EPPM 23.1 by EPPM Magazine

MAR/APR 2021 | VOLUME 23/ISSUE 1

REWARDING RECYCLING The world is waking up

SABIC VERSUS COVID

THE EFFECTS THAT LNP ELCRES CRX PC COPOLYMERS HAVE HAD IN THE MEDICAL SECTOR.

FLIGHT SIMULATION

TPRC EXPERTISE IN STAMP FORMING FOR THERMOPLASTIC COMPOSITES.

THE THRILL OF THE CHASE

CHASE PLASTICS CEO DAVID HARRIS ON RISING TO NUMEROUS CHALLENGES.

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IN THIS ISSUE MAR/APR 2021

FOREWORD

Interplas Conference Producer Charlotte Chambers discusses the effects of the pandemic, and looks forward to the return of the trade fair.

LETTER FROM THE EDITOR

Rob Coker introduces the first edition of 2021 – and hopefully the last during lockdown.

REWARDING RECYCLING

TOMRA’s latest white paper scrutinises the success of the deposit recycling systems, and how they have brought about real change in consumer behaviour and policy making.

PACKAGING

Engineered to protect The expertise at eurotec now extends to engineering plastics for packaging applications.

MEDICAL PLASTICS

SABIC versus COVID Nithin Raikar discusses the effects that LNP ELCRES CRX PC Copolymers have had in the medical sector.

Flight simulation Sebastian Wijskamp and Sebastian Haanappel discussed their expertise in stamp forming for thermoplastic composites during a recent TPRCled webinar.

COMPOSITES

RECYCLING

Delivering the goods EPPM spoke to VP Medication Delivery at Becton Dickson, Chee Lum, about support for COVID-19 vaccination planning.

More than a mask Breathe99 CEO Max BockAronson’s creation was named among TIME Magazine’s Best Inventions of 2020.

Chinaplas 2021: ENGEL at Industry 4.0 – Factory of the Future ENGEL will return to Chinaplas to showcase some of its pandemicinspired Industry 4.0 technology.

Closure for the future Michael White, Business Development Manager for Beverage Closures at Husky Injection Molding Systems, discussed his ‘Essential Guide to Tethered Closures’ during an EPPM exclusive webinar.

CLASSIFIEDS

EUREKA

The thrill of the chase Chase Plastics CEO David Harris on rising to the numerous challenges faced by the plastics industry.

INJECTION MOULDING

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COLUMN

FOREWORD I

t was a sad day when we were forced to postpone Interplas 2020, and the work that went into postponing – and reorganising – the UK’s largest plastics and rubber trade fair was just as hard as producing it in the first place. The meetings with all the various stakeholders seemed neverending. Renegotiating with the venue; keeping the exhibitors, partners and sponsors interested, not to mention the visitors – it all seemed like a bit of a lost cause at this time last year. We knew we weren’t the only ones, however, with other big names in the European plastics trade fair and conference industry cancelling or postponing too. But the togetherness of players was plain and clear to see, and all were supportive and understanding of the need to delay. The pandemic has affected everyone in much the same way, with all plans and dreams on hold until the return of better days. Thanks to the coordinated efforts of the entire sector – as well as those on the frontlines of healthcare institutions across the continent – I think those days are near. We have therefore announced that Interplas will indeed return, with all the new and necessary safety measures in place to protect exhibitors and visitors alike, on 28-30 September at the NEC in Birmingham, UK. Many plastics manufacturers have themselves contributed greatly to the innovations and solutions that have helped

The positives of plastics are what we like to focus on in the plastics events industry, and they’re firmly back in the game; no longer the bane of the environment

Interplas Conference Producer Charlotte Chambers discusses the effects of the coronavirus on the events industry, and what exhibitors and visitors can look forward to when it’s all over. bring this announcement to light. Whether by converting their manufacturing processes to address a shortage in facemasks and visors, by the swift production of protective screens, or using their expertise in packaging to bring more bottles of hand sanitiser to market, the industry efforts have been herculean. Drug delivery device manufacturers have received record-breaking orders. Masterbatch, additives

and coatings producers have likewise revolutionised their production methods to make plastic products more effective, more hygienic, and more durable than ever before. The positives of plastics are what we like to focus on in the plastics events industry, and they’re firmly back in the game; no longer the bane of the environment, as many in the media

would have had us believe. Plastics recyclers, too, have been busier than ever since more people are remaining at home and therefore consuming more packaged goods. Recyclers and medical device manufacturers have really got the word out, and now everyone knows the hygienic, protective qualities of well-made plastic products, and it’s up to all of us to come together once again in order to address the ongoing issues of plastics pollution – whether that’s through better collection, sorting and recycling, or through interacting more closely with consumers, or otherwise collaborating more with those up and down the value chain. All these topics and more will be under discussion at Interplas this year, where hundreds of experts, trade body members, and influencers will come together again to try to find ways to make the world a better place.

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LETTER FROM THE EDITOR

Back for good Dear readers,

An industry such as this has grown and thrived on personal interactions, relationships, and hands-on introductions to new materials, technologies and applications

With all the Coronavirus-inspired innovation going on in the plastics industry, I thought it apt to bring back the Medical Plastics feature for the first edition of 2021, wherein we hear from Becton Dickson, whose injection devices manufacturing capabilities are much sought after; from SABIC, whose polymer technology is improving the performance and the longevity of healthcare-related plastics; Breath99, whose B2 facemask was listed among TIME Magazine’s best inventions of 2020; and from Berry Global, who are expanding their packaging services into the healthcare field. The regular Packaging feature also returns as eurotec announces a novel use for engineering plastics in the sector, and Aimplas and AINIA bring back MeetingPack in a virtual format to warm us up for the in-person event next year. Packaging and Recycling are synonymous in today’s market, so I caught up with Chase Plastics CEO David Harris, who I last spoke with at the Plastics Recyclers Annual Meeting in Brussels in 2019, to find out which challenges have been thrown at UK-based suppliers. As part of what is continually – and annoyingly – being termed as the ‘new normal’, I attended a webinar hosted by the Holland-based Thermoplastics Research Center (TPRC), where the exciting things happening in the aerospace sector, amongst others, were shared. A condensed summary of that webinar appears within these pages, but I

urge readers interested in lightweight technology to search for the full recording online. This edition also features good news from ENGEL and Chinaplas, and closes off with some (ahem!) closures news from HUSKY, who kindly presented in an EPPM exclusive webinar hosted by our own Grace Nolan. Webinars, online meetings, increased telephone activity – all these things are well and good, serving a purpose for what I hope will – by now – be the short-term. All the industry professionals I speak with are of the same mind, namely aiming to return to the ‘old normal’, with some necessary modifications, of course. An industry such as this has grown and thrived on personal interactions, relationships, and handson introductions to new materials, technologies and applications. Who knows when exactly those days will return, but this industry – i.e., the media – also prefers the in-person experience, so I’m looking forward to meeting you all again, face-toface at one or more event in the 2021 industry calendar. Did I mention the return of Interplas this autumn yet? No? Yeah. It’s back. Enjoy the read. I’m off to pack a suitcase. Rob Coker, Editor

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COVER STORY GOVERNMENTAL AFFAIRS MANAGER AT TOMRA MIKE NOEL HOSTED THE FIRST IN A SERIES OF WEBINARS FOCUSING ON INSIGHTS INTO DEPOSIT RETURN SYSTEMS IN FEBRUARY. JOINING HIM WAS TOMRA’S SENIOR VICE PRESIDENT OF GOVERNMENTAL AFFAIRS WOLFGANG RINGEL.

