company launched its first generation of machines in its founding year, 1983. The technology combined a cutter/compactor with a – back then, still radial – extruder, which made it possible to cut, compact and extrude waste plastic in a single, continuous process. In its second generation machines (from 1993) the extruder was located tangentially to the cutter/compactor.
This, Erema claims, enhanced the quality of the end products while increasing output and performance. Additionally, a newly defined scaling of the cutter/compactor in relation to the screw diameter of the extruder connected (patented) made feeding even easier with very large individual portions. Project-oriented modifications to the cutting tools in the cutter/compactor also helped to optimise this process. The longer dwell times in the big cutter/compactor made
it possible to direct the material to the extruder with much more homogeneous temperature distribution. Erema Tel: +43 732 31900 Email: erema@erema.at Web: www.erema.at
Metal replacement and healthcare innovations from additives brand Presenting at a recent pre-K press conferences in Mainz, Germany, PolyOne, a global specialist in additive technologies highlighted a theme of metal replacement, with Anne Hippert, Marketing Director, Engineering Materials Europe emphasising the benefits of design freedom and corrosion resistance, as well as the natural advantage of weight saving. Hippert outlined a new partnership with Matériautech, a specialist in plastic design and innovation. The new cooperation allows PolyOne customers to streamline product development at the earliest stage. John Voyce, PolyOne GLS TPEs discussed new innovations in the 20 • WWW.EPPM.COM • JULY 2013
healthcare sector. Versaflex HC is a new TPE designed for use in infusion therapy stoppers and septums. The product is said to offer healthcare manufacturers excellent resealing performance. It achieves the coring performances required by ISO 15759, avoiding the harmful effects of sheared off articles. Unlike vulcanised rubber, the product is a single-step injection moulded processing material. Additionally, it can reportedly reduce design complexity, in turn keeping costs down. Fernando Sanchez, Global Marketing Director, PolyOne Global Color, Additives & Inks described a new approach to the group's business model, based on increasing connectivity between
customers - even using social media - to deliver insight and market awareness. As an additional portal, the group's 'colour inspiration' site, www.invisiocolor.com, offers a platform for customers and designers to access information on the latest colour trends and forecasts. Similarly, the recently launched OnColor iPad app offers a portfolio of colours for quick, simple selection. Since the last K event, the group has acquired ColorMatrix, a specialist in liquid additive technologies. Globally, PolyOne has expanded in Brazil as well as the Middle East. Previewing the K Show stand, Holger Kronimus, Vice President of PolyOne Europe highlighted the planned
interactivity of the group's booth, with applications to go on display for visitors to see and touch. PolyOne Tel: +1 440 930 1000 Email: info@polyone.com Web: www.polyone.com
K 2013: THE PREVIEW Lightweighting in cars a key K Show theme Lightweighting in the automotive sector will be one focus for DuPont at K 2013. Recent examples will include a truck oil pan (pictured) made of the group’s Zytel polyamide resin up to 6kg (50%) lighter than the aluminium it replaces, and a thermoplastic composite technology for lighter structural, load bearing and crash-protection parts. “Designing for plastic rather than using plastic in a component designed for metals requires a different approach and material data, but helps ensure all the lightweighting, strength and functional benefits are captured,” said Patrick Cazuc, Automotive Director EMEA, DuPont Performance Polymers. “Testing we have done with the industry shows that we are able to better predict performance, helping to improve the material selection process and speed the development time.” DuPont will show the large truck oil pan of it’s Zytel polyamide resin, injection moulded by ElringKlinger for Mercedes-Benz. The group states that it is up to 6kg (50%) lighter than aluminium, and can resist stone and gravel chip impact during the typical 1.5 million kilometre lifetime of a truck or bus engine. There is also said to be a 2dB reduction in noise level compared with metal.
“The auto industry is facing many difficult challenges, the most critical in Europe being CO2 emissions reduction. Coupled with more aggressive engine coolants and temperatures, and the added weight of new performance, comfort and safety features, these challenges are creating major lightweighting opportunities for DuPont’s engineering polymers and high performance elastomers,” Cazuc explained. “The industry is more open than ever to step changes in design that push the limits of plastics to meet these challenges. Light thermoplastic composites offering enhanced stiffness, and adoption of new oil pans, exhaust mufflers and tailpipes in DuPont plastics, are prime examples. We are collaborating with automakers to get these innovative ideas into the market faster with greater reliability, and at affordable cost.” DuPont is also working with car makers and tier one component manufacturers on developmental projects using thermoplastic composites for structural or loadbearing components, such as seat structures, lift-gates, crossmembers, bumper beams and suspension systems. The group has worked with PSA Peugeot Citroen on testing a side impact beam using DuPont Vizilon, a developmental thermoplastic composite technology.
