APR/MAY 2019 | VOLUME 21/ISSUE 2
YOUR HOT RUNNER MOULD IS
JUST A FEW
AUTOMATION REVOLUTION
ABB’S FAUSTO BELOTTI REVEALS HOW AUTOMATION IN THE PLASTICS INDUSTRY WILL CHANGE THE WAY WE PRODUCE AND USE PLASTIC.
PIPING UP
MICHAЁL VAN DER JAGT OF PARX PLASTICS HAS HELPED DEVELOP AWARD-WINNING SUSTAINABLE PIPE TECHNOLOGY.
AWAY
FAMILY FOCUS
OLIVIA ROUTLEDGE OF YORKSHIRE PACKAGING SYSTEMS LTD ON AWARDS NOMINATIONS, SUSTAINABLE SHRINK FILMS, AND BEING PART OF A FAMILY.
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EDITORIAL
editor rob coker robert.coker@rapidnews.com assistant editor grace nolan grace.nolan@rapidnews.com
PRODUCTION
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BPA Worldwide Membership ISSN No - 2052-4811
IN THIS ISSUE APR/MAY 2019
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INTERNATIONAL RESCUE
Editor Rob Coker introduces the second 21st Anniversary edition and summarises the mood of the European plastics industry.
12
PACKAGING
Your hot runner mould is just a few clicks away
Yorkshire Packaging Systems LTD’s Marketing Manager Olivia Routledge discusses awards nominations, and what they mean for her, for the business, and for the environmental concerns in the community
Industry 4.0 enables us to interface with machinery in unprecedented ways, and Austria-based manufacturer of high-quality products for die, mould, and jigs and fixtures construction, Meusburger Georg GmbH, asks what this means for hot runner moulds and its customer base.
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At this year’s Petcore Europe Conference in Brussels, Aliplast’s Paolo Glerean addressed the role that thermoforming plays in advancing the paradigm of increased quality and collection rates for recycling.
Michaël van der Jagt of Parx Plastics recognised the need for piping with antibacterial and antimicrobial properties, which led to him sharing the World Technology Award stage with Elon Musk and Jane Goodall in 2014.
THERMOFORMING
25
Dr Tahira Ahmed, director and co-founder of Curve Works, explains how her thermoforming process promises fast, flexible solutions without waste from tooling.
PIPE & PROFILE
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AUTOMATION & ROBOTICS
Fausto Belotti, the Global Segment Manager for Rubber and Plastic at ABB, discusses what automation means for plastics, and how plastics is leading the way for other industries.
Comau’s Academy Director Ezio Fregnan on the e.DO Experience initiatives, and what they mean for both humans and robotics.
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CLASSIFIEDS
50
EUREKA
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LETTER FROM THE EDITOR
International rescue Dear readers,
EDITORIAL CREDIT: / SHUTTERSTOCK.COM
Welcome to the second 21st anniversary edition of EPPM. From the annual Petcore Europe conference in Brussels in February, to IdentiPlast 2019 in London, and more recently at the Moulding Expo press event in Ljubljana, the panEuropean mantra remains one of a united, concerted effort by the plastics manufacturing industry versus plastic pollution and misuse. Amongst the many things I’ve learned from travelling in this still new role, and from speaking with experts and stakeholders – already numbering in the hundreds – is that no one company, country, or continent can expect to solve the problems of the world alone. But the human spirit clings to optimism in times of adversity, and optimism seems to be the protagonist in the zeitgeist of the international plastics manufacturing sector, with a supporting cast of education, extended producer responsibility, and efficiency. With this in mind, the April/May edition leads with Austria-based die and mould manufacturer Meusburger introducing a new configurator for hot runner moulds, which is now able to customise a complete mould base with speed and precision.
Speed and precision are among the objectives of automation and robotics specialists, with much innovation in this sector coming from Italy. This edition therefore has interviews with Fausto Belotti of ABB Italy and Ezio Fregnan of Comau, as well as an introduction to Moretto’s take on the developing 4.0 revolution, amongst others. Award-winning pipe and thermoforming technology and techniques from the Netherlands features alongside UK-based family packaging business YPS, with Olivia Routledge discussing the use of shrink film technology from France. US contributions show how Brown Machine Group are adding speed and precision to the thermoforming process through automation and product handling, and DavisStandard’s Joe Wnuk and Ernst Geider share the past, present and future challenges of pipe manufacturing. With DavisStandard featuring in issue 1:1 way back in September 1999, Wnuk helps us celebrate our anniversary. Likewise, you are invited to share your own stories and memories of EPPM over the years and join us in celebrating. I look forward to hearing these, as well as hearing about your collaborations and strategies, whether sectoral or international, and finding out about your role in the worldwide challenges that face us.
Optimism seems to be the protagonist in the zeitgeist of the international plastics manufacturing sector
Rob Coker, Editor
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EPPM EDITOR ROB COKER TURNED 21 A LONG TIME AGO. HERE HE LOOKS BACK AT THE FIRST EDITION OF EPPM TO MARK THE PUBLICATION’S 21ST ANNIVERSARY.