OMRA recently launched a white paper titled ‘Rewarding Recycling: Learnings from the World’s Highest Performing Deposit Returns Systems’, which shares research into best practices in deposit return system design. Based on an analysis of nearly every deposit return system in the world, as well as from TOMRA’s almost 50 years of experience in the field, the white paper also discusses why policy makers are showing an interest in effective plastic packaging waste prevention and recycling solutions. The webinar enabled Ringel, a lawyer by profession, to share findings from his research that covers the four principles of high-performing deposit return systems. These are Performance, Convenience, Producer Responsibility and System Integrity. THE WORLD HAS WOKEN UP “The world has woken up to the challenges and the opportunities of managing waste,” Noel began, speaking from his home in Connecticut, “and deposit return systems have very much become a part of that conversation. They could be what the future of our waste systems looks like, but these systems are complex. No deposit return system is identical, and that’s why we took on this research to pinpoint the best practices that separate the leaders from the laggards.” TOMRA is well-known in the European plastics and recycling industries for pioneering advances in collection and sorting technology. The company provides a range of services and technologies specifically for deposit return systems, with experience extending beyond developing and managing technology. Data management and material recovery can also be counted amongst TOMRA’s core competences. “We understand the full value chain of deposit return systems in various places

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around the world,” Noel added, “and that gives us real insights about how they work in practice, and how they can be optimised.” Every year TOMRA’s machinery collects 40 billion cans and bottles, yet public outrage around plastic pollution remains high, generating bottom-up pressure from grassroots movements on policy makers. Furthermore, the world is focusing more and more on material quality, as well as recycling quality, due to policies such China’s National Sword. Recycling quality costs money, so this pressure is raising the costs of recycling for local municipalities. “Around the world,” Noel continued, “circular economy aspirations are changing as leaders grasp the concept that we are literally throwing away valuable materials. There’s a real economic loss there. If we were to capture that material, jobs can be created, and circular economy leaders are really grasping that. But just because you have access to recycling does not necessarily mean the public will participate.” The US, for example, has embraced single-stream recycling wherein all materials go into one bin. But glass can often break and crosscontaminate other materials, devaluing the recyclate. Deposit return systems are therefore being looked at as a way to collect and store separate materials, thereby retaining that material’s value. “What we see is policy makers getting behind brand-owners and starting to enshrine those commitments in law. It’s going to take some real system-wide changes to reach those targets at scale. As policy makers start to work on this, they realise they are looking more closely at deposit return systems.”

REWARDING LEFT: MIKE NOEL BELOW: WOLFGANG RINGEL

We took on this research to pinpoint the best practices that separate the leaders from the laggards

be considered as a menu of options, Ringel clarified, but rather a symbiotic ecosystem wherein one without the other diminishes the performance and costeffectiveness of the whole.

recycling, which is often referred to as ‘the “Holy Grail” of recycling’, can increase the percentage of material collected in a closed loop. “Right now we are paying to throw away a valuable material, so if you divert more material away from the waste stream, you save money. What you’re able to create with that is a circular economy,” Noel concluded.

RECYCLING Where deposit return systems are in place, they have become known for collecting two, three or four times as many containers as those without a deposit, according to Ringel’s research. The financial incentive therefore becomes a powerful motivator for changing consumer behaviour. Using the US again as his example, Noel added: “27 per cent of containers without a deposit on average are collected for recycling versus 88 per cent of containers with the deposit. This has a series of knock-on environmental, economical and social benefits.” Once collected, plastics can be recycled and their value maintained so they can be recycled again and again. Bottle to bottle

But what does this translate to in the political environment? Authorities are beginning to show commitment to updating existing deposit systems or are otherwise developing new ones. The TOMRA Governmental Affairs Manager believes that this will ignite a conversation regarding the design of these deposit systems. Having one in place, he said, does not necessarily generate the desired outcome, and not all are performing to their full potential. In Germany, however, which is collecting 98 per cent of all deposited containers, we can observe that there are some fundamental best practices when it comes to designing deposit return systems. This is why TOMRA initiated the research. Why are some container deposit return systems succeeding while others are failing? PLASTICS, POLITICS, AND THE PUBLIC Speaking from his office in MülheimKärlich, Germany, Ringel introduced the four principles that have brought about such high-performing deposit return systems. These are still being scrutinised by the analysts at TOMRA and consist of three sub-elements that should not

Deposit return systems alone cannot entirely address the equation and ensure new bottles are made out of recycled material. Perhaps the most important reason for this is that the market values for recycled material are volatile. When it comes to making risky investments in collection and recycling, few will agree to invest in a plastic recycling plant without knowing about a constant, reliable supply. This will lead to “a lack of a stable market” as Ringel put it, and “a lack of supply where content recovery requirements are able to stabilise this key funding stream for the commodity value”. Listing two best practice examples, the EU has set a 30 per cent recycled content target for plastic bottles to be achieved by 2030, and the US state of California has adopted recycled content legislation that aims for 50 per cent. “That, of course, is very very important,” Ringel concluded. “Those targets give investment security and will help to achieve content requirements.” The Rewarding Recycling white paper goes into much more detail regarding deposit return systems best-practice case studies from around the world, and clarifies the 12 key design elements that make up the four principles of Performance, Convenience, Producer Responsibility and System Integrity, as well as what high-performing systems are capable of delivering when it comes to recycling targets and getting consumers engaged in the transition to circular economy. In 1972, TOMRA produced the world’s first reverse vending machine. Over the past ten years, additional models came into play that enabled the system operator to place the machines for free where the general public have access. With digitalisation ever-growing, and new technologies ever-increasing, the next 5-10 years are certain to show some real progress in public participation in plastics, and other materials, recycling.

PACKAGING NEWS UNITED CAPS ANNOUNCES NEW PRODUCTS DURING INTERACTIVE VIRTUAL EVENT UNITED CAPS CONTINUES TO HARVEST FROM ITS RICH PRODUCT PIPELINE, DEVELOPING AND LAUNCHING NEW PRODUCTS THAT WILL HELP ITS CUSTOMERS BE MORE PRODUCTIVE AND HAVE MORE SUSTAINABLE PACKAGING. THESE ANNOUNCEMENTS WERE MADE DURING UNITED VIRTUALLY, AN INTERACTIVE VIRTUAL EVENT HELD IN LIEU OF THE MANY INDUSTRY IN-PERSON EVENTS THAT HAVE BEEN CANCELLED OR POSTPONED DURING THE PANDEMIC.

EO Benoit Henckes said: “We are pleased to be able to bring these new and improved products to market during this difficult time … Stay tuned over the next weeks and months for additional innovation news from UNITED CAPS as our talented R&D team continues its

important work.” New products to the United Caps portfolio include the 29 FLIP ON edible oils closure; PROLINE 2, a closure for still beverages; its awardwinning DOUBLEFLOW line; and a family of lightweight closure solutions for 26mm necks.

AIRPLUS SETTING NEW BENCHMARKS IN PROTECTIVE PACKAGING PROTECTIVE PACKAGING SPECIALIST STOROPACK HAS LAUNCHED A NEW AIR PILLOW FILM PRODUCED FROM 100 PER CENT RECYCLED MATERIAL.

mixture of postconsumer and post-industrial waste, AIRplus 100% Recycled offers the same protective properties

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as conventional air pillows. The product also results in 30 per cent fewer greenhouse gas emissions during production compared

A GROUP OF 18 EUROPEAN COMPANIES ACTIVE IN EXPANDED POLYSTYRENE (EPS) RAW MATERIALS, PACKAGING MANUFACTURING AND RECYCLING HAVE LAUNCHED THE SMART PACKAGING EUROPE CAMPAIGN TO HIGHLIGHT THE ENVIRONMENTAL, ECONOMIC AND SOCIAL BENEFITS OF EPS PACKAGING.

EPS industry launches ‘Smart Packaging' S mart Packaging Europe aims to demonstrate that EPS has an important role to play in the future European packaging market. Spokesman Sven Heppes said: “We fully support efforts to reduce pollution and are doing our part by investing in waste collection, recycling and increasing the use of recycled materials. A variety of recycling options, combined with the fact that EPS packaging generally consists of a single polymer, make EPS one of the most recyclable packaging materials available.” EPS is widely used as

packaging for valuable objects from sensitive electronic equipment and white goods to fresh fish and super-cooled COVID-19 vaccines. Because it is composed of 98 per cent air, EPS is

to air pillow films made from virgin material. Additionally, PAPERplus paper cushions and the PELASPAN packaging chips are made entirely from recycled raw materials. Many other Storopack products contain a significant percentage of recycled or renewable material. Product Manager Vicentina Pereira said: “AIRplus 100% Recycled […] helps us to achieve

our sustainability goal to manufacture at least 50 per cent of our internally produced protective packaging from recycled or renewable raw materials by 2025. We’re therefore always working on improving the recycling infrastructure and the overall production process.” Storopack is also a member of the Alliance to End Plastic Waste

inherently resource efficient and helps to save energy and reduce greenhouse gas emissions during transportation. Across Europe, there are many SMEs that specialise in recycling EPS.