Results reportedly showed a 40% weight reduction compared to ultra-high strength steel, while absorbing more energy than metal and short glass-fibre polymer beams; the beam passed PSA Peugeot Citroën’s crash test. Vizilon also offers stiffness performance in temperatures from -40°C to +90°C, and, the group says, outperforms polypropylene-based composites above 80°C. DuPont Web: www.dupont.com
Rubber and plastic to demonstrate green mobility potential The High Performance Materials (HPM) business unit of chemistry group Lanxess is looking to use K to showcase its strides in lightweight automotive construction based on Durethan and Pocan high-tech polyamides and polyesters. Lanxess recently acquired Bond-Laminates, a manufacturer and supplier of continuous fibre-reinforced thermoplastic performance composites marketed under the TEPEX brand. “We are now one of the few thermoplastics manufacturers in the world that can supply performance composites and compounds proven in large-scale production, complete with the associated applications know-how for the volume production of lightweight components,” said Dr. Michael Zobel, Head of HPM. Among the recent applications of HPM lightweight construction were front end carriers consisting entirely of polyamide 6 and the first car brake pedal made of polyamide reinforced with continuous glass fibres suitable for large-scale series production. In addition, the High Performance Elastomers business unit claims it is pursuing a “four-prong strategy” in nitrile-butadiene rubber (NBR). As well as cost-effective NBR grades and diversification of the portfolio through customer-specific materials, for example, the focus is also on innovative NBR grades and new Baymod
powder NBR grades. A compounding step in polychloroprene production extends the range of applications for this rubber. “This has helped us develop two new product families, Baypren HP and GF. Baypren HP includes products with properties that are not yet available on the market,” said Jan Paul de Vries, head of High Performance Elastomers. Among the polyethylene-vinyl acetate (EVM) Levapren materials under development, a grade for impact resistance modification of polylactic acid is highly promising. The focal point of the business unit’s investment activities is Asia. For instance, a nitrile rubber plant with an annual capacity of 30,000 metric tons was opened in Nantong in China in May 2012 in conjunction with a partner. Lanxess says it is looking to capture the market share worldwide for ethylene-propylene high-performance elastomers (EPDM) with Keltan. The group produces EPDM without the use of chlorine in a high-purity process and with a composition that can be controlled with a degree of detail that has hardly been possible in
the past. “Seven grades in the EPDM portfolio have the ACE technology to thank for their superior performance. It is also enabling us to add new EPDM grades to our portfolio,” said Dr. Torsten Derr, head of the Keltan Elastomers business unit. Its investments include the world’s largest EPDM plant at Changzhou in China, with an annual capacity of up to 160,000 metric tons. Start of production is scheduled for 2015. Lanxess Web: lanxess.com
Oriented PVC pipe breaks new diameter records Molecor, a specialist group in PVC-O technology for pipe extruders will display its Integrated Seal System (ISS+) as well as PVC-O pipes up to 800mm. The group has developed air-based molecular orientation technology for water transport pipelines. Now, the company has grown into two business units: Molecor Canalizaciones (manufacturing and commercializing PVC-O pipes) and Molecor Tech, which has developed a technology to manufacture PVC-O pipes up to DN 800 mm and 365 psi. The first PVC-O pipe manufactured with Molecor’s patented technology was produced in 2007, just in time to be shown at K 2007. This first tube was a DN 200mm. In 2008 the range increased to DN400mm, which Molecor claims was the “unofficial limit” for PVC-O pipes at the time. By 2010 the group was able to manufacture tubes with diameters of 450-500mm. The group marketed this at K 2010 as “the biggest PVC-O pipe in the world”. Now, in 2013, the group claims that its technology is ready to reach the DN 800mm mark for PVC-O pipes. The manufacturing concept uses an air-based technology in which no water is involved, which reportedly makes a safer, cleaner, more efficient and 22 • WWW.EPPM.COM • JULY 2013
profitable process. It is a flexible system able to work continuously with an extrusion line, or it can operate in batches. The new integrated seal system (ISS+) is one of the more recent technological developments. This system, patent pending, is designed to manufacture socketed oriented pipes with automated integration of the gasket, retaining the orientation degree in the critical areas of the pipe. Molecor Tel: +34 902 566 577 Email: info@molecor.com Web: www.molecor.com
K 2013: THE PREVIEW Additives for aesthetics, clarity and sustainability on show
Additives specialist Milliken will use K to discuss its work in the aesthetics and performance of polypropylene (PP) and polyethylene (PE), new opportunities in inter-material replacement, lightweighting and sustainability. Allen Jacoby, Business Manager, Plastics Additives Milliken said: “Processors, designers and brand owners attending K 2013 will get a valuable insight into the exciting possibilities generated by our cuttingedge development, for applications from food storage containers and beverage cups to interior automotive components.” Products on display will include: Millad NX 8000 and NX 8500E clarifying agents for PP; Hyperform HPN 68L, HPN-20E and HPN-600ei nucleating agents for PP; Hyperform HPN-20E nucleating agent for PE; and Hyperform HPR-803i reinforcing agent. Millad NX 8000 clarifying agent for PP is said to offer productivity gains of up to 18%, energy savings of up to 13% and 10% reductions in carbon dioxide emissions. Since K 2010, Milliken has targetted converters using polypropylenes clarified with Millad NX 8000 at lower temperatures to improve productivity and save energy. It has also been working closely with specifiers to achieve their sustainability targets by replacing materials like polystyrene as well as PET and PC. NX 8500E is a variant of NX 8000 that has been fine-tuned for extrusion blow moulding polypropylene applications. The product allows for the same grade of PP to be used for both the outer and inner layers. It may also improve gloss on the inside and outside of bottles. ClearTint polymeric dyes complement the Millad clarifying agents. They are non-extractable, are suitable for food contact applications, and do not affect part shrinkage, which can be a problem with pigments often used in polyolefins. Hyperform is the first family of nucleating agents for PP that directs balanced orientation in processed parts resulting in dimensional stability, improved physical properties, and reduced warpage and shrinkage. Milliken says that the effects of Hyperform nucleating agents on PP crystallization temperature result in up to 15% increase in productivity for convertors. At K 2013, the group will present its claim that Hyperform nucleating agents as more effective and cost-efficient alternatives to additives such as talc and sodium benzoate. Opportunities to override the nucleation of pigments and maximise production and part quality and consistency can be gained through the addition of Hyperform HPN-20E to injection moulding grades, claims Milliken. Milliken Tel: +32 9 265 1100 Email: eurochem@milliken.com Web: www.millikenchemical.com
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K 2013: THE PREVIEW Making the most of your K 2013 investment
By Paulien Boumans, Client Service Director, EMG
Even though the K Show is still a few months away, now is the time for exhibitors to prepare their marketing communication plans for the show. Paulien Boumans is Client Service Director at EMG – the world’s leading plastics media relations agency and as she prepares to attend her 10th K, EPPM asked her for some practical marketing advice. o you are going to be part of the greatest plastics show on earth. The stand space has been reserved, the accommodation is booked and your promotional budget cleared. You are ready for the big show, or are you? Stop for a moment and think again. The first thing we would ask our clients is this: do you have clear messages that you want to convey? What makes you different from the competition? Do your messages and proof points resonate with a global audience? And why should busy people spend some of their valuable time at the show talking to you? The answers to these questions will provide customers and prospects with compelling reasons for looking you up during the event – and will also help you to formulate some interesting material for editors of plastics trade media. These editors are key if you want to take your messages beyond the show and gain share of voice throughout the global industry. But a word of warning: avoid general claims such as “we are a sustainable company” or “our solutions are better” without substantiating them.