EPPM 21ST ANNIVERSAY
At
age 21 I had long greasy hair past my shoulder blades and played drums in a band that enjoyed moderate success (if you can define moderate success as supporting a Stone Roses tribute band in Macclesfield once). Unfortunately, there are no surviving photographs of me during this period as it pre-dates the digital camera and social media, otherwise I would definitely have included one here to fill up space in this short article. No, really. EPPM at 21, however, is a much more worldlywise entity than I ever was at that age. And, like me, it has undergone some major changes of image over the years. In its inaugural edition from September 1999, the publication appeared as much more of a pragmatic, practical directory of businesses showcasing materials and technology than a trade magazine featuring the human ideas, stories and challenges behind the industry. What caught my eye in this edition was a piece consisting of fewer than 150 words
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titled ‘New Acrylic Resin’ which discussed – in brevity – the advances made in the materials used for DVDs. For those with long memories, Oroglas VOD100 was the name of this ‘specially formulated’ new acrylic resin from Francebased Elf Altochem. ‘It features a lower viscosity which improves replication within shorter cycle times … and superior optical qualities – in particular a low birefringence and good light transmission. For DVDs, the lower the birefringence, the more accurate the laser reading and hence the better the sound and visual reproduction.’ The first DVD I ever watched was The Messenger: The Story of Joan of Arc starring Milla Jovovich, John Malkovich and Dustin Hoffman, but this could not have been until at least a year after EPPM had made its debut. The number of DVDs I have watched since is countless, and I can say with authority that the word ‘birefringence’ never entered my personal lexicon until now. Therein EPPM was able to establish its objective on its
eppm 1999
birthday: acquiring a priori information on the latest technologies, methods and materials, whether industrial or domestic, before they become household products. This remains the modus operandi today and the publication will continue to be the constant source of reliable information, straight from one
manufacturer to another, with the aim of driving business through shared ideas and technological developments. 21 years on and although DVDs are slowly being made obsolete by digitalisation and streaming, and although plastics are experiencing a rough ride in other media formats, EPPM is confident that there will still be a major part for plastics to play 21 years from now. There will be changes, like those seen in EPPM’s smaller format, new design and layout, and fresh logo. Technologies will in turn come, change our lives, and go: we all change to suit our environments, whether that change
is in our attitudes or in the length of our hair, things change all the time. If we can learn and grow as we roll with those changes, we can look forward to stronger and brighter futures. Cheers, Ed.
EPPM WILL CONTINUE TO BE THE CONSTANT SOURCE OF RELIABLE INFORMATION, STRAIGHT FROM ONE MANUFACTURER TO ANOTHER, WITH THE AIM OF DRIVING BUSINESS THROUGH SHARED IDEAS AND TECHNOLOGICAL DEVELOPMENTS
QUALITY PROTECTS.
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COVER STORY
YOUR HOT RUNNER MOULD IS
JUST A FEW
AWAY
EFFICIENCY HAS BEEN ONE OF THE DRIVING FORCES OF INDUSTRY SINCE SCOTSMAN ADAM SMITH PUT ECONOMIC THEORIES INTO PRACTICE IN A PIN PRODUCTION FACTORY IN THE 18TH CENTURY THROUGH THE DIVISION OF LABOUR. 250 YEARS LATER, IT REMAINS THE WIND BENEATH THE WINGS OF THE FOURTH INDUSTRIAL REVOLUTION, BETTER KNOWN AS INDUSTRY 4.0, WHEREIN SUCCESS IS NOW NOT ONLY MEASURED IN PRODUCTIVITY AND OUTPUT, BUT IN PRECISION, ECONOMICS, AND ENVIRONMENTAL IMPACT.
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n order to meet the demands of the market, manufacturers require more than just fast, efficient output. The acquisition of high-speed, effective data enables optimum performance, flexibility and machine operation, as well as minimised downtime and maintenance labour. Now that humans are able to interface with manufacturing machinery in unprecedented ways, Austria-based leading international manufacturer of high-quality products for die, mould, and jigs and fixtures construction, Meusburger Georg GmbH, asks what this means for the configuration of hot runner moulds and its customer base. With the brand new Meusburger configurator for hot runner moulds, a complete mould base including hot runner manifold can be customised with just a few clicks. The configurator offers optimum flexibility, immediate creation of the 3D data, and immediate price display. This world-first on the market solution is the result of the co-operation between Meusburger and PSG. The new configurator for exclusive hot runner moulds from Meusburger offers the possibility of selecting the hot runner manifold as well as the flexible positioning of the nozzles and the entire manifold in the manifold plate. The thickness of the FH 63 manifold plate and the nozzle length are automatically calculated on the basis of the various parameters entered Quick and easy configuration of hot runner moulds with the new FH configurator from Meusburger © Meusburger
in the configurator. The dynamic display of the mould size shows the manifold plate relative to the manifold. In the event of any uncertainty, a larger or smaller plate can be selected as required. After the configuration of the temperature regulation system, the operator can finally select the material of choice of the manifold plate and the rest of the plates required to complete the mould base. 3D DATA AND PRICE DISPLAY During configuration, a live display of the manifold is visible to the operator. This way individual adjustments can be tracked and edited directly on-screen. At the end of the process, the 3D data is created immediately and can then be made available to the customer for download right away. Furthermore, both the customer and manufacturer is able to immediately calculate prices, bringing other individual advantages to both, as well as latent advantages to the entire value chain. All this of course leaves the designer free to concentrate on other matters during the mould design and thus saving valuable time. FAST DELIVERY OF THE COMPLETE PACKAGE In addition to the hot runner mould, the required components and the right accessories can also be ordered directly from Meusburger. This way the customer receives everything from a single source and in only one order. The individually selected components of the hot runner mould are delivered promptly with the usual high quality, and the customer receives a fully assembled hot runner manifold. Although the mould base for the hot runner mould is not pre-assembled, the customer is still spared the task of dismantling as the components are immediately ready for subsequent machining. STANDARDISED HOT RUNNERS “Following the takeover of PSG in 2016, this is a further step towards standardisation in the hot runner sector. There is very good co-operation within the Meusburger Group, which has resulted in an expansion of project-related business,” said Managing Director Guntram Meusburger of the launch of the new product group.