PACKAGING AINIA AND AIMPLAS PRESENT THEIR STRATEGIC OVERVIEW IN THE DEVELOPMENT OF BARRIER PACKAGING AND A PRELUDE TO MEETINGPACK 2022.

prelude to MeetingPack2022, the Virtual MeetingPack workshop will present the most disruptive solutions in barrier packaging through inspiring presentations, roundtable discussions and visits to virtual exhibitors. As a consequence of the health crisis caused by COVID-19, the next in-person edition of MeetingPack has been postponed until 20-21 April 2022. Nevertheless, given the rising interest in this meeting concerning barrier packaging and sustainability in the sector, the virtual live event will take place on 27 May as a prelude to the inperson event in 2022. The latest technological innovations in sustainable barrier packaging will be

presented in two blocks: Solutions in sustainable packaging and Incorporation of recycling in packaging. The goal of Virtual MeetingPack 2021 is to offer companies a strategic vision of the sector trends in barrier packaging and to share the common challenges which the sector will face in the coming years. For this reason, inspirational presentations, roundtable talks and visits to virtual exhibitors will be available. The platform selected for this virtual format will make it possible to replicate the model of the in-person event in a way that maintains interactions and promotes networking – a highly important part of the success of the MeetingPack format.

Jointly organised by AINIA and AIMPLAS, and in association with the Valencian Association of Plastic Enterprises (AVEP) and PlasticsEurope, MeetingPack is a biannual event sponsored this year by Enplater, RSM, TPL and UBE. Bringing together more than 300 people from the packaging and related sectors to discuss the main developments in barrier packaging, its latest edition, MeetingPack 2019, saw the consolidation and internationalisation of the event. PACKAGING OF THE FUTURE: BARRIER AND SUSTAINABLE The evolution in packaging to form the supply available today has been conditioned by the characteristics of the food it contains. The requirements are different when it comes to packaging a ready meal or fresh food; a conserve or refrigerated products. The correct choice of packaging for professionals in the food industry must guarantee food safety through the technology and materials, as well as consider the comfort and convenience of the final user. The conditions in which the food reaches the consumer, as well as its shelf life, depends to a large extent on the atmosphere inside

the packaging. For this reason, the latest trends in research are aimed at optimising barrier packaging as it protects the product from external factors (light, humidity, oxygen), delaying its deterioration without the use of additives and therefore avoiding food waste. Barrier packaging, combined with innovative packaging systems, is one of the most complete technological solutions in response to the complex world of services that the packaging value chain requires from manufacturers. Selecting technology and innovation according to the needs of the food product for which it is intended is key. All this, under the umbrella of the circular economy and sustainability model that must necessarily unite technical criteria with environmental criteria, is undoubtedly the greatest challenge facing the packaging industry and the central focus of this edition of MeetingPack.

Barrier packaging, combined with innovative packaging systems, is one of the most complete technological solutions

PACKAGING THE EXPERTISE AT EUROTEC NOW EXTENDS TO ENGINEERING PLASTICS FOR PACKAGING APPLICATIONS.

ENGINEERED TO

PR TECT

n the packaging industry, materials must be safely protected, stored and delivered to the consumer without any deterioration. Thanks to the combination of their flexibility, strength, cost effectiveness, impermeability, durability and high-performance, plastics play a key role in the packaging industry. eurotec offers innovative solutions for food packaging, automotive and electricalelectronics sectors, which meet the engineering and high safety demands.

The food industry is one of the sectors wherein plastic packaging is most frequently used, and the company offers Tecolen OXY0 MF17 NL IL QF (Polyolefin, 17% mineral filled, impact modified, natural, suitable for food contact) as a lidding sealant resin for the food industry, which has high peeling strength and provides smooth and consistent production during coextrusion. With the specially designed formulation, lids are easily openable while protecting the beverage against spoilage, leakage, contamination and/or tampering. Metal detectable plastics are also critical materials for food processing and packaging for the elimination of contamination. In this area, eurotec

offers Mastertec EM additive and compounds of metal detectable grades in different polymers to avoid any plastic contamination. The two metal detectable options are iron-based products that provide cost-effective solutions, and steelpowder products that make it possible to achieve brighter colours. Tecolen CP20 GR264 EM 0C QF (PPCP, metal detectable, grey, suitable for food contact) is approved for metal detectable case application. The material is sensitive enough to allow small particles to be easily detected using metal detection methods in the food industry.

Many solutions in the electrical or technological packaging industry are provided by eurotec. Conductive or antistatic thermoplastics are especially essential when protecting material or equipment from all potential damages from handling to electrical or static charge. One of eurotec‘s conductive solutions for the packaging industry is Tecolen OE20 BK111 EC 0F (PE, conductive, black) which is used in electrically conductive fibers and films to provide safe transportation and storage of large bags for protection against explosive or inflammable materials. Arcs generated by static accumulation can lead to combustion as well as a breakdown in circuit lines – e.g. in electronic cards. Therefore, the packaging of sensitive electronic applications such as this should be able to protect them from uncontrolled discharges of electrostatic electric load. As electrostatic accumulation could deteriorate cards with sensitive circuits immediately, this results in high costs for manufacturers. To meet these demands, Tecolen OE10 RD018 EC

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0B (PE, conductive, red) was developed. The translucent product – that can be any color – assures the safe transfer of electronics cards from manufacturers to end-users. Tecolen OE20 BK EC 0E (PE, conductive, black) has a high conductive range that is used in the film packaging industry for electrical-electronic applications to prevent electrostatic discharging. It is also vital for cards which are taken from serial production to intermediate manufacturers to be protected from arcs for the avoidance of damages during handling, delivery and storage. Tecolen CP30 BK EC 0B (PPCP, conductive, black) and Tecolen CP10 BK EC 0C (PPCP, conductive, black), developed for crates and ancillary equipment used for storage and delivery, dissipate static electric immediately during these processes and protect products from static charge. eurotec provides unique and tailor-made solutions to customers in every aspect of life. Stay tuned for new updates.

WE DRIVE THE CIRCULAR ECONOMY.

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MEDICAL PLASTICS NITHIN RAIKAR, SENIOR BUSINESS MANAGER AT SABIC SPECIALTIES FOR LNP RESINS AND COMPOUNDS, DISCUSSES THE EFFECTS THAT LNP ELCRES CRX PC COPOLYMERS HAVE HAD IN THE MEDICAL SECTOR.

SABIC versus COVID How has the increased use of disinfectants in healthcare settings brought about a change in the way plastics are used? Device manufacturers and material suppliers have worked diligently to elevate their understanding of the compatibility of new chemical agents with plastic materials. The COVID-19 pandemic has accelerated the focus on the types of materials used to address infection control challenges. Specifically, device manufacturers are considering newer material solutions with improved chemical resistance to withstand the cumulative effects of cleaning, aggressive disinfectants and the increased frequency in cleaning protocols. How do SABIC products help maintain the structural integrity of surfaces? SABIC understands the need to develop materials with improved chemical resistance to help extend the useful life of critical plastic medical products. In terms of traditional polymer chemistry, repeated exposure to aggressive chemicals over time may result in