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Putting down a marker before the show The K-show attracts large numbers of international visitors – and not all of them will be of interest to you – or you to them. So it’s a good idea to make sure that the right people will be looking for your stand during their visit. Advertising is a very effective way to achieve this – because you will be able to select the right media for your message. However, you may also want to involve the editorial teams of these media. Why not send them some advance information on your
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highlights, news items, and new product launches. No need to provide all the details – just a taster will do nicely. In the run-up to the K, many editors look for pre-show information – and the earlier you submit your press release – the more chance you have of seeing it included. Getting your message across during the K-show Whether you have sent out an advance release or not, it makes sense to prepare a release on your show highlights. Unlike smaller trade shows, the K-show is attended by a large number of editors from around the world, many of whom are there throughout the show. This provides you with a unique opportunity to arrange some one-on-one interviews. It will take some legwork to set up an appointment as editors are usually very busy – and for most of them half an hour is about the most they can afford to allocate. If editors agree to visit your stand, it is your responsibility to make sure that they get the attention they deserve; a discussion partner they will find compelling, information that will interest their readers and in some cases, you will need to provide the content in local language. By the way, one-on-one discussions are also an excellent opportunity to gain some insight into the interests of specific editors and the scope of their publications. If your news is big enough for a more general announcement, then consider organising a press conference – either on your stand, or in one of the conference rooms. Again half an hour would be the ideal length – and take care to book your slot in the K-
show press conference calendar. Make sure you know which editors are planning to attend and make the event relevant for them and their readers by providing “in- country” examples. And finally, put in place a social media strategy during the show. Leverage these additional communication channels to reach a wider target audience and promote your presence at the K with pre, during and post show content that ties to your news and generates dialogue. Remember: nothing beats a good story Today there is much discussion about different types of media and while the industry’s media landscape has become more complex - with many traditional print magazines also having a digital presence – nothing can beat an interesting story that is well told. A good story should be straightforward, contain news and not too much technical clutter. However, further information should be available, so editors who want to write a more in-depth article can be given relevant background material. The delivery of a good story requires a skilled storyteller, especially as editors look for headlines first before going into details. Some people are natural storytellers – and they won’t need much encouragement. Most of us, however, are more reluctant and a little uncertain. Thankfully, you can learn to get your message across fairly quickly – and over the years we have trained many shy people – and seen them make the transition from hesitant speakers to effective spokespersons.
K 2013: THE PREVIEW Packaging made more efficient on new high-speed IMM
The new ‘e-speed 650’ injection moulding machine will be on display at K on the Engel stand, as part of the group’s focus on the packaging sector. Engel will display machines for a host of other markets at the show. The group says that the e-speed 650 combines the all-electric high performance of machines in the emotion and e-cap series as well as the benefits of the speed range to combine maximum injection speeds with energy efficiency. Even with bigger screw diameters from 60 mm onwards injection speeds of up to 800 mm/s are reached. With its new drive system and energy storage system, the e-speed 650 is suitable for high performance applications with a large clamping force requirement. The hybrid machine with the electric clamping unit and hydraulic injection unit has a sizeable opening stroke that enables large stack moulds to be mounted easily. At K, an e-speed 650/90 will produce thin-wall containers in an 8+8-cavity stack mould by StackTeck of Ontario in Canada with a total cycle time of under four seconds. The containers will be removed by a high-speed robot from Campetella, a company based in the Italian town of Montecassiano.
Gravimetric blender range released in ‘mini version’ Materials handling specialist Process Control is now offering a mini version of its X-Series gravimetric blenders. The units will form part of the company’s offering at K 2013. The throughput target is below 80kg/h. The base is a common frame with the installed blender elements and on top of a loading plate for installation of the refill system. The hoppers are automatically refilled via internal gates. Adapter hoppers are also available on request, according to Process Control. Each of the blender elements are located on an independent load cell for precise and accurate feeding of all materials in the blend. Low feed rates
are made possible by digital weigh signal filtering and high resolution load cells. The gear motors for driving the high precision feed augers have been designed to offer greater repeatability. A high resolution speed encoder helps keeping the throughput based on measured weight loss at each element. The blender has been designed for small equipment or co-extruders which require high performance and accurate blending to keep the final product specifications. Process Control says it can also be used for small fibre applications such as spin fibre lines with low throughputs.
Process Control Tel: +49 6054 91290 Email: info@processcontrol-gmbh.de Web: www.processcontrol-gmbh.de
The latest addition to the Engel duo double-platen machine series is the eduo. With its electric injection unit, the machine combines the high precision and repeatability of electric machines with the space-saving double-platen technology of the group’s large-scale machines to create an efficient hybrid machine. At the K Show, an Engel e-duo 5440/700 with a mould by Haidlmair of Nussbach in Austria will demonstrate how the integration of gas injection technology (Engel gasmelt) and inmould labelling allows highly decorated, high volume packaging parts such as beverage crates and containers to be manufactured with minimal resources, costs and energy. The use of Engel gasmelt also reduces part weight; an Engel viper 60 linear robot is used for the in-mould labelling. IML films will be provided by Viappiani (of Milan in Italy) while the cooperation partner for the gas injection technology is Bauer Kompressoren of Aix-Les-Bains in France. Engel Tel: +43 50 620 0 Email: sales@engel.at Web: www.engel.at JULY 2013 • WWW.EPPM.COM • 25
K 2013: THE PREVIEW New 900 tonne machine to debut in Hall 15 Since launching the GX series of machines last year, KraussMaffei has now expanded the sizes in the range. The GX series will make its K Show debut in the form of a 900 tonne machine moulding a packaging application with a cycle time of seven seconds. By the time of the show, 44 different machine combinations will be available across the 400 to 900 tonne range. The machines are adapted to suit many different applications using various PowerPack drive modules. “Minimal cycle times with ideal efficiency. The GX series impresses our customers with its quick movements and minimal energy consumption,” said Frank Peters, Vice President of Sales at KraussMaffei. On the GX 900-8100 parts will be demoulded using a linear robot and transferred to a second robot via a “handshake” movement. The two LRX 250 HS robots are both in the highspeed configuration, which improves the demoulding time. Both robots and the machine will be equipped with the MC6 control system. The automation and the machine can therefore be operated from every control cabinet. A visible monitoring function for the working area constantly provides the operator with a view of the robot's working area on the display and facilitates tooling and optimisation processes. The aim of every plastics processor is maximum machine production time.