MEUSBURGER – SETTING STANDARDS As a part of the Meusburger Group, the Meusburger company is the market leader in the field of high-precision standard parts. 21,000 customers all over the world make use of the advantages of standardisation and benefit from the company’s more than 50 years of experience in working with steel. Offering an extensive range of standard parts, combined with selected products in the field of workshop equipment, Meusburger is the reliable global partner for making moulds, dies, jigs and fixtures. PSG develops, produces, and markets hot runner and control systems for the manufacturing of plastic products as a part of the Meusburger Group. Over 50 years of experience in the plastics industry guarantees customers a broad and innovative range of products. The cross-industry knowhow makes PSG a reliable project partner in the automotive, electronics, medical, transport, packaging and consumer goods industries. A high degree of standardisation guarantees very short lead times and highest quality. In reinforcing the strategic importance of collaboration, Meusburger and PSG have opened up new pathways for innovation, as well as for the smart, precise configuration of hot runner moulds that are ready to impact businesses and markets in fast, efficient and thoroughly smart ways that complement the increasing environmental and economic demands of the industry, and of Industry 4.0.
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PACKAGING NEWS RKW WILL BE HIGHLIGHTING THE FIVE KEY BENEFITS THAT THE RKW PROVENT ECORE 5 SELF-VENTING PLASTIC SACK OFFERS OVER PAPER SACKS IN TERMS OF SUSTAINABILITY AT THIS YEAR’S POWTECH EVENT HOSTED BY NUREMBERG, GERMANY.
RKW’S PLASTIC SOLUTION ‘MORE SUSTAINABLE THAN PAPER’
T
he ProVent ECORE 5 is fully recyclable, meaning less packaging, reliable product protection, maximum moisture barrier, and a clean filling process. Johannes Heintges, General Manager at RKW Echte, said: “The RKW ProVent ECORE 5 packaging solution is made from pure, 100% recyclable polyethylene. While competing paper sack manufacturers use composites that at best can be incinerated, we supply a fully recyclable solution that has been compliant with the 2020 EU standards for more than ten years.” When it comes to investment decisions, the sustainability of a technology plays a crucial role. The question of material continues to dominate the packaging debate. While paper is regarded as a ‘natural’ material in
the eyes of the public, plastics increasingly suffer from the image that they are unsustainable. But in reality, plastic packaging is often a more effective and sustainable alternative to conventional paper packaging – especially in terms of recycling, material savings, product protection, moisture barriers, and the entire process chain. 100% RECYCLABLE The RKW ProVent ECORE 5 plastic sack solution is an outstanding example of sustainable industrial packaging. RKW highlights key advantages that make the polymer-based alternative stand out from paper bags in terms of sustainability. One such advantage is in the low film thickness. Research has shown that RKW ProVent ECORE 5 reduces packaging material by up to 40% compared to paper bags. This minimises the consumption of natural resources and reduces weight. Compared to paper sacks, the plastic solution reduces
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energy consumption and lowers storage, transport and recycling costs. The RKW ProVent ECORE 5 is rarely damaged during storage and transport. Its protective properties are another key advantage of the plastic sack over paper solutions. The dustproof plastic packaging is the first to feature an integrated venting system. The innovation has been used for many years to reliably protect building materials and products supplied by the food and chemical industries. With 10% less product loss compared to paper sacks, RKW ProVent ECORE 5 reduces CO2 by 1.4kg per sack of cement.
PET in the Circular Economy: Member states to meet EU PET recycling capacity PETCORE EUROPE CONTINUES COLLABORATION WITH EUROPEAN PARLIAMENT MEMBERS TO GAIN GROUND ON RECYCLING TARGETS
A
mbitious recycling targets have been set by the EU Plastics Strategy to ensure collection and sorting meets capacities. Petcore Europe and the Parliament Magazine therefore organised two roundtable discussions in the European Parliament. On 19 February, the PET industry shared best practices with EU policymakers, NGOs and stakeholders. The second event on 20 March, hosted by MEP Mark Demesmaeker, focused on collection and sorting progress; Patrick Laevers from Fost Plus presented Belgium's curbside collection system; Wolfgang Ringel from Tomra focused on deposit schemes; and Gian De Belder from P&G presented the Pioneer project HolyGrail. Executive Director of Petcore Europe Christian Crépet said: "European PET recyclers lack material to reprocess, to an extent that there is an unused capacity of 296,400 tonnes. Insufficient quantity and quality of collection can be observed in several EU countries. Increased collection and sorting of PET bottles
and trays, be it via curbside collection or deposit schemes, would ensure sustainability and circularity of PET packaging.“ PET PROJECT Demesmaeker pointed out that the Single Use Plastics Directive will bring separate collection targets of 90 per cent for PET beverage bottles by 2029, which is an important and necessary target. Grzegorz Raziejewski, Member of Cabinet of Commissioner Jyrki Katainen and Malgorzata Golebiewska from DG ENVI shared the European Commission's plan to drive collection and sorting. Industry representatives from the entire PET value chain and policymakers will continue to collaborate to reach the ambitious collection and recycling targets. Petcore Europe play's an essential role through working groups and the expertise of its 70 members.
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PACKAGING
YORKSHIRE PACKAGING SYSTEMS LTD (YPS) IS A FAMILY-OWNED SME BASED IN THE YORKSHIRE TOWN OF DEWSBURY, UK, SUPPLYING PACKAGING SOLUTIONS FOR BIG-NAME BRANDS AS WELL AS COTTAGE INDUSTRIES, AND FOSTERING BIG AMBITIONS FOR THE REUSABILITY OF SHRINK FILM PACKAGING.