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either physical degradation (environmental stress cracking, crazing, swelling and discolouration) or chemical attack (negative reaction of chemical with polymer). SABIC has innovated to help hospitals mitigate this risk by developing a new family of LNP ELCRES CRX polycarbonate copolymers featuring improved chemical resistance over existing materials. Compared to traditional PC, ABS, and polyester and co-polyester resins and blends, which are potentially incompatible with highly aggressive disinfectants, the new LNP ELCRES CRX copolymers can help prevent stress cracking and mitigate crack propagation. This means that hospitals can continue to use the most aggressive and effective forms of disinfectant without compromising device functionality. How rigorous were the tests that prove the technology works? SABIC follows an established environmental stress cracking (ESC) testing procedure (ASTM D543) to screen chemicals and environmental conditions that mimic a part’s typical exposure. We conducted this study to assess compatibility between incumbent materials and twelve leading surface disinfectants widely used to clean devices. This includes many of the disinfectants published on the United States Environmental Protection Agency list that meet their

criteria for combatting SARSCoV-2, the novel coronavirus that causes COVID-19. To test compatibility with various chemicals, SABIC used a quantitative ESC test that evaluates retention of tensile properties from three to seven days at one per cent strain and at room temperature. With no established industry standard, this exposure range was selected to push the material to its test limits. The test bars are kept saturated with the chemical agent, i.e. they’re wrapped in disinfectant wipes. This test method is one of the most stringent protocols and serves as a highly accelerated version of normal exposure to disinfectant wipes in a healthcare setting.* How complex is the process of getting these polymers/ copolymers to market in Europe? Applications in the healthcare industry and medical devices have unique and stringent requirements for thermoplastic materials. The proper selection of plastics for medical devices and equipment housings will continue to be a focus to provide better patient safety and reduce operating costs. It is important for OEMs to involve material suppliers early on in the design process to identify the appropriate

materials to support both mechanical requirements (such as flow, impact, creep resistance) and also the growing requirement of chemical resistance performance to withstand harsh disinfectants. As designers explore benefits to utilise new plastic technologies during product development, SABIC offers support beyond material selection in terms of part design and moulding processing. A proactive and collaborative material selection approach supports the ability to bring new materials to market that can meet product performance and address applicable regulatory requirements for medical devices. *Compatibility criteria may vary since there is currently no agreed-upon industry standard. SABIC defines compatibility as ≥90% retention of tensile stress at yield and 80-139% retention of tensile elongation at break.

MEDICAL PLASTICS BECTON DICKSON RECEIVED GLOBAL ORDERS FOR NEEDLES AND SYRINGES TOTALLING MORE THAN 1 BILLION INJECTION DEVICES TO SUPPORT COVID-19 VACCINATION PLANNING. EPPM SPOKE TO VP MEDICATION DELIVERY CHEE LUM TO FIND OUT MORE.

DELIVERING

THE GOODS What role has Becton Dickinson played in getting us to this point in the fight against COVID-19? As one of the largest medical technology companies in the world, BD is deploying our capabilities, expertise and scale to address critical health needs related to coronavirus – from our diagnostic offerings, to real-time informatics and electronic surveillance technology, to essential medical devices to support patient care. Specific to the vaccination campaign, BD is the world’s largest manufacturer of needles and syringes. We produce billions of these devices annually for a wide range of applications from insulin injection, to many different types of pharmaceuticals and biologics, to vaccines. In the midst of this pandemic, we understand the responsibility we carry. BD has been working around the clock, educating and discussing needs with governments across the globe, and running needle and syringe production lines 24/7.

Delivering COVID-19 vaccinations will take the co-operation of the entire marketplace: government agencies, multilateral organisations, vaccine manufacturers, and distribution partners all working to stop the pandemic. What does this mean for BD’s reputation on the global scale? Our innovation, scale and execution has made BD the essential company in the pandemic response – providing technology across the healthcare spectrum, from immunology research, to diagnostics, to devices used in treatment, to injection devices for vaccines and real-time data analytics, surveillance and reporting. No one has been more committed to helping the global healthcare community control and defeat this virus, and BD will continue to be a major contributor to the vaccination efforts and overall pandemic response. How have players in the public sector responded to the news? The orders for more than a billion injection devices is a milestone that reflects commitments from Australia, Belgium, Canada, Germany, the Netherlands, Saudi Arabia, Spain, the UK and the US, among others, as well as NGOs supporting vaccine deployment for developing countries. The scale of orders means hundreds of millions of people, such as frontline workers and at-risk loved ones, will be able to receive a vaccination as soon as they are available. What are the most important factors that had to be considered? Early planning and preparation are critical. Planning ahead provides the best opportunity for the global industry

to manufacture the number of devices required to be ready for mass vaccination programmes. As early as April 2020, when we saw worldwide shortages of PPE and testing, BD was already beginning to ramp up production, primarily for devices to support flu vaccination, because flu vaccine demand typically increases during or after a pandemic. From that point, BD partnered with governments to educate them on when to order supplies and better understand what devices they would need and in what quantities. What has BD learned about medical manufacturing over the past year that was perhaps taken for granted previously? What is important is to ensure there is a long-term strategy in place to prepare for future pandemic vaccination efforts, in addition to supporting immediate efforts for COVID-19 vaccination readiness. We are partnering with the US government on a $70m (~€58m) capital project to further expand our operations and manufacturing capacity in Nebraska. This is expected to be online this summer and, once completed, the federal government will have access to hundreds of millions of injection devices to support vaccination efforts for COVID-19 and future pandemics. We are also investing approximately $1.2bn over a four-year period to expand and upgrade manufacturing capacity and technology for pre-fillable syringes and advanced drug delivery systems, as well as adding a new manufacturing facility in Europe. This will not only enable continual growth of new injectable drugs and vaccines, but also provide surge capacity for increased pre-fillable syringe demand during the pandemic.

MEDICAL PLASTICS EPPM CONTACTED BREATHE99 CEO MAX BOCK-ARONSON AFTER THE B2 FACE MASK WON INTERNATIONAL RECOGNITION AS ONE OF TIME MAGAZINE’S BEST INVENTIONS OF 2020.

MORE THAN A MASK CONGRATULATIONS ON YOUR TIME MAGAZINE ACCOLADE. WHAT IS SPECIAL ABOUT THE B2 FACEMASK? The B2 Mask is a patent-pending reusable facemask that provides industrial-grade protection in a lifestyle design. The ergonomic facepiece helps minimise air leakage and foggy glasses, and the sustainable design can reduce environmental filter waste by up to 80 per cent by weight compared to disposable N95s. The facepiece is covered by an interchangeable fabric overlay that comes in a number of styles and colours, allowing people to personalise their look without compromising on protection. In the coming months we’re going to launch a service to make filter changes even more seamless and affordable, as well as an overlay marketplace so other designers can release and promote and sell their own styles for B2’s fabric overlay. WHAT DOES IT MEAN ON A PERSONAL LEVEL TO RECEIVE RECOGNITION FROM SUCH A PRESTIGIOUS PUBLICATION? I am incredibly grateful for the recognition of our team’s work in developing the B2

information about the filter performance, we encourage people to explore the technology page on our website and download our filter white paper.

Mask. As a kid, I was an avid reader of Popular Science and had a particular love for the end-of-year ‘Best Inventions’ issue. So, being featured on the cover of TIME as one of the Best Inventions of 2020 is a dream come true, especially because it has been for a product that helps bring peace of mind to people during this turbulent and stressful year. WHICH PRESTIGIOUS ACADEMIC INSTITUTIONS HAVE OFFERED ENDORSEMENTS TO THE PRODUCT? We have done all of our testing with thirdparty labs at the University of Minnesota’s mechanical engineering department. These tests have shown that our standard filters remove >99% of particles down to .1 micron during normal breathing rates. For more

WHICH MATERIALS ARE USED TO CREATE THE FILTERS? The B2’s filters are constructed from electrostatically-charged meltblown and spunbond polypropylene. We offer filters in a four and three-layer style, which give people an option of whether to prioritise for breathability or maximum protection depending on their use case. HOW DOES THE MASK COMBINE STYLE WITH SUSTAINABILITY, AND MOST IMPORTANTLY, WITH FUNCTIONALITY? The B2 Mask’s unique functionality all starts with our patent-pending facepiece. By reusing large portions of the mask, the B2 Mask is able to provide a high degree of protection while producing 80 per cent less waste than disposable N95s or surgical masks. We’ve also designed the B2 to be really easy to customise with fabric overlays that come in a range of styles and are made partially from recycled bottles. As we move forward, our goal is to continue to optimise our packaging for sustainability by switching to bio-based plastics and even compostable packaging, and also introduce a marketplace for overlays made by other businesses and designers. WHEN THE COVID-19 PANDEMIC FINALLY ABATES, IN WHAT OTHER WAYS CAN THE USER BENEFIT FROM THE B2? Unlike cloth or surgical-style masks, the B2 Mask was actually designed for filtration of fine particulate matter. The mask also protects a user from inhaling other particulates such as mould, allergens, and dust. When the pandemic finally abates, people can use the B2 Mask to gain protection from elevated air pollution, wildfire smoke, and activities around the house.