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With its project engineering and system competence KraussMaffei offers qualified support in the search for an optimal solution for every customer. At K 2013 the company will show a fully automated solution for horizontal mould change on the GX 900-8100. This is ideal for production plants with frequent mold changes, which are the result of small lot sizes or released quantities. The processors benefit from reduced storage and JIT (just in time) delivery to the customer. Together with its partner EAS, KraussMaffei will present a quick change system with fully automated production conversion within three minutes. In this
Extrusion pump technology offers greater flexibility
time the preheated mould from the mould changing table is inserted in the machine and secured in the machine using magnetic clamping plates. The connections for the media supply are provided by multi-coupling systems. Both robots will operate independently of the gripper station using the hand compatible for the current mould. The MC6 control system is simple to program and guarantees smooth processing of all processes for automatic production conversion, including timely warm-up phase and preparation. KraussMaffei Web: www.kraussmaffeigroup.com
Witte Pumps & Technology GmbH is a manufacturer of precision gear pumps for the polymer and chemical industries. At K 2013, the supplier will present its latest models from its 'Booster' and 'Extru' series. The Booster series is used for prepolymer and polymer applications that require a jacketed pump design. The new design is offered with DIN or ANSI flange options as standard. Witte says it can adapt to a wide range of flange designs and sizes outside of the standard design. This flexibility allows customers to replace existing pumps with a larger Witte pump that fits in the same envelope without any piping changes. The Booster III is designed for throughputs of 10 kg up to 50,000 kg per hour. In addition to the Booster III the Extru III will also be presented. The Extru III is an electrically heated extrusion gear pump. The Extru is installed at the discharge of the extruder and is used to off load the pressure building requirement from the extruder and provide consistent flow of material to the downstream equipment. The Extru III has an optimised design to meet a range of extrusion applications. Other exhibits include herringbone gears that help improve process control in fine film extrusion, information on high pressure gear pumps and information on rubber pump technology. Witte Pumps & Technology GmbH Tel: +49 4122 92 870 Email: info@witte-pumps.de Web: www.witte-pumps.de
K 2013: THE PREVIEW Pipe extrusion innovation on display
Chemical group returns to K with new additives brand
Extrusion brand KraussMaffei Berstorff will present its QuickSwitch system for fast dimension changes, which has now been extended to the 250–450mm diameter range. The system was designed to offer an economical consumption of both energy and material during the dimension change. Each PO pipe extrusion system (for the 110– 2500mm diameter range), as well as the QuickSwitch systems, can be equipped with IPC (internal pipe cooling) technology. This means that in addition to external cooling, the pipe is also cooled from the inside using ambient air, which is suctioned with help of a side channel compressor, contrary to the extrusion direction. As well as reducing space and investment costs, this may also lead to a more sustainable production, as the cooling water consumption is reduced and ambient air is used. The trend towards more complex plastic pipes with various functional layers has continued to develop, claims the group. Individual layers meet technical requirements for the functionality of a pipe. Thus, for instance, barrier layers
At a pre-K press event in Mainz, Germany, the recently re-branded Clariant announced that its appearance at this year's K Show will include a host of new developments. Since the last K show, the group, which admits it has seen some difficult times in the past decade, says it has made a series of key structural changes which have helped form a new, stronger business model. Dr. Kai Rolker, Corporate Communications for Clariant stated: “You cannot compare the Clariant of 2008 to the Clariant of 2013. It's a completely different company.” Appearing for the first time at K this year will be the 'Addworks' brand, the new name for the polymer additives business group. Ernesto Dongiovanni, Global Head of Marketing Polymer Additives, said of the
reduce diffusion, fibre-reinforced pipes increase internal crush resistance and pipes filled with glass fibre reduce linear expansion. KraussMaffei Berstorff says it offers suitable systems for every application area using specifically designed multilayer pipe heads. “In addition to that, the well-considered process technology concept of this kind of complex system also plays a critical role. It ensures, for instance, that the layer thicknesses of the barrier layers can be minimised and thus the pipe manufacturer saves on costs. In addition, the market demands for flexible solutions are also met,” said Peter Roos, President of the Extrusion Technology segment and the KraussMaffei Berstorff brand. KraussMaffei Berstorff Web: www.kraussmaffeiberstorff.com
Logo used courtesy of Clariant. new brand: “We distinguish two families of solutions. A family of Addworks is designed to serve the needs of specific applications in the plastics industry. Second is Addworks SLR, designed to provide speciality effects.” The group is also working on an Addworks ATR series, specifically for the automotive sector. The series will incorporate multi-functional stabilizers for polyamides, with the aim of boosting quality in moulded automotive parts. Clariant Web: www.clariant.com
New biodegradables and flame-retardants launched in time for K The Perstorp Group, a specialty chemicals organisation will be presenting its new plastic raw materials at K 2013. The group says its new products address current issues including sustainability and product safety. Håkan Björnberg, Market Development Director said: “We will be showcasing not one but four new product families for plastic materials. The substantial investments in these new innovative products are driven by Perstorp’s passion for greater sustainability and
improved chemical safety. This includes focusing on the reduction of waste and dealing with safer plastics.” Perstorp will be showcasing new products for biodegradable plastics, carbon source for intumescent flameretardants, non-phthalate plasticisers for sensitive applications and new high heat resistant transparent thermoplastic copolyesters for plastic packaging and durable applications. The Perstorp Group Web: www.perstorp.com
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Steve Jones, European Business Manager, Cincinnati Milacron Extrusion Systems Business – Europe
Q&A THROUGH THE DOORS AT CINCINNATI MILACRON
On 20th-21st June, Cincinnati Milacron held an Open House event for new and existing customers to come and view what it described as “a first for the European plastics industry”. Later this year the group will be at K. EPPM caught up with Steve Jones, European Business Manager, Cincinnati Milacron Extrusion Systems Business – Europe, at the end of the event to discuss new technologies, plus the trade fair stand.