FA
After hearing about YPS’ nominations for Yorkshire’s regional Family Business of the Year (FBOTY) Awards and the Plastics Recycling Europe Awards (PREA) 2019, Rob Coker called Marketing Manager Olivia Routledge to discuss what they mean for her, for the business, and for the environmental concerns in the community.
LY FOCUS
WHAT DOES IT MEAN TO HAVE BEEN NOMINATED FOR THE FBOTY AND PREA 2019? It is really, really special. Particularly the FBOTY award because it sometimes feels that family businesses are underrepresented, yet they are a strong part of the economy. They should be encouraged and allowed to flourish. It is not the first time we have been recognised; last year we won three family business awards in different categories, but this year’s nomination is especially exciting because the Family Business United Awards are specifically for the Yorkshire region – obviously we’re passionate about Yorkshire – it’s in the name, so that makes it a little bit more special.
Family is important to YPS. We’re a second-generation family company so the
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directors are all family members, and the wider team feels like an extended family; we’ve got colleagues who have been with us for more than 30 years, and they stick around because we feel like a team and everybody feels valued. As a family business, and because it’s your name on the line, it makes you work harder for each and every customer, so it’s really special to have the family business element recognised – it’s recognition for protecting a legacy as well as a business. The plastic recycling awards nomination is absolutely brilliant, we were thrilled because we haven’t had any awards for our products yet, only for our services. It draws attention to the green credentials of what we offer with our shrink film, which is crucial at a time when plastics are vilified. It shows they can be part of an environmentally friendly packaging operation, it shows they have a place.
The B-NAT film we use is bio-based and 100% recyclable, so that’s an important message to get out there, so we’re keeping our fingers crossed for that one. It’s a good accolade to have; it’s an international stage, and we’re on it. Having it recognised internationally is just huge. WHAT IS IT THAT YPS HAS BEEN DOING THAT LED TO THE PREA AND FBOTY NOMINATIONS? As a B2B company, we’re known all over the UK, but locally we have a presence in our community, which is why I think the FBOTY nomination has come about. We have sponsored sports teams, participated in local charity events and donated to local foodbanks, etc. I think these actions reflect our family-led principles and hopefully this will be recognised at the awards. With the PREA nomination, we’ve been working hard to develop the technology and the product, but also raising awareness of it, which is getting us noticed. For example, we attend big packaging exhibitions several times a year, displaying machinery exhibits with these recyclable films. We’ve really tried to spread the message about what can be done with bio-based film. We launched the B-NAT film in 2017 and have been promoting it as much as possible, and it’s not just these awards that it has been nominated for; it was shortlisted for Environmental Initiative of the Year in 2018 and has gained more and more attention since. The other great thing about B-NAT is that it sells itself – despite its bio-base, there’s no sacrifice to any of its outstanding optics and shrinkage properties when compared with older films. I think it’s important to point out that our entire shrink film range is 100% recyclable to LDPE 04 though. Many people don’t realise how environmentally friendly film can be. You can reuse shrink film as waste plastic sacks or turn it back into shrink film: people are quick to write off traditional shrink films but they can definitely be part of the circular economy.
WHAT ELSE ARE YOU PLANNING TO CONTINUE RECEIVING SUCH RECOGNITION? We’ve grown consistently and exponentially over the past five years, but we are still an SME with only 20 employees and there’s plenty of room for more growth, and more awards! For example, we didn’t have a dedicated full-time marketing department before January 2018 so as we’ve grown we’ve realised how important it is to have one. It comes naturally to me, I’m quite creative so I decided to take on the role, bringing an increase in our exposure as a result of dedicating time to marketing. Our strategy for growth in the coming year includes expanding our product and machinery ranges to stretch wrap and stretch wrappers, which we hope will make us a one-stop-shop for our customers. We’re looking into e-commerce packaging, which is becoming huge and therefore something we are going to put an offer in for in the sector with a print and apply labelling solution that works in tandem with shrink. We have lots of plans for growth and improvement that I hope judges will recognise when it comes to awards. Of course, as well as all this we will keep offering the same great service that we are already recognised for. HOW DO YOU ENSURE YOUR CLIENTS KEEP RETURNING? We supply huge household names like Kellogg’s and a range of blue-chip businesses like BT, as well as Jacobs Biscuits and Procter & Gamble – they’re all longstanding customers of ours – down to cottage industries, farms and prisons – randomly. We’re a highly flexible business and it doesn’t matter how big or small you are, we like to keep people coming back. Our motto is ‘if you don’t look after the customer, somebody else will’, so customer service is entrenched in what we do. Every year more than 40% of our machinery orders come from existing customers. One of our USPs is the aftersales support and focus on our customers. We understand how huge each investment is and will therefore do everything we can to support them. We see a sale as
the beginning of a relationship, not just a transaction. Every shrink-wrapping machine comes with service contracts included for preventative maintenance, we’ll often add spares packages, and we have a team of engineers who will do what they can to get customers going again as fast as possible whenever needed. It’s the focus on aftersales backup and support that keeps our customers coming back. HOW DO YOU SEE THE PLASTICS INDUSTRY EVOLVING AS WE ENTER A NEW DECADE? Plastics manufacturers will need to continue striving for products with greener credentials. Bolloré Technologies’ – for whom we are the exclusive UK distributor – B-NAT film has a current bio-base of 46%, but we are pushing and pushing them to continue trying to improve that figure through investments in its technologies and research. Because both the public and governments are calling for it, we need to be doing what we can to improve those green credentials in the products all the time. Importantly,
and I know this is a challenge, we need to do what we can to keep prices down for the end-users. Hopefully this will encourage a wider uptake, which will help to achieve environmental goals and generate a viable option for the client base. Ultimately, however, it is the responsibility of everyone in the entire value chain to do their part.