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MEDICAL PLASTICS EPPM SPOKE WITH JEAN MARC GALVES, BERRY GLOBAL’S NEW HEALTHCARE DIVISION LEAD, TO FIND OUT HOW THE PACKAGING COMPANY IS EXPANDING ITS PRESENCE IN HEALTHCARE APPLICATIONS.

THE FULL PACKAGE WHAT IN THE MEDICAL PLASTICS INDUSTRY HAS DRAWN THE EYES OF BERRY GLOBAL? Berry has a long history in the healthcare industry and creating a better patient experience through unique innovations is what differentiates us. Today, we are a global leader in pharma packaging and medical devices with more than 15 healthcare-focused sites in the US, EU, China, India and Mexico. Our newly formed global healthcare division will support new investments and partnerships in the space. ASIDE FROM THE PANDEMIC, WHAT EVENTS HAVE TAKEN PLACE WITHIN THE MARKET THAT HAS LED TO SUCH GROWTH? The healthcare industry is in the midst of a global transformation and demand for a better healthcare experience from an expanded pool of consumer-patients is increasing. Global healthcare costs are also expected to double in the next seven years with an ageing baby boomer population. Our growth is driven by new products to improve quality

of care and reduce costs. A great example of how we’re designing with the patient in mind is our digital inhalation devices. Our dry-powder inhaler technology includes sensors and digital capabilities that enable connection to apps and the cloud. Our newest inhaler, RS01X, connects through Bluetooth to the Respiro app developed by Amiko to provide reminders, personalised insights and inhaler technique tips. Patients can share their data with healthcare providers, in person and digitally, to enable collaborative and data-driven treatment adjustments.

investments include ISO Class 7 to Class 8 cleanrooms for manufacturing.

WHICH EQUIPMENT OR TECHNOLOGY ARE YOU PLACING YOUR PRIMARY INVESTMENTS IN? Our global investments focus on digital capabilities, childresistant and senior-friendly packaging solutions, and airless and preservative-free technologies. We’re allocating resources and capital to bring more innovative patient-centric drug delivery solutions and digitalisation capabilities for medical device packaging. New

WHICH OF YOUR PRODUCTS ARE THE CURRENT MARKET LEADERS? We lead in nasal, eye care, dermal, pulmonary and diagnostics healthcare. Some of our key innovations include:

HOW DOES BERRY HOPE TO CONTINUE TO MEET SUSTAINABILITY TARGETS? Sustainability is not new to Berry and is at the core of our innovations. We’ve been a trusted partner in closed loop sustainable solutions for many years. For example, we recycle contact lens cases and reuse them successfully in the same application. We also offer one of the lightest OTC healthcare packaging portfolios, which reduces plastic use and saves on GHG emissions.

RISDROP – an eye dropper technology with a unique nozzle that dispenses uniform drops of the same size and weight to ensure the right dosage every time. It was recently recognised with an award during CPHI China. PALMSOFT – a childresistant, senior-friendly closure technology. It creates a soft rubber feel to the top of the closure to make it easier to open for seniors and anyone with arthritic conditions.

POLITAINER – offers a unique closed filling system for healthcare applications so it creates a mess-free operation and minimises the risk of contamination. The Politainer collapses as the product is used, which helps to ensure complete emptying of the container with minimal residue. The collapsed PE container is fully recyclable, which aids in disposal. RS01 INHALER DEVICE – a patented capsule-based, refillable single-dose drypowder inhaler which is the worldwide standard for this category of devices. In addition to performance, safety and compliance, the RS01 design was designed for sustainability – it’s lighter weight and uses fewer components than previous generation devices. AIRFREE OTC – our Vega Ecosolution sustainable airless dispensing range is available in five different capacities from 50ml to 500ml, all light and 100 per cent made out of plastic. The oxygen barrier protection in the bottle protects a formula’s active ingredients and allows for fewer needed preservatives.

COMPOSITES TECHNICAL DIRECTOR OF NETHERLANDS-BASED THERMOPLASTIC COMPOSITES RESEARCH CENTER (TPRC) SEBASTIAN WIJSKAMP AND MANAGING DIRECTOR OF ANIFORM ENGINEERING B.V. SEBASTIAN HAANAPPEL DISCUSSED THEIR EXPERTISE IN STAMP FORMING FOR THERMOPLASTIC COMPOSITES DURING A RECENT TPRCLED WEBINAR. EPPM WAS THERE.

undreds of thousands of parts are finding their way into the automotive industry in combination with injection over-moulding, but now the time has come to take the stamp forming process and the materials a step higher – literally. “We really would like to move into the primary structure of aircraft,” Wijskamp began. “That means we need to understand better what we are doing and need more research in that field.” Putting it simply, you take a flat sheet of pre-consolidated laminate material, the TPRC technical director explained, which consists of fibres and polymers already joined. This flat plate already has “ultimate material performance”. Sounds promising. “The world is not flat,” Wijskamp added. “We like threedimensional shapes, so we are heating and melting the polymer matrix so we can then fold or mould material into a certain shape. If we do this well, we retain the material properties that were already inherent in the plate material. We can make very strong, lightweight products.” Again, this sounded very promising – but what about efficiency? Between them the engineers explained how heating takes around three to four minutes, or perhaps five, depending on the thickness of the material. Stamping itself takes just a matter of seconds even though a lot of different things are happening at the same time. It then takes another minute or two for the material to cool and for the polymer to crystallise, giving the material the properties needed for aircraft applications. The increasing use of thermoplastic composites in aerospace applications is becoming more and more important. “We would like to make aircraft lightweight,” Wijskamp confirmed. The aim is to have aircraft contain over 50 per cent by weight composite materials, but usually parts with these materials take a very long time to manufacture. For example, the curing of thermoset material in an autoclave oven might take an entire

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day. With thermoplastic, since it is only requisite to heat, melt and shape the material, the process can be very fast by comparison, enabling engineers to implement more composites in aircraft – and lighter aircraft mean less CO2 emissions during their lifespan. “In the end, it’s all about minimising weight and reducing CO2 emissions,” Haanappel added. “With composites, we can design light parts – as we have done for years now – but the material has more potential in it, so we can further minimise weight and minimise energy. We only need to design the parts and the process a bit smarter.” REACHING FOR THE SKIES The engineers admitted that while big steps have been made, further optimisation requires more effort than the industry has put in up until now. “Shaving off this last bit of weight will take more and more research,” Wijskamp added, “but it’s time for stamp forming to go to the next level.” For an engineer, that means considering a huge variety of different parts that could become a thermoplastic composite part. To achieve that, an engineer has to think about designing and manufacturing, which are very strongly interlinked with thermoplastic composites and with composites in general. With thermoplastic composites, a whole new mindset is required entirely. “You can’t just design a part,” Wijskamp continued. “You need a certain material thickness here and maybe work with a thinner part there, but you have to take the manufacturing process itself into account. You need to know your processing during designing. You can build up this knowledge by doing a lot of trial and error, so you start with a certain blank, you go to the press, you stamp it, you find out if something’s wrong, you take the tool back to the tool shop, if you’re lucky you only have to remove some steel from the tool; if you’re unlucky

The material has more potential in it so we can further minimise weight and minimise energy. We only need to design the parts and the process a bit smarter

FLIGHT

you have to make a new tool. You might have to discuss again with the design engineer. These iterations take a long, long time, and you really want to minimise that. Simulation software can really help you to design very fast.” This is where AniForm’s simulation software comes in. Such software provides insights into the behaviour of the composite materials, and therefore provides numerous benefits to the industry. “The benefit is that you obtain less trial and error using simulation tools,” Haanappel clarified. “If you just forecast things, you know more or less already what will happen, so you can anticipate that. To give you an idea, if you do a

practical trial session in the lab, where you make your moulds and have your equipment, it all costs money: the labour, the material. Such a trial session will cost you around €15,000. But if you need to take back the mould and do some modifications or even redesign your mould, redesign your gripping or handling system off the blank, you have a new trial session. The more trial sessions you have, the more €15,000 adds up. If you use simulation forecasting tools, even if you just reduce the number of trial sessions by two or three, it really saves you a lot of money.” SIMULATING SUCCESS A lot of the design guidelines and rules are already in the software due to the experience and expertise of others. The