First of all, how did the event go for you? Will you be holding similar events in the future? The event went very well and was a great success. This was our first ever European Lab demonstration for Cincinnati Milacron Extrusion products so we ran it more as an ‘invitation-only’ event with targetted companies and individuals being invited. We had a very good response with most of the visitors being new companies to us which made the event very exciting. Our sales team were kept very busy on both days with non-stop questions around the extrusion lines and many private meetings to discuss individual company enquiries and requests for quotes. Based on the success of this first Open House I am sure we will be holding similar events in the future. The success of the event was highlighted by the fact we were hosting the event at our sister company’s manufacturing plant – Ferromatik Milacron. This is our European Injection Moulding manufacturing facility and it was important for the attendees to take part in the plant tour of the facility and see what capabilities and facilities we have in Germany. Many of the those attending the event had interests in both extrusion processing as well as injection moulding processing so this was an ideal stage to set this event and show the capabilities of Milacron and its plastics processing technologies Why is it important for you to reach out to the market in this way? It is important for the industry to come and see our extrusion lines running. They want to see our extruders up and running and be able to get a close look over them and see how they work and perform. They cannot get the same feedback from seeing a brochure or hearing the Salesman’s presentations. It takes it to another level and allows for a more dynamic discussion with the customers
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The event had a focus on medical technology and pipe extrusion. Which new innovations were on display? There were several new innovations and technologies being displayed for the first time. The GPAK45 made its European debut. This is our new addition to the range of GPAK groove feed high output single screw extruders. These extruders have specifically optimised screw designs for each process and material they extruder. The GPAK45 was running a typical gas pipe yellow HDPE material with a line speed of over 13m/min and an output in excess of 240kg/hr. The MPAK250 also made its European debut. The Medline range is specifically designed for extruding medical tubing at high line speeds. The MPAK250 is designed to run at outputs of 110m/min of a typical medical grade flex PVC tube. The screw design is again optimised for each individual application and material. Another first for Europe was the Multipass tank. The Multipass tank from Conair is featured on all of our medical extrusion lines. This tank allows the extruded tube to make several passes before it exits and goes through the puller. This has many advantages; firstly the footprint of the line is reduced from three tanks possibly (21m plus) down to one tank typically 6m long. The extruded tube passes through a vacuum sizing and calibration tank then exits and returns back up a normal cooling bath to return back down the standard cooling side of the tank giving the same cooling time and length as a three tank downstream line, but with a smaller footprint and shorter line length – saving space and costs. Another benefit from the Multipass tank is that the drive wheel in the tank acts as the puller for the line thus bringing the puller much closer to the extruder die and reducing the “stretch” normally associated with long cooling lines which have pullers at the end of the line. This stretches the extruded tube and then causes problems when it is coiled as the product “recoils” back to its “unstretched” state causing a tightening up of the coiled tube which then distorts the tube making it oval – a key quality control factor for dialysis applications for medical tube. Using the Multipass tank cancels out this problem and gives a much better control of the final OD and ovality making a superior product. In addition there was “Hot-Control” from Zumbach. To complement the Multipass tank technology the Medical lines have the latest 3-axis laser technology to provide accurate OD/ID wall thickness control. To further enhance the quality control of the line and tube wall thickness our medical lines utilise “Hot
Control” technology. On conventional systems the laser measuring device is normally put after the cooling tanks and before the puller. This makes the measuring of the wall thickness very delayed as any adjustments made at the point of measuring by the puller has a delay of the 3 cooling tanks in product length – 24m or more – before the adjustment made actually alters the tube dimensions form the die. This lag or delay for the adjustment to take effect on a typical tube line means that any tube made in between the adjustment is out of tolerance due to the long line length in between the die and the laser measuring head. Zumbach working with Conair and Cincinnati Milacron can utilise the Ultrasonics wall measuring device near the die linked to the laser scanner to provide hot diameter measurements. This greatly improves the accuracy of the line and reduces short term variations of the extruded tube. This can also reduce material usage and minimise start up scrap and out of specification tubing. Thus optimising the production process. The medical lines from Cincinnati Milacron encompass all of the technologies highlighted here and this makes these medical extrusion lines at the leading edge of high speed medical extrusion technology.
And were they well-received by the visitors? The feedback from the visitors was very positive. They were all impressed by the extrusion technologies and the technical presentations that were given throughout each day. Most visitors have asked for some kind of follow up and had lots of interests in the extrusion technologies that were running and displayed. Everyone found the injection moulding plant tours very interesting as well which was a first-time unique opportunity for most visitors to see. You'll be at K 2013 of course. What will you be unveiling? Yes we will be at K2013! We will be showing for the first time our new TP75 Twin Parallel Twin Screw extruder on the stand. This is our newest model to our range of Twin Parallel extruders. Finally, you've created a very strong medical brand. Does the future hold similar developments in other sectors? Or will you continue to focus on and grow in the medical arena? We have spent a lot of effort over the last year to push the Medical brand to increase the awareness of our leading Medical extrusion technologies. For the future, we are looking to promote our high speed pipe extrusion technologies as well as looking at our sheet extrusion product lines.
K 2013: THE PREVIEW ‘Ultramid’ to be available to blow moulders and extruders BASF will release new grades in its Ultramid product line, which have been adapted specifically for extrusion and blow moulding. The grades have been launched in time for K, and will feature at the show. Ultramid Endure was developed in 2010. BASF claims it is “the most heatresistant, polyamide-based injection moulding material that is available in the market.” The group has now launched a blow moulding version of Endure. It is targetted at the manufacture of blow moulded pipes with high heat resistance. Named ‘Ultramid Endure D5G3 BM’ the grade has a glass fibre content of 15%, is said to be easy to process, and
reportedly features strong acoustic properties. As with the injection moulding grade, the temperature resistance is 220˚C during continuous use and the peak temperature is 240˚C. The relatively low melt temperature during blow moulding may present ‘favourable system costs’ says the group. Endure grades use a stabilisation technology which suppresses the oxidative attack of atmospheric oxygen. The protection is not just on the surface, but runs throughout the part. This feature also allows for machining. For blow moulding applications, the plastic requires a specific melt stability and favorable swelling performance. In the special suction blow moulding process, the molten material is pushed through an annular gap nozzle via a piston in the blow head and threaded into the closed mould. An air current generated by a suction pump and gravity guide the parison through the mould. After the squeezing off of the top and bottom end, the parison is penetrated by a needle and inflated, which ultimately leads to the final shape. Initial components made from Ultramid Endure BM were manufactured at the Dr. Reinhold Hagen Foundation in Germany. Following further tests at blow moulding plants, the processing quality of the material has now reportedly been optimised for mass production. It is now available in sample quantities and will be ready for commercial use from Autumn 2013 onwards.