As a family business, and because it’s your name on the line, it makes you work harder for each and every customer – it’s recognition for protecting a legacy as well as a business. WWW.EPPM.COM 013
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PACKAGING
Acceptable receptacles NANOPACK IS A HORIZON 2020-FUNDED PROJECT WITH THE OBJECTIVE OF DEVELOPING ANTIMICROBIAL PACKAGING SOLUTIONS FOR PERISHABLE FOODS BASED ON NATURAL NANOMATERIALS, PREVENTING FOOD-BORNE ILLNESS OUTBREAKS, AND REDUCING FOOD WASTE.
T
he three-year project will address scientific, technological, economic, safety and regulatory challenges to ensure that consumers can benefit from innovative, nanomaterial-based packaging.
general remarks including reference to size. What they showed more concern with was the ‘essential oils’ aspect and the ‘active’ nature of this technology – elements with which they were more familiar.
In addition to developmental challenges, Polymeros Chrysochou, Associate Professor in Marketing and Consumer Behaviour, and Alexandra Festila, Assistant Professor in Marketing at Aarhus University, Denmark, share the product feasibility challenges including retailer and consumer acceptance.
To emphasise, the use of natural essential oils created a spill-over of ‘naturalness’ in that the product will adopt a natural character as it becomes infused with these oils. On the downside, end-users feared the food products would become ‘contaminated’ or ‘altered’ once the active element was released in the packaging.
Active food packaging technologies have numerous benefits for industry players and retailers alike. For example, improved food safety, extended shelf-life, improved freshness, and reduced food waste are all important by definition, but don’t justify the adoption of every promising new food packaging technology. Other factors, e.g. costs, come into play but the determining parameter is, arguably, how end-users perceive the technology and its benefits.
SUSPICIOUS MINDS Benefits are not always at the fore in the minds of the consumer. For example, the combination of extending the shelf-life of
In the framework of the NanoPack Project we explored this variable by engaging in 10 consumer focus groups with lay consumers and 10 in-depth interviews with retail managers from China, Spain, Italy, Denmark and Ireland. What we found was that consumers interpret new food packaging technologies by engaging in retrospective and forwardlooking ‘sense-making’ when establishing their loci in a broader context, as well as in a closer inspection of the novelty of the technology relative to what is familiar. For example, in the case of the NanoPack technology, consumers were not concerned with the ‘nanotechnology’ aspect, on which they mostly made
a product and maintaining its freshness seem to be contradictory rather than complementary in consumers’ minds. Freshness is seen as a rather vague benefit and there are numerous different interpretations of it. In sum, rather than seeing a product with extended shelf-life, they see a longer passage of time since production. For retailers, a new food packaging technology first needs to meet some basic criteria (e.g. product safety) before it can be aligned with company strategies and internal processes (e.g. transportation and storage, versatility, recyclability). Many of those surveyed saw the degree of fitness with these internal factors as highly important, alongside technological assurances – such as legal requirements, proof of effectiveness, endorsements and accreditations from certification bodies – and product-related aspects such as quality and safety guarantees, as well as its sensory properties. If the packaging is not desirable, is it likely to be successful? Our findings reveal that the benefits are not the same for retailers and consumers. What we learned from this is that communication needs to be streamlined and that some benefits may backfire. Can we extend shelf-life without impacting freshness? Such considerations must be identified and communicated to reassure consumers that the product’s freshness remains the same. The project runs until January 2020. Before then we plan to understand if these benefits actually influence consumer preferences, and if they impact adoption of active, nanomaterial-based food packaging technologies.
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PACKAGING
Collections and connections IN FEBRUARY, EPPM TRAVELLED TO BRUSSELS FOR THE ANNUAL PETCORE EUROPE CONFERENCE, AN IMPORTANT DISCUSSION AND COLLABORATION PLATFORM FOR THE RAW MATERIALS PRODUCERS, CONVERTERS, BRAND OWNERS AND RECYCLERS OF POLYETHYLENE TEREPHTHALATE. PETCORE PROVIDES A SPACE FOR THE EXCHANGE OF IDEAS AND BEST PRACTICES AMONG THE DIFFERENT ACTORS, AND CREATES BRIDGES BETWEEN THEM.
C
asper van den Dungen, Vice President of Plastics Recyclers Europe, an active member of the various taskforces and working groups that collaborate on finding solutions for more sustainable production, efficient sorting and recycling of PET, shared his thoughts on what governments, the industry and consumers can do to reconcile plastics packaging with modern sentiment. FUTURE OF PET RECYCLING: INCREASED COLLECTION AND NEW MARKET DEVELOPMENTS Increased PET collection is a must in order to achieve new recycling targets, as was confirmed by Van den Dungen during the annual conference of the PET value chain. The driving force for changing the status quo in the collection for PET
specifically will be the new Directive on Single Use Plastics and the voluntary commitments of the brand owners, focused mostly on food grade rPET. The directive introduces specific targets for recycled beverage bottles, which are 77% for 2025 and 90% for 2029. In 2017 there were 1.9 million tonnes of PET recycled and 1.4 million tonnes of recyclates placed on the market. The biggest share of recycled material comes from beverage packaging, and if the new targets are to be achieved the collection of this packaging will need to increase. Accordingly, the collection rates will need to rise to 2.5 million tonnes in 2025 and around three million tonnes in 2029. The additional volumes are expected to come from nations such as France, Spain, Poland and the UK, who are Europe’s biggest PET consumers. This, nevertheless, would imply introducing deposit schemes for beverage bottles in those countries. Steady growth is observed in beverage packaging recycling that will continue to be the main input material for
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recyclers. However, new developments in trayto-tray recycling, for example, are underway with two production lines currently running in Europe. This packaging will therefore contribute to additional volumes. Furthermore, PET food containers are already incorporating around 450,000 tonnes of rPET, which equates to more than 50% of the total demand in this segment. The higher collection, however, must be paired with better sorting, which would increase the quality of waste by decreasing contamination levels and the amount of nontargeted materials. In parallel, investments in infrastructure and new business models will need to be developed. Design for recycling will then need to be effectively established and implemented, and the chain of custody improved. The current certification of recycling plants with the EuCertPlast scheme will need to be extended back to suppliers and customers, including converters, up to the final product to guarantee traceability and the best quality of recyclates.