SIMULATION

simulated material shows what happens during forming and, whilst this may be considered a limitation on creativity, it ensures one cannot attempt something that others had previously tried. Haanappel continued: “We have quite a toolset in the software which you can utilise to play around – it really helps that you can already see what happens with the laminate because, in reality, it is more or less a black box. You can make the tooling invisible and you can really see what’s happening. it can help you to assess what challenges an engineer will face when you do a process implementation, and it really helps you to assess the project risk. If you have some footage of the process simulation and you’re working in a structures team, for example, doing distress calculations, this tool can really help you to communicate a problem.” As well as cost savings, simulation includes benefits such as better communication. Designers and manufacturers can utilise the stamp forming process without simulation based on craftsmanship, and that’s considered a good thing at TPRC, but newcomers to the industry are advised to start with simulation. “Software enables us to move in this direction,” Haanappel concluded. “It really makes a difference for the industry. The TPRC consortium brings together composite processing specialists [and] forming specialists from the industry. In this platform, we share our common challenges and, from that, we can quite easily distil and hear what the current needs of the industry are – as well as how they are likely to develop and what the forthcoming challenges will be.” Being part of just such a community, it seems, helps improve and direct each member’s own technology roadmap, cost, communication channels, productivity, and parts and materials knowledge. With the endgame of achieving more lightweight, long-lasting, and fuel-efficient aircraft, research and development consortia such as the TPRC are helping Europe’s composite part designers and manufacturers prepare for a smooth take-off.

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EPPM Magazine

RECYCLING NEWS

RAPID INTERVIEW: STIPHOUT PLASTICS CEO ELINE STIPHOUT WHICH AREA IS YOUR SPECIFIC AREA OF EXPERTISE? I’m the CEO of two plastic recycling companies specialising in processing household plastic packaging waste. We currently wash, grind and separate PP and PE packaging. In the future, we will invest in a more extensive processing line to recycle mixed plastic waste. HOW DO YOU FIND TIME TO BE CEO OF TWO START-UPS? Busy, but I’ve collected a very strong team around me. HOW HAVE YOU HELPED CHANGE THE WAY PLASTICS ARE RECYCLED IN THE NETHERLANDS? We were the first company to recycle plastics from the waste bin. Plastics that would otherwise be burnt. WHAT IS IT ABOUT THE RECYCLATE YOU PRODUCE THAT MAKES IT APPEALING TO CONVERTERS? Our regrinds are very clean and can be directly used in production. HAS THE PANDEMIC BEEN DETRIMENTAL OR BENEFICIAL? Beneficial, more household waste was generated.

Eline Stiphout Copyright: Stiphout Plastics

HOW DO YOU GO ABOUT GETTING YOUNG PEOPLE INTERESTED IN PLASTICS RECYCLING? Show them the green entrepreneurial benefits, subsidiaries, a lot of support, and economic potential.

New circular packaging solutions for the Spanish dairy sector REPSOL HAS REACHED AN AGREEMENT WITH PACKAGING MANUFACTURER JOKEY GROUP, AND SPANISH ORGANIC DAIRY COMPANY CANTERO DE LETUR.

antero de Letur will pioneer the use of recycled plastic packing in the organic dairy industry in Spain for its cheese products. The packaging will use ISCC Plus certified Repsol Reciclex circular polypropylene. In early 2020, Repsol certified all its petrochemical complexes to produce under the ISCC Plus accreditation. Jokey received this certification in August 2020 at four production

sites, including Spain. Michael Schmidt, Chief Procurement Officer at Jokey, said: “The Repsol-JokeyCantero project is one of the first to pilot the purpose of demonstrating the longterm applicability of recycled plastics. Real, working business and material flow models will attract more partners and drive the plastics industry toward a circular economy.” The collaboration aims to reduce

the production and consumption of virgin materials, and respond to demands for environmentally friendly packaging.

HENKEL MAKES RECYCLING TARGETS VISIBLE HENKEL IS INCREASING THE DEVELOPMENT OF CIRCULAR ECONOMY ACTIVITY THROUGH THE PURSUIT OF AMBITIOUS PACKAGING TARGETS. THE GOAL BY 2025 IS THAT 100 PER CENT OF HENKEL’S PACKAGING WILL BE RECYCLABLE OR REUSABLE. BY THE END OF 2020, THE COMPANY HAD ACHIEVED THIS FOR AROUND 89 PER CENT OF ITS PACKAGING.

enkel is also working steadily to increase the proportion of recycled material in its packaging. While many of its brands already offer products with packaging made from recycled material, the company aims to increase the share of recycled plastic to more than 30 per cent for all consumer goods products worldwide by 2025. By the end of 2020, this proportion was around 15 per cent.

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RECYCLING BREXIT, CORONAVIRUS, THE PACKAGING TAX, ENVIRONMENTAL SCRUTINY. THESE ARE JUST SOME OF THE MAJOR ISSUES FACING UK PLASTICS PRODUCERS. EPPM SPOKE WITH SUFFOLKBASED CHASE PLASTICS CEO DAVID HARRIS TO FIND OUT HOW HE RISES TO THEM.

The thrill of the CHASE WHAT’S THE NEW BIG THING IN RECYCLING? The big thing about recycling is that in many ways the shape of the industry is changing. People are looking to use recycled content – driven by the packaging tax – although there are brands out there who are looking for recycled packaging anyway. But there was already a move for the increased use of recycled content before the tax. That, for us, is a very big feature of the business. It’s fair to say that, historically, people used recycled material because it was a cheap option and applications suited it. But now, it’s much more about quality and performance. SO, THE QUALITY OF RECYCLED CONTENT HAS IMPROVED? As a business, we’ve always operated in a niche where we’re selling to customers who appreciate quality and service. Our process involves careful buying to produce good quality materials and a very reliable supply. It’s not the ’offer what you’ve got set-up’, which is very much the traditional way of doing things. Now you’ve got people producing high-performance packaging and their requirements are completely different to the traditional user of recycled material. It’s about much more than just appearance. This is what many people are going to be learning over the next year or so as they get ready for the packaging tax. It’s about materials that run efficiently on the machines. It’s about the materials that deliver the mechanical properties that they need for the film to work in the end application.

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IS THIS APPLICABLE TO ANYTHING WITH LESS THAN 30 PER CENT RECYCLED CONTENT? The thing with the packaging tax is it’s very much a cliff edge. If you’re at 29 per cent, you’re paying the tax; if you’re at 30 per cent, you’re not. We’ve a very broad spectrum of customers, but where we’re seeing an awful lot of growth is people coming in who don’t normally use recycled material. Our job is not only to give them materials that tick the recycled box, but also to ensure they’re not compromising on quality, productivity and efficiency – and at the end of it, the packaging they produce meets all the requirements. People may want sustainability, but it doesn’t mean they want to compromise on performance. WHO IS THE ONUS ON TO ENSURE THAT 30 PER CENT THRESHOLD IS MET? Everything we make is 100 per cent recycled. Whilst it’s for the customer – whether a film producer or a packaging producer – to get over the 30 per cent mark, it’s our job to enable them to achieve this profitably. One thing the manufacturers have really got to get on with is product development and trialling so they can learn the lessons of incorporating this into their products. If anyone was to wait until April 2022, they’re going to be very disappointed because there isn’t an abundant supply of the right feedstock to create the quality of materials that the packaging industry will need. So, the players who are ahead of the

Our job is not only to give them materials that tick the recycled box, but also to ensure they’re not compromising on quality, productivity and efficiency

curve, getting their products developed, and getting their customers to approve the products will have a great advantage because they’re already securing that supply. To be fair, packaging manufacturers are very much alive to this issue, but of course the COVID-19 pandemic has not made it easy to run production trials. A sensible assumption is that they’re going to have to do it in the current situation for an extended period. It’s vital that people are also looking at what’s happening with the output of their machinery. Even if they’re hitting the 30 per cent threshold, they need to be maintaining productivity and efficiency on their machinery or they’re going to see their business moving backwards. WOULD THAT PARTICULARLY AFFECT PLASTICS CONVERTERS MORE THAN MOST? Absolutely. We’re in a business where every penny counts. It’s a 24-hour process. You need to know that the material is being delivered to the machine at three o’clock on a Sunday morning and that it’s going to perform beautifully. You can’t afford to take chances on what might turn up, which is why we are committed to giving our customers confidence in the quality, consistency and reliability of supply.