The group will also introduce two flexible grades of Ultramid S Balance that are suitable for extrusion of pipe and tubing, and are intended for use specifically in the automotive and machinery sectors as well as for oil and gas lines. Named ‘Ultramid S4Z5 Balance’ and ‘Ultramid S4Z4 XS Balance’ the two new products will be available in sample quantities as of November 2013. Ultramid S4Z5 Balance is a semi-flexible grade for liquid-conveying lines that must satisfy demanding temperature requirements. Ultramid S4Z4 XS Balance, on the other hand, is a more flexible product for vacuum and vent
lines. It is features even greater resistance against stress cracking. The formulations for the two new compounds use a high-viscous polyamide 6.10 that has been modified to achieve good low-temperature impact strength. Burst pressure and fitting retention force are higher in the S4Z5 grade, which also exhibits a better performance in terms of heat aging, while the S4Z4 XS grade is characterised by zinc chloride resistance. BASF Web: www.basf.com
Melt flow indexer offers ‘host of new features’ Ray-Ran Test Equipment Ltd has been a specialist in the design and manufacture of polymer testing equipment since 1977. Part of its extensive product range deals with instruments to test the physical characteristics of raw materials such as bulk density and pourability, density testing or the testing of MFI or MVR of materials. At K will be the 6MPCA, a new microprocessor controlled melt flow indexer machine, which includes a host of new features, such as highly accurate microprocessor temperature control; dual zone heating; single or multi slice testing; high/low limit settings; userselectable test distance; number of slices; pre-heat time; intuitive menu system with alphanumeric keypad and 4.75” LCD Screen, as well as built-in RS232 and Ethernet connectivity. The auto density measurement system is a new piece of equipment based around the three column system that is normally supplied. It is able to determine the height of the samples and floats by means of an encoder. The encoder is linked to the microprocessor board which accurately calculates the density of samples without the need for graphs. The bulk density apparatus can be used to test the apparent density of material
which is the weight per unit volume of material, including voids, inherent in the material as tested. The same equipment can be used to test the bulk density of a material such as moulding powders, and is the ratio of the volume of any given quantity of the loose plastic material to the volume of the same quantity of the material after moulding or forming. In some manufacturing processes this is sometimes called the compression ratio. The group will be in Hall 11, Stand B30. Ray-Ran Tel: +44 24 7634 2002 Email: polytest@ray-ran.com Web: www.ray-ran.com JULY 2013 • WWW.EPPM.COM • 29
INDUSTRY NEWS & EVENTS
Recycling machinery group acquires filtration specialist
Foaming injection moulding process wins industry recognition
Next Generation Recyclingmaschinen GmbH in Austria, has acquired 100% participating interest in BRITAS Recycling Anlagen GmbH. NGR will operate BRITAS as a subsidiary. BRITAS is known as a manufacturer and developer of filtration systems for heavily contaminated plastic melt streams. The automatic screen changers are especially well suited for filtration of post-consumer plastics waste and are used for high output rates. NGR develops, manufactures and markets plastics recycling equipment in five different lines. The product portfolio covers applications in the areas of industrial in-house waste management and post-consumer plastics recycling. This deal provides BRITAS with access
Trexel, along with its partners Paccor International and Britton Decorative, was awarded a Silver Award at the 25th annual DuPont Packaging Awards competition during an award ceremony held in the USA on May 16th. The winning application was a 3D IML margarine tub injection moulded with expanded polypropylene using the MuCell process. MuCell technology, when combined with Britton Decorative’s 3-D IML technology is said to have enhanced the brand presentation with a soft touch effect, while the tub is manufactured with 13% less material. The brand owner is Unilever, and the designer and molder was PACCOR Packaging. Britton Decorative supplied the label. “The MuCell process brings a compelling value proposition of material reduction for packaging companies, and our technology will improve the sustainability of any product, which adds significant value for brand owners,” said Steve Braig, President and CEO of Trexel.
to NGR's global sales network and enables NGR to improve its market position and expertise in the postconsumer applications segment. The new owners of BRITAS Recycling Anlagen GmbH have confirmed the company's former owner Mr. Lucian Britchi as CEO. Next Generation Recyclingmaschinen GmbH Tel: +43 7233 70107 0 Web: www.ngr.at
Reifenhäuser Group acquires Italian winder manufacturer Nuova Protex After more than 25 years of cooperation the Reifenhäuser Group has acquired the Italian company Nuova Protex as of 1st June 2013, a company specialising in designing and manufacturing take-up winding systems for synthetic fibres such as monofilaments, multifilaments, raffia, flat tape and strapping tape as well as supplementary components. The new company will operate under the name Reimotec Winding Technology as part of the business unit Reimotec thus completing the Reimotec product range of monofilament, artificial turf and strapping tape lines. The current Managing Director Pino Manieri will retain his position. The existing team is transferring with the business and ensures that customers will be offered tailored solutions in the
Shanna Moore, program leader, DuPont Awards for Packaging Innovation, DuPont Packaging & Industrial Polymers said, “The DuPont Awards for Packaging Innovation is an opportunity to showcase the value of packaging and celebrate the power of collaboration in bringing innovative ideas to market. The Paccor Margarine Tub embodies that spirit.” Trexel Web: www.trexel.com
Plastics literature now available online
same proven quality as before. Reimotec Winding Technology will focus on the development of innovative winder technology. Reifenhäuser Group Web: www.reifenhauser-group.com
A new plastics e-book collection has been announced, geared towards plastics researchers and engineers. Elsevier, a provider of scientific, technical and medical information products and services and Hanser Publishers, a publisher of plastics technology and applied material titles maintain the collection. The collection will be available on ScienceDirect and contains 55 pieces of plastics engineering literature from Hanser including pieces by authors including Dr. Robert A. Malloy, a member of the Plastics Academy’s Hall of Fame. Also included are books covering plastics design principles, adhesives,
rubbers, polymers and extrusion. The Hanser collection complements the engineering books from Elsevier’s William Andrew and ButterworthHeinemann imprints, as well as chemistry and materials science books collections already available on ScienceDirect. This focus on plastics and polymers aims to benefit corporations in plastics manufacturing, chemicals, consumer goods, construction, aerospace and automotive, and other downstream sectors where plastic materials are utilised. Elsevier Web: www.elsevier.com
Rubber conference deemed a success his year’s International Rubber Conference (IRC) has been heralded as a success. The event, held this year in Paris, saw 1225 guests visit the conference, with a large European contingent. The event was organised by AFICEP under the auspices of IRCO and had attendees from various industry sectors in the world of rubber: automotive, chemical, aeronautics, industrial equipment, the medical industry, pharmaceutical industry, BTP, arms, naval construction, leisure activities, sport and others. One third
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of these visitors were decision makers in their respective fields. 76 companies were present at IRC 2013. Between them they represented a large range of skills and know-how: suppliers and distributors of raw materials, processing equipment, laboratory equipment alongside rubber and polymer processers and companies with various other business activities within the sector. Bodycote was particularly happy with its participation in the event. Their Business Development Manager M.
Sylvain Badbedat said: “We made a large number of important contacts in various activity sectors and representing important movements for our company. We have already got site visits and tests in place.” Sacred also found the experience a positive one. Their CEO Mr Didier Fegly said that the event was “well organised and offered useful contacts both in the world of rubber and business and technical contacts. The whole rubber ‘family’ was represented and our stand at the event enabled us to meet various
other companies we weren’t familiar with”. 120 conferences took part over the event’s 3 days, with 330 people attending them. The topics covered included a whole range of different areas that aim to allow the whole industry to evolve on an international level, responding to market forces as it does so. International Rubber Conference Web: www.internationalrubberconference .org/
INDUSTRY NEWS & EVENTS ROUNDUP Recycling venture hits half a billion bottles A recycled PET joint venture has reached the milestone of processing half a billion bottles, one year after it opened. Continuum, the JV of Coca-Cola Enterprises (CCE) and ECO Plastics, opened in May 2012 claims that if it placed end-to-end all of the bottles processed to date, they would stretch around the world more than twice (based on the approximate length of a Coca-Cola bottle – 20cm). To mark Continuum’s first full year in operation, CCE and ECO Plastics welcomed Lord de Mauley, Parliamentary Under Secretary at the Department for Environment, Food and Rural Affairs (DEFRA), for a tour of the facility. The visit allowed the Waste & Recycling Minister to witness first-hand the technology and people driving the transformation of plastics reprocessing in Great Britain. Located on the site of ECO Plastics’ existing facility in Hemswell, Lincolnshire, the development of Continuum Recycling is said to have created the world’s largest plastics reprocessing facility, more than doubling the amount of bottle-grade recycled plastic (rPET) previously created in Britain.