PLASTICS RECYCLING SHOW EUROPE (PRSE), LAUNCHED IN 2016 AS THE FIRST SHOW IN EUROPE ENTIRELY DEVOTED TO PLASTICS RECYCLING, AND PLASTICS RECYCLING AWARDS EUROPE (PRAE) ARE BOTH GREAT VEHICLES THAT BRING PLASTICS RECYCLING INTO FOCUS.
RECYCLING IN FOCUS: MAKING PLASTICS CIRCULAR
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he launch of PRAE in 2018 was the next logical step in grasping the momentum to extend the publicity around recycling. The awards are also an ideal platform to celebrate the achievements and technological advancements in the industry. Around 100 entries were submitted to both 2018’s and 2019’s editions of the competition. Member of the PRAE jury panel Rune Thoralfsson, owner and director of Norfolier GreenTec, the largest film recycler in the Nordic region, said: “Plastics Recycling Awards Europe is the celebration of the achievements of our industry and the demonstration of the fast-growing innovation. The interest in this competition and the number of high-quality entries are a perfect illustration of the importance of plastics recycling.” The quality and the variety of applications are evidence proving that the market for recycled plastics is expanding. What is more, the interest in the
awards does not come only from the usual value chain actors such as recyclers, converters, machine producers, or brand owners, but also from designers, design studios, engineers and other organisations. The awards identify the best projects in seven categories which represent a variety of applications: • Recycling machinery innovation of the year, • Product technology innovation of the year, • Plastics recycling ambassador of the year, • Plastic packaging product of the year, • Household and leisure product of the year, • Building and construction product of the year, and • Automotive, electrical or electronic product of the year.
The quality and the variety of applications are evidence proving that the market for recycled plastics is expanding.
AMPACET SAFARI WHITE PET MASTERBATCH PROTECTS PACKAGED DAIRY PRODUCTS FROM PHOTODEGRADATION.
A The competition also recognises individuals who make an outstanding contribution to plastics recycling in Europe. PRAE became the platform that puts in focus the innovation, technological developments and number of possibilities in the sector. Platforms like PRSE and PRAE are necessary in showing the tremendous changes that have shaped plastics recycling, a relatively young industry with its roots as an in-house, post-industrial waste recycling initiative in the late 80s. Improvements such as Near Infra-Red (NIR) sorting, more efficient washing technologies, decontamination processes and enhanced filtration and extrusion have shaped the industry’s rapid evolution. They now enable the recycling of more difficult, more demanding, postconsumer streams whilst returning to the same applications and even food grade qualities.
mpacet, a global masterbatch leader, has introduced Safari White PET masterbatch 7100177-E, designed to protect packaged dairy products from photodegradation by imparting a high level of opacity while dramatically reducing mineral loading. Safari White meets European guidelines of less than four per cent of mineral loading in PET bottles and preserves the flavour and nutrients of milk even at wavelengths of 400-550nm, the most harmful wavelength range for dairy products. It is also suited to the preservation of UHT processed milk, which has an unrefrigerated shelf life of six to nine months.
Compared with conventional preforms loaded with 10 per cent titanium dioxide (TiO2), litre bottles produced with 6.5% of Ampacet Safari White perform better in preventing light transmission while allowing throughput increases of 15 per cent bottles per hour or more and reducing the number of IR heating elements by half. This new technology helps to decrease energy consumption and the overall environmental impact of preform stretch-blow moulding operations. Sense and sensitivity Dairy products are particularly sensitive to photodegradation. The sensory quality of milk and its essential nutrients are affected after just a few minutes of sun exposure with degradation
also occurring under the artificial light of retail stores. Dairy beverages must be correctly packaged in opaque containers for prolonged shelf-life, taste protection, and health benefits, as well as for food safety. Due to cost effectiveness and better recyclability, more and more monolayer PET bottles are used to package dairy drinks. Light barrier properties are provided by opacifiers and the most commonly-used is TiO2. For UHT milk, between 12 and 15 per cent of opacifiers are usually mixed with the PET polymer to achieve an opacity greater than 99.5%. The fast-growing market of opaque PET impacts the recyclability of PET packaging in Europe. A large amount of opacifiers in the collected PET stream reduces both the quality of recycled PET and its usability for transparent applications. In order to reduce minerals in recycled PET collected, a malus-tax has been introduced in France for opaque PET packaging containing more than four per cent of mineral opacifiers. All PET containers with
more than 4% are subject to a malustax representing an increase of 50 per cent of the total eco-tax. Because it is NIRtransparent, Ampacet Safari White also allows sorting with NIR optical sensors and recycling. Safari White technology is compatible with PET and polyolefin resins and can be tailored to customer needs.