SO WHERE DOES CHASE PLASTICS SOURCE THIS FEEDSTOCK FROM? Our material is predominantly a mixture of post-industrial and post-consumer UK or EU-sourced scrap. For over a year now, we’ve been accredited by EUCertPlast, which is incredibly important for assuring customers that any claims of recycled content are robust. What that means is that we’re audited and have traceability in place so that every batch of material we produce, we know the feedstock that we’ve used, and therefore customers can be confident that we can say we have used post-consumer or postindustrial material. We branded our packaging grade material as RECOTHENE, and the way our process is designed is we give our customers absolute consistency and quality. Quite often with recycled material, you can get big variations between batches and bags of the recyclate. Ours is designed using a mixture of blending and pelletisation, so that every pellet is the same. If you then issue that material to the factory on a Friday to run over the weekend, you will not find the process or the quality of the material changing. It gives you assurance that you can run a 24/7 operation with high levels of efficiency. WILL THE EUCERTPLAST ACCREDITATION STILL BE VALID FOR UK PRODUCERS POST-BREXIT? EUCertPlast accreditation is the one internationally recognised standard that customers can turn to. I can’t imagine that the UK will do its own standalone system, so it’s absolutely valid and it’s something our customers place an awful lot of value on. We’re absolutely committed to that standard and it’s a vital element of an effective supply chain for recycled packaging. The majority of standards are now being created by European trade bodies, of which we’re still members. I don’t think anybody will be getting kicked out or devalued as a result of Brexit because you need that volume of people to support the infrastructure.

YOU ARE ALSO SIGNED UP TO OPERATION CLEAN SWEEP. WHAT MEASURES DOES CHASE PLASTICS HAVE IN PLACE TO ENSURE NO PELLETS ARE LOST? We’ve got strict housekeeping procedures and standards. The industry is very conscious of the need to present itself well and it’s therefore in everything we do as a business. We are constantly communicating with our workforce about pellet loss and high environmental standards. We recognise that the plastics industry, and the plastic packaging industry in particular, is facing great challenges – from the packaging tax and from the media – and we’re great supporters of these industries in the UK and Europe. WHAT IS THE LIKELIHOOD THAT PEOPLE WILL BE ABLE TO VISIT CHASE PLASTICS AT A TRADE FAIR THIS YEAR? We remain within the rules and within the current guidance, and we have very strict procedures in place to protect our workforce, but the day I’m able to go out and meet customers, and operate in the real world, can’t come soon enough. This is a business and an industry built on people and relationships. It’s where we get our enjoyment from. However, we’re still just as accessible, but it’s a bit more fun when you get out there. We’re looking forward to it, but I don’t know when that day will be as yet. The people you’re dealing with is what makes it enjoyable. The new alliances are how businesses grow, and I’m looking forward to getting back out there at the first opportunity.

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INJECTION MOULDING NEWS POLYKEMI AND RONDO PLAST KRAUSSMAFFEI GROUP HAS SOLD ITS SUBSIDIARY KRAUSSMAFFEI AUSTRIA TO THE AUSTRIAN FAMILYPRESENT COMPLUS POLYKEMI AND RONDO PLAST HAVE INTRODUCED THE COMPLUS CONCEPT, GIVING MULTIPLE CHOICES OF SEVERAL MATERIALS BASED ON VIRGIN AND HIGHQUALITY RECYCLED RAW MATERIALS. THE COMPOUNDS ALL HAVE SIMILAR PROPERTIES BUT ARE ADAPTED FOR INJECTION MOULDED PARTS WITHIN AN ASSEMBLED PRODUCT.

roject Manager Johan Svenmo said: “One example within the automotive industry are door panels, being complex assemblies of numerous parts. Each part has an individual demand profile to be fulfilled. Here you can use the materials from

the COMPLUS Concept for the different parts.” Customers have the unique opportunity to choose different materials from the COMPLUS Concept without having to modify, change or produce a new mould. The first example of the COMPLUS Concept from the POLYfill (PP) and REZYcom (PP) families will be launched soon. The same concept will also become available for other products, including POLYblend (PC/ABS) and SCANAMID (PA).

NEW HASCO PROTECTIVE CAPS FOR CONNECTING NIPPLES WHEN COOLING SYSTEMS ARE USED IN INJECTION MOULDS, IT IS IMPORTANT TO PREVENT LEAKED COOLING MEDIA FROM CONTAMINATING THE WORK ENVIRONMENT. CONNECTING NIPPLES SHOULD ALSO BE PROTECTED AGAINST SOILING AND DAMAGE.

OWNED COMPANY LUGER GMBH, WHERE IT WILL CONTINUE TO OPERATE UNDER THE NAME KMAT MASCHINEN- UND SERVICE GMBH.

KRAUSSMAFFEI GROUP SELLS KRAUSSMAFFEI AUSTRIA TO LUGER GMBH

eadquartered in Purkersdorf, near Vienna, Luger and KraussMaffei had already extended their sales co-operation in 2020. KraussMaffei CEO Dr Michael Ruf said: “The sale of KraussMaffei Austria is part of our strategic realignment. It will bring us even closer to our customers. With the sales and service competence of Luger and its employees, we will be able to act even faster and more efficiently in Austria and Hungary in the

he new protective caps Z8087/… can be fitted without tools and are designed to match HASCO’s proven temperature control programme, offering compatibility with all size 9 and 13 connecting nipples. The caps provide reliable protection for the functional and sealing surfaces of connecting nipples, prevent any uncontrolled outflow of cooling media and reduce the risk of leakage. Using the

CREDIT Karolis Kavolelis | Shutterstock.com

future.” Luger intends to expand its market

presence in the coming years, particularly in Hungary.

protective caps also effectively stops any dirt from entering the cooling channels from the outside.

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INJECTION MOULDING ENGEL WILL RETURN TO CHINAPLAS TO SHOWCASE SOME OF ITS PANDEMIC-INSPIRED INDUSTRY 4.0 TECHNOLOGY.

Chinaplas 2021: ENGEL at Industry 4.0 –

Factory of the Future

ow can consistently high product quality be maintained in the face of fluctuations in raw material? How can high machine availability and productivity be ensured even in the face of travel restrictions? ENGEL will be providing answers to these burning questions during Chinaplas 2021, which is scheduled to run from 13-16 April in Shenzhen, China. The Austria-based injection moulding machine manufacturer and system solution provider will once again be participating with its own exhibit at Industry 4.0 – Factory of the Future, in Hall 11, Shenzhen World Exhibition and Conference Center (SWECC). Gero Willmeroth, President, East Asia and Oceania, said: “COVID-19 has accelerated digitalisation in the plastics industry. Our customers are increasingly investing in digital solutions, smart service and intelligent assistance, which have become even more prominent in the last twelve months.” These trends will be reflected in ENGEL’s Chinaplas exhibit. The allelectric and tie-bar-less ENGEL e-motion 80 TL injection moulding machine is equipped with many digital products from ENGEL’s inject 4.0 program.