The site is now responsible for processing around 50% of all the plastic bottles collected in the UK and played a key role in Coca-Cola’s recycling efforts during the London 2012 Olympic and Paralympic Games. In total, some 15 million plastic bottles were collected from Games venues and returned to shelves as part of 63 million new bottles, during a process that lasted six weeks. Alongside the plant’s environmental credentials, which includes saving a reported level of CO2 equivalent to taking over 15,700 cars off the road per year, the partnership has created over 30 new jobs since opening. Lord de Mauley, Waste & Recycling Minister at DEFRA, commented: “Continuum has shown the real benefits of recycling. It has helped to cut down on waste and brought millions of plastic bottles back into use, which would have otherwise been sent to landfill. The plant has further helped Lincolnshire’s rural economy to thrive by creating more jobs - this is exactly what we want to see.” Nick Brown, Associate Director for Recycling at Coca-Cola Enterprises, said: “We are immensely proud of the long-term partnership forged with ECO
Plastics. Sorting more than half a billion bottles after only one year in operation is an extraordinary achievement, and shows once again the significance of a project which is truly shaping the future of plastics reprocessing in GB. “Continuum was fundamental in helping the Coca-Cola system to deliver on its Olympics legacy pledge and its materials are now used across our full range of plastic packaging. Perhaps most significantly its success should demonstrate to everyone, from householders to Local Authorities and policy makers, the real environmental and economic benefits of recycling.” Jonathan Short, Managing Director of ECO Plastics, said: “Delivering a worldfirst is always a challenge, so to have hit the 500 million mark within a year of opening is a real achievement.” “But as significant as that accomplishment is in terms of jobs created and in terms of carbon saved, it is only part of the story. We hope that Continuum will prove to be a gateway project, demonstrating the value of long-term partnership and providing a template that others can follow. “The challenge of creating a sustainable and 360 degree UK recycling industry is
a real one. Projects like Continuum can make a material difference in helping us to achieve that vision.” ECO Plastics Ltd Tel: +44 845 6784500 Email: info@ecoplasticsltd.com Web: www.ecoplasticsltd.com
UK moulder re-brands and re-locates MG Stuma, which employs 70 people and was formerly based in Bolton, UK, has purchased two new sites in Blackburn, UK, and is changing the names under which it trades. The company will now operate under two separate names, MGS Technical Plastics and MGS Medical Plastics, in a move that seeks to improve logistics and ease of access. John Sturgess, director, said: “We've always had the latest injection moulding machinery, but the old mill we operated from had some logistical challenges not least of all because we worked across three floors. “Our new homes allow us to focus on what each department does best, with
room for growth in the future. We see the medical side of our business especially as having great potential and now we are better prepared to capitalise on that.” MGS Medical Plastics moulds medical filtration products and disposable medical devices. The medical facility is a brand new, purpose-built site covering 1,000m2, of which 250m2 is a Class 8 clean room that cost £90,000. It will allow full medical moulding, assembly and packing through six injection moulding machines, and also means that MGSMP can now work towards its ISO 13485 accreditation. MGS Technical Plastics has moved into
a 2,000m2 factory, housing 15 injection moulding machines, which will be used to mould a wide variety of products ranging in size from 1 gramme up to 3700 grammes. Typical sectors that MGSTP currently works with include hygiene, leisure and sports, and health and safety and lighting. John Sturgess continued: “We are delighted with our two new acquisitions, especially as they are not too far from our previous home in Bolton.”
MG Stuma Tel: +44 1254 267750 Email: yes@mgstuma.co.uk Web: www.plasticinjectionmoulding.co.uk
European packaging experts to speak at thin wall packaging conference pplied Market Information has unveiled the programme for the eighth European edition of its Thin Wall Packaging conference. After record-breaking attendance in 2012, this event is expected to continue to attract attendees from across the global supply chain. AMI’s Thin Wall Packaging 2013 will be taking place 3-5 December 2013 in Cologne, Germany. Industry experts will gather at this international conference and exhibition for lightweight plastic tubs, trays, and cups for the food packaging industry. Thin wall packaging can be used in a wide range of applications. The ambient long-life food sector positioning is challenged with consumer concerns about quality in comparison with the chilled and/or frozen variants. Canned meals are perceived as inferior quality, less fresh and less authentic products. The segment is in need of modernisation, which can be done
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with the use of new plastic packaging solutions, and their improved process technology to deliver higher quality, long-life food products. Plastic packaging has the potential to revitalise mature markets such as soup, canned fruit, vegetables and fish, by introducing convenient, added value containers suited to modern day living. Silgan Plastic Food Containers will explain the trends in ready meals packaging. Long-life barrier properties are created using a variety of technologies, which will be discussed at the Cologne conference. AMI will present findings on retortable packaging formats. Aspects of barrier co-extrusion thermoforming will be presented by Kuraray Eval, supplier of EVOH while Mold-Masters will explain the merits of using barrier coinjection. University Hasselt will present the research findings on the oxygen permeability versus thickness of thermoformed trays.
The development of technologies used in TWP is driven by increased efficiency and cost savings. The audience will appreciate the brandowner's perspective on operational efficiency for yoghurt packaging presented by General Mills. The suppliers of injection moulding machinery, Arburg and Engel, and extrusion machinery, SML, will explain how further efficiencies can be achieved in thin wall moulding. Cost savings can also be achieved by working with innovative material technologies, such as foaming (presented by Coopbox) and natural filler compounds (presented by Mondo Minerals). Working with product image is critical for improved shelf-impact. Paper Pak Industries will show how absorbents can help creating smarter food packaging. Illig will talk about advancements of IML technology in thermoforming. Trexel will discuss how the effects of 3D technology can
be used to enhance product packaging. Sumitomo Demag will present innovative colour technology for thin wall packaging. Ineos Olefins & Polymers will explain the material development around organoleptics. Thin Wall Packaging 2013 Tel: +44 117 924 9442 Web: www.amiplastics.com
INDUSTRY NEWS & EVENTS ROUNDUP Bioplastics association elects new board European Bioplastics, an association representing industry interests, has elected a new board.