Safari White meets European guidelines of less than four per cent of mineral loading in PET bottles and preserves the flavour and nutrients of milk even at wavelengths of 400-550nm.
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THERMOFORMING
Tray of GREETING DELEGATES FROM ACROSS THE PET VALUE CHAIN AT THIS YEAR’S PETCORE EUROPE CONFERENCE IN BRUSSELS, BELGIUM, ALIPLAST’S PAOLO GLEREAN ADDRESSED THE ROLE THAT THERMOFORMING PLAYS IN ADVANCING THE PARADIGM OF INCREASED QUALITY AND COLLECTION RATES FOR RECYCLING, AS WELL AS THE DEVELOPMENT OF NEW MARKETS AND TECHNOLOGIES.
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ith his more than 20 years of experience in managing plastics recycling companies and leading relevant R&D projects, Glerean is now responsible for strategic business developments and industrial affairs at Aliplast. He also cochairs Petcore Europe’s Thermoforms Recycling Working Group and has a seat on the Board of Plastics Recyclers Europe. He began by summarising the main drivers required for change – the circular economy, feedstock availability, and the need for new common technologies – in the short and mid-term and how they are likely to undergo continuous investigation in order to see progress. “We are starting to see what the circular economy is with some new technologies and therefore new norms and activities from all parts of the value chain. One of the outcomes is the set-up of new recycling targets and of course collection and sorting has to increase in quality as well as quantity. If we would like to meet these targets, then of course we have to include PET trays, which form a large part of specific food containers.” Taking care to emphasise the opportunities over the potential pitfalls, Glerean added how new pledges were being made within the value chain, and specifically the value of the pledges belonging to manufacturers of thermoformed trays. “How can we get the value?” he asked. “There is much
good news, but we have to create a cooperation to get a clear understanding of making tray-to-tray recycling a reality, and bring good results to recycling targets.” DESIGN FOR LIFE Petcore Europe’s Thermoforms Recycling Working Group explains what is technologically possible in today’s market, as well as what can be improved in the design for PET trays. As Glerean said, “The better the design for recycling, the more sense it makes to invest in collection – and the better, therefore, it is economically.” The same goes for single-use plastics, which pose the big threat to EU-wide recycling efforts, according to Glerean, as PET trays are one of the most used material for food containers. SUPs are also loaded with trends, opportunities, and dangers that Glerean would like to see addressed in order to open a path that enables producers of PET trays to close the loop in a satisfactory and economic way. The trick, however, is in the timing, which he said was imminent as well as imperative. “We have to run good collection, sorting and recycling initiatives and
infrastructures. Only at that stage will we have a good story to tell … but we have to play our best cards now. If we want to look back in three or four years’ time, when we have this very nice story complete, then now is the time to act. The threat is there, but there is also opportunity.” New feedstock availabilities, technologies and materials are beginning to be a visible element in a growing trend, Glerean concluded, with technical improvements expected even in the coming months. “The demand is there,” he repeated, “and there are rival companies working on this topic, so the competition is there also. We have some technologies available – probably not meeting 100% of the criteria – but to some parts of the market, these bring possibilities and will improve the recyclability of thermoformed trays.”
If we want to look back in three or four years’ time, when we have this very nice story complete, then now is the time to act.
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THERMOFORMING
ON FORM AMUT THERMOFORMING MACHINERY IS IN DEMAND. DUE IN PART TO ITS VERSATILITY, EASE OF OPERATION, AND PROVEN EFFICIENCY, THE COMPANY HAS BEEN ABLE TO ENTER THE NORTH AMERICAN MARKET WHERE ITS MACHINERY HELPS TURN POST-CONSUMED PET PLASTIC INTO USEFUL AND INNOVATIVE NEW PACKAGING SOLUTIONS.
In
this way the AMUT Group, based in Novara, Italy, has joined forces with two forward-thinking USbased companies to give a second life to post-consumer plastic. Global Plastics is a well-known Californian manufacturer of PET packaging made entirely from post-consumer bottles, of which around four million a day are recycled, sorted, ground and washed. The company then pelletises the flakes and extrudes the sheet for use in thermoforming. The entire process is performed using AMUT machinery and complies with FDA certification regulations for packaging suitable for direct food contact applications. Hickman’s Family Farms, located in Arizona, is involved in extensive eggs production and has launched an ecofriendly container made entirely from post-consumer PET bottles. Hickman’s is also starting its own in-house thermoforming business using AMUT COMI machinery. In this case, the ACF920 model and newly developed
The ACF920 model and newly developed Easy software helps simplify machine operation, especially for those companies that are only beginning to thermoform. Easy software helps simplify machine operation, especially for those companies that are only beginning to thermoform. ACCESSORIES AND STRATEGIES Positive sales reports show that AMUTCOMI’s ACF series is the right solution due to its ability to satisfy the various exigencies of thermoformers, as well as the demands of market players from all over the world. This reinforces
the ACF series’ status as the top-ofthe-range model among AMUT-COMI thermoforming machines, and vindicates the company’s continuous investment in upgrades in efficiency, accessibility and versatility. New accessories have been specifically conceived to suit the ACF model to cover end-line automation steps such as stacking systems, handling, and packaging solutions. These include the Up-Stacker model, the Down-Stacker IVB model, and Pick and Place Robots in the ERX model. Their performances and skills are well enhanced by the smart Easy software, which has also been developed in-house by AMUT-COMI engineers to ensure that all parts interact harmoniously and that the fully tailored approach offers machinery for features ranging from thermoforming to packaging systems.