SELF-OPTIMISING INJECTION MOULDING MACHINE While smart assistance systems from ENGEL’s iQ series help plastics processors to leverage the full potential of the injection moulding machine, even if qualified personnel are not present at all times, digital service products are all about ensuring high productivity in order to remain able to deliver even in the event of a crisis. The human-machine interface plays an important role in the factory of the future. As production processes become increasingly complex due to process integration and automation, management and control of them must become all the more simple and intuitive. This is where smart assistance systems boost process capability and quality without requiring operators to acquire additional special skills. During the four days of the show, fluctuating process conditions can be simulated on the CC300 control unit of the e-motion 80 TL machine in order to track automatic readjustment by the smart assistance systems on the machine display. For example, iQ weight control keeps the injected melt volume consistent throughout the entire injection moulding process, while iQ clamp control determines the optimum clamping force based on mould breathing. KEEPING TRACK OF NUMEROUS PROCESS PARAMETERS ENGEL is continually developing its smart assistance system portfolio. The latest products to be presented in Shenzhen include iQ process observer and iQ melt control. Where smart assistance systems have so far been able to optimise individual

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This is where smart assistance systems boost process capability and quality without requiring operators to acquire additional special skills

steps in the injection moulding process, the new iQ process observer continually analyses several hundred process parameters across all four phases of the injection moulding process – plasticising, injection, cooling and part removal – in order to automatically detect drifts. In the form of plain text messages, the system points out unfavourable process settings and conditions as well as the possible causes of them. Willmeroth added: “This helps the user to optimise stability over the entire process and to correct errors quickly.” The goal of iQ melt control is to conserve both the material to be processed and the mechanical components of the plasticising unit. In practice, plasticising often occurs faster than the cycle requires, which can have an impact on product quality, but also on the service life of the screw. iQ melt control therefore determines the optimum plasticising time. Instead of plasticising at the maximum possible speed, the system makes full use of the part’s in-mould cooling time for plasticising, ensuring very good melt homogeneity. UNIFYING SIMULATION AND THE REAL WORLD Another new feature is ‘sim link’, a joint development by ENGEL and Autodesk, the provider of the Moldflow simulation software. Willermoth explained: “To date, many findings from the simulation of injection moulding processes on the machine remain unused, and this is precisely what is now changing.” With the support of the software, both the parameters optimised by Moldflow can now be converted into a process settings data set and used directly on the injection moulding machine, and conversely, process parameters and measurement results from the injection moulding machine can also be imported into Autodesk’s simulation program. “We are opening the door to a new approach to optimising ongoing production processes,” Willmeroth continued. “Simulation speeds up the task of

creating process settings, mould setup processes and process optimisation, in turn significantly boosting productivity. This is increasingly making simulation an affordable competitive edge even for smaller injection moulding operations.” ENSURING PRODUCTIVITY, EVEN IN TIMES OF CRISIS To boost the availability of injection moulding machines and manufacturing cells, smart service relies on online support, and condition-based, preventive maintenance. Covid-19 has shifted e-connect.24 in particular even further into the focus of plastics processors. The online support and remote maintenance tool empowers ENGEL service staff to connect to the injection moulding machine from a remote location so that they can respond without delay in all support cases. The screen pages of the machine control unit are transmitted via a secure internet connection.

Since the data are accessed in real time, the current state of the machine is displayed. As a result, the machine operators on the ground and external support staff can see the same production data, and they can offer advice and guidance to one another. The manufacturing cell can be controlled remotely, if necessary. Another benefit is that the user is notified by e-mail in the event of a malfunction. Due to this range of options, e-connect.24 ensures very high levels of machine availability, even if travel is not possible or production is temporarily unmanned. ENGEL does not use external manpower in service, but relies exclusively on its own highly qualified service technicians. “We have extensive resources here in China and support our customers in the local language,” Willmeroth concluded.

INJECTION MOULDING MICHAEL WHITE, BUSINESS DEVELOPMENT MANAGER FOR BEVERAGE CLOSURES AT HUSKY INJECTION MOLDING SYSTEMS, DISCUSSED HIS ‘ESSENTIAL GUIDE TO TETHERED CLOSURES’ DURING AN EPPM EXCLUSIVE WEBINAR.

SURE

FOR THE FUTURE

esponsible for introducing new products and technologies to the market in the closure space, White and his team go through the product lifecycle on an injection moulding machine and, on the application side, on closures technology. As a new neck finish comes onto the market, the role of the product manager is to identify the market needs through understanding how they can be translated into products. The department operates in the preform PET market with manufacturing locations in Canada, the US, Europe and China. “With that global footprint,” White said, “we have a global distribution of local sales and service support networks. So, chances are wherever you’re located you’re not that far from a Husky service or salesperson. Every

This is something that is going to energise other geographies outside of the European Union

second somewhere on the planet our equipment is producing more than 15,000 preforms and, similarly, more than 1,000 beverage closures.” You’ll notice the number of closures is far lower than that of the PET preforms, even though the cycle time is about three times faster. The reason for this, white added, is because Husky entered the closure space about 10 years ago as a full system solution provider. Up until that point the company was supplying injection moulding machines and hot runners. In 2012, Husky entered the closures space as a tooling supplier in order to apply its knowledge in other aspects of the business, and incorporate that into a total system manufacturing approach. By July 2024, any single use plastic beverage container that has a volume of three litres or less must have a closure that is tethered to the bottle – a requirement for any brand looking to sell into the European Union. “This is something that is going to energise other geographies outside of the European Union. We’re going to start to see this type of legislation in the United States, in Canada, Australia – this is something that’s going to spread globally.” At K 2019, every discussion White was involved in focussed on tethers and tethering and how that can be achieved. The legislation being proposed is one of the areas wherein governmental bodies can effectively reduce marine plastic pollution, for example.

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Another key design feature concerns how the tamperevident band is formed. Basically, there are two approaches to this within the injection moulding space. Husky’s tooling solutions satisfied both. “You have your shell,” White continued, “and your bridges. What the bridges do is they essentially are a safety feature. They connect the shell to the tamper-evident band, and the tamperevident band is the feature that remains on the neck finish itself. The bridge is designed to fracture as the closure is unscrewed from the bottle. Any whitening or fracturing of the bridge indicates that the product has been tampered with.” To summarise, the premium tethered design provides 180-degree locking. This represents the importance of the consumer experience, as well as how brand-owners are able to differentiate their brand. “We have different intuitive features within our closure portfolio,” White concluded, “including weight neutrality to the non-tethered variant. All of our solutions comply with the European SUP Directive with the same performance levels as all non-tethered variants. Again, the moulded bridge solution offers the most flexibility with a lower capital investment. We really feel that this is not a European-specific phenomenon. We feel that this is really the first domino to fall and that you’re going to start to see tethering legislation being adopted in other jurisdictions – and that’s reinforced by some of the brands that have approached us.” If you want to learn more, the webinar is available in full on the EPPM website.

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his new film is an addition to Toppan’s ‘SMART LIFE-VALUE Packaging’ line-up, which is part of the recently launched ‘TOPPAN S-VALUE Packaging’ range. The fire extinguishing film has been available since February and targeted at manufacturers of batteries and electrical appliances. With applications for rechargeable batteries expanding to such fields as mobile devices and mobility, lithium-ion batteries are becoming more widely used and offering higher power levels. However, this increases the risk of fire-related accidents, not only during use but also after disposal. Toppan has combined its advanced coating technologies and transparent vapordeposited GL BARRIER film with a highly effective fire extinguishing agent from Yamato Protec Corporation to produce an adhesive film with outstanding long-term durability and workability. Toppan’s fire extinguishing film is highly effective in extinguishing fires at an early stage or preventing their spread in the event of equipment problems or short circuits. It is lightweight and compact, meaning it can be used with ease in enclosed spaces and locations in which there is a fire risk.

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The film works by filling an enclosed space with fire extinguishing aerosol particles in response to the heat generated by a fire

Potential applications include attachment to the inside of lithium-ion battery cases, switchboards and power distribution equipment, outlet covers, or waste containers at public facilities. The film uses no substances that pose a risk to humans or the environment and produces no harmful gases when it is activated. The film works by filling an enclosed space with fire extinguishing aerosol particles in response to the heat generated by a fire. The aerosol particles extinguish the fire through negative catalysis. This makes it an effective solution for putting out fires promptly and containing their spread to prevent further damage.

TOPPAN PRINTING HAS DEVELOPED A FIRE EXTINGUISHING FILM THAT RESPONDS TO HEAT BY EMITTING AEROSOL PARTICLES.

Yoshimitsu Anamizu, Managing Executive Officer of Toppan’s Living and Industry Division, said: “This film enables greater fire safety without any negative impact on people or the environment. We intend to develop more products based on this technology to contribute to accident and disaster prevention and a safer, more sustainable society for everyone.” Toppan Printing showcased its fire extinguishing film at TOKYO PACK 2021, which was held at the Tokyo Big Sight exhibition centre in February.

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