The board has been elected to represent the association and its members for the coming two years. François de Bie (Purac) was elected as Chairman, while Mariagiovanna Vetere (NatureWorks) and Stefano Facco (Novamont) are ViceChairpersons. At the beginning of his term as Chairman of European Bioplastics François de Bie said: “Bioplastics will help make this world a more
sustainable place for now and for our future generations. In our society many consumers, brand owners and converters are not yet aware of the benefits of bioplastics. In the coming years, European Bioplastics will focus on changing this. Today we are at the brink of the bioplastics revolution and a lot of work still needs to be done.” Further members of the Board are: Jürgen Keck (BASF), Peter Brunk (Biotec), Rainer Schweda (Braskem), and Johnny Pallot (Roquette). With an annual growth rate of more than 20 percent, the biopolastics industry is developing dynamically in a number of application fields. Already today, bioplastic materials and products can be found in the packaging sector, in the
toys and textile industry, in automotive or consumer electronic applications and in agriculture and horticulture. European Bioplastics Tel: +49 30 28482 350 Email: info@european-bioplastics.org Web: www.conference.europeanbioplastics.org
Correction In issue 15/3 this year, EPPM magazine referenced the Plastpol trade fair as taking place in ‘Kiev, Poland’. This was an error, and should’ve read ‘Kielce, Poland’.
Italy’s major trade show confirmed for 2015 t the annual meeting of Assocomaplast (the Italian trade association which groups together 160 manufacturers of machinery, moulds and equipment for plastics and rubber) held on the 6th June, the group’s President, Giorgio Colombo, confirmed the dates of the next Plast trade show, which will be held in Milan from 5 to 9 May 2015. This means that the show will begin immediately after the start of EXPO 2015. The organiser says it hopes that this concomitance with the world
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exhibition will have a “catalysing effect” on the trade show. Mr. Colombo went on to stress that Italian manufacturers of machinery, equipment and moulds for plastics and rubber must continue to innovate in view of the ongoing slump of the domestic market. Recalling the Italian sector’s results for 2012 — production output at €4 billion, around the same as in 2011, and exports up 6% to nearly 2.6 billion — Mr. Colombo emphasised that it continues to be foreign sales
(which account for around 65% of the total) that are sustaining the industry. This idea was also taken up by Professor Marco Fortis (of Università Cattolica, and Vice-President of the Edison Foundation), who claimed that the perceived weakness of the Italian market may be due in part to overlystringent austerity policies adopted by governments. His claim was that these policies are “crippling the manufacturing sector”, which, he said, needs an immediate and energetic impulse to thrust it out of
the current recession. To support the Italian companies in this sector, Assocomaplast has scheduled a series of promotional events, including trade show appearances, workshops and B2B technical seminars and buyer missions. The group will be represented at K 2013. Plast 2015 Tel: +39 02 8228371 Email: info@promaplast.org Web: www.plastonline.org
JULY 2013 • WWW.EPPM.COM • 33
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2400mm Cincinnati PVC Sheet line 2300mm Omipa Pmma Extrusion Line 1800mm Virginio Mai 3 layer coex line 1700mm Bandera/virgin Mai ABS Line.
EXTRUDERS
1500mm Bandera 3 roll stack 1350mm Welex/Union line 1350mm Welex 3 roll stack 1350mm wide Welex coextrusion sheet line with 115mm and 50mm extruders. 1270mm wide sheet die, 1350mm x 450mm rolll stack, haul off, winder.
1300mm Battenfeld coextrusion sheet line. 1040mm Welex Coex sheet line.
1850mm Battenfeld Gloenco PP PE Cast Film Line: 120mm+60mm extruders, feedblock. 1650mm Cloeren auto die, 1850mm Chill roll, haul off, winder.1993.
1040mm Welex 3 roll stack
890mm Welex World Standard sheet Line. 90mm Extruder. Gear Pump 900mm Die. 890mm Welex Stack winder. 1997.
1000mm Esde 3 roll Stack 1000mm OMV co ex sheet line 890mm Welex Pet sheet line
115mm Hartig Extruder, 30d 100mm Union extruder. 90mm Welex single screw extruder 80mm Cincinnati Titan twin screw 90mm John Brown Egan single screw extruder 70mm Battenfeld-kuhne Extruder 60mm Cincinnati coextruder 50mm Welex co extruder. 25:1 l/d ratio. 50mm Betol extruder 25:1d 45mm Kuhne model K45E 30D
1000mm Omv Coextrusion Sheet Line. 120mm Omv Extruder, 60mm Coextruder, Melt Pump, 1000mm X 500mm Roll Stack, Haul Off, Winder.
THERMOFORMING DIES
700mm Illig RDM 63/15B cup forming line 605mm Kiefel KL2 SH Thermoformer,
6 colour Van Dam 560AA PT printer
25mm Betol single screw extruder. Model 2525. L/d Ratio 25:1. Dc drive. 6 zone panel. Screw cooling, throat cooling.
4.5” Welex single screw extruder. 30D vented., static mixer, gear pump. 2003.
980mm EDI model Ultraflex HR75 915mm EDI flex lip sheet die 900mm Kuhne model BDF 90F 863mm EDI Ultraflex H75 flex lip sheet die 500mm Masterflex flex lip cast film die 1987
500mm wide Illig RDM 50/3 lid thermoformer, Double heaters, Motor Indexing. Auto Rail Spreading, Counter/ Stacker, 1982 very good condition.
1700mm Bandera Virginio Mai PMMA ABS sheet extrusion line. 80mm extruder, 1600mm Simplas die, 2-7mm thickness. Complete line 1987.
100mm Union single screw extruder. 35D vented with fan cooled barrel. Vacuum vent. 110kw dc motor and drive. Temperature panel. 1987.
2 Component Maguire model WSB 420 gravimetric weight scale blender. 2 hopper loaders.
540mm Kiefel KL2EH vacuum former 1040mm Welex sheet extrusion line: 90mm Welex extruder with gear pump, die head, 1040mm wide Welex 3 roll polishing stack, haul off and winder.
1900mm wide Oman Polishing unit, 3 1900 x 400 mm diameter rolls in line saw haul off and Cross cut Saw.
500mm Kiefel Model Kmv 50d. Thermofomer 500mm Illig RDM 50/3 Lid Thermoformer
300mm wide Schwarbentham 2 roll laboratory mixing mill. Polymix 110 P.
60mm Betol / Corelco pipe corrugation lines model EC255LLV complete with die head and corrugation dieset, cooling bath, hauloff & fly cutter!!!
TRANSXL INTERNATIONAL THORNHILL SOUTH MARSTON SWINDON WILTSHIRE SN3 4TA ENGLAND MORE MACHINERY, MORE PHOTOS ON THE WEB: www.transxl.co.uk
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