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Photos: istock
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THERMOFORMING
THINK FAST... BROWN MACHINE GROUP IMPROVES THERMOFORMING WITH AUTOMATION AND PRODUCT HANDLING.
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rown Machine Group of Beaverton, Michigan, designed the Elite Series Servo Driven Horizontal Trim Presses equipped with cutting-edge automation features for improved speeds, precision, tool life, maintenance and changeover times. “We continue to push the technological envelope; to be fast you must think fast,” CEO Bryan Redman said. “We encourage a culture of innovation to continue to lead this industry with the most creative ideas and solutions.” To complement Brown’s leading Quad Series Thermoformers, the focus was placed on augmenting trim press capabilities, and required examination of the details of Brown’s Elite Series Servo Driven Horizontal Trim Presses. Faster production output with highperformance, high-speed trimming is achievable. These machines are packed with features, including Brown’s balanced main frame assembly, enhanced linearguided platen systems, patented neutral link counterbalance systems, cammed servo feed systems, servo driven treadles, servo ejectors, and efficient drive systems. These machines are designed to run fast without sacrificing quality or durability. Brown Quad-Series Thermoformer © Brown Machine Group
Brown has designed new features and re-engineered components to achieve high-speed changeover times, which include safety guards for maintenance accessibility, side-loading capabilities, patented EZ-adjust crank throws, fine adjust platen parallelism, patented dropaway release connecting rods, treadle lift, canopy retraction, and automated controls for tool change positioning. The Elite Series is capable of speeds in excess of 165 stokes per minute and changeover times of under 30 minutes. Combining this trim press with the NAS Trim Press Handling (TPH) System provides easy, precise and compact product handling. NAS produces TPH Systems to automate product handling from the trim press to the downstream equipment. Add to that a NAS Case Packing System and you have a fully automated line from forming the product to packing the cartons all from one source. PRECISE AND PROPER Product fallback is virtually eliminated with product containment features throughout the entire system, ensuring smooth transitions throughout and further eliminating damage. Upon a long eject from the trim press, the rake system cradles the product, ensuring proper and precise retention. The rakes are easily adjusted and servo-driven on linear rails. “When we developed our first TPH system we were commissioned to design the handler as simple as possible,” Tom Nalle, Sales, said. “Our customer had experience with TPH systems and understood the complexity and talent level involved to make these systems operate efficiently. We have carried some of that mentality into our new systems today, understanding the need for operator-friendly controls, ease of
maintenance, set-up and dependability.” The patent-pending overhead pick-head is designed for quick change and finetuning. The fingers can be independently modified to specific product diameters and to match multiple centre line positions. Servo-driven and actuated on linear bearings to provide smooth, precise movement, the overhead pickhead features a cleanout mode to reduce downtime during start-ups, and can be used during production runs to remove individual stacks of lids prior to being introduced to the bagger. Bob Gordert, Brown Machine Group’s Vice President of Sales, said: “The NAS TPH system is a substantial addition to our product line and fits seamlessly with our servo trim press offerings. The collaboration allows us to be at the forefront of innovation.” Redman added: “This new addition to the NAS product line further positions our turn-key offerings in the market place; our customers are able to take advantage of a single source of responsibility to ensure their success. Available in top and/ or side load, the HTP-1T Case Packer synchronises perfectly with new or existing end-of-line packaging systems.” A global leader in thermoforming technology and innovation with high-quality product lines, Brown Machine designs and manufactures a complete line of continuous and cutsheet thermoforming equipment and automation systems, and provides services such as retrofit and upgrades, tooling, prototyping, process optimisation and technical support. Made in the US since 1952, Brown has thermoforming systems operating in more than 65 countries and in virtually every industry.
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THERMOFORMING NEWS
A smarter way to thermoform SPECIALISTS IN THE DESIGN AND MANUFACTURE OF PLASTIC AND COMPOSITE MATERIALS, THE CURVE WORKS FOUNDERS SAW A GAP IN THE MARKET FOR LARGE CURVED PRODUCTS FOR ORGANIC-SHAPED STRUCTURES. THE ONLY ISSUE WAS FINDING A SOLUTION TO THE PROBLEM OF PRODUCING A NEW MOULD EVERY TIME. THE ‘EUREKA’ MOMENT CAME JUST FOUR YEARS AGO, WHEN THEY STUMBLED ACROSS ADAPATIVE MOULD TECHNOLOGY. Dr Tahira Ahmed is the director and co-founder of Curve Works, located in Zoetermeer, The Netherlands. Here she explains how Curve Works promises fast, flexible thermoforming solutions without waste from tooling. NO ORDINARY MOULD Based on a pin-bed concept, the technology consists of a fully automated adaptive mould and an advanced CAD/CAM software package. The software operates through Rhino3d and enables the user to create, check and select panels. The panel information is sent to the adaptive mould which forms itself in minutes to the desired shape. Manufacturing can begin immediately. This is its essential function: to reshape and be reused over and over again. The mould and the software behind it is in itself a work of art. Built to our specifications by Danish company Adapa ApS, we have modified it for use with plastics and composite materials, making Curve Works the first
company in the world to have done so. The mould works on individually controlled motorised linear actuators, or stepper motors, that can move up to one metre from the mould’s home position. Thousands of magnets lie on top of the actuators, keeping the silicone rubber membrane, which is filled with iron particles, in its place. In this way a smooth shape is created over the discrete points of the actuators underneath. To aid trimming, a laser projector projects the lines of the net-shaped panel. The mould is capable of making parts of up to 5.5m2 which falls within the 4-6m2 range required by most architectural applications. It is also capable of radius of curvature down to 400mm singly curved, and 600mm doubly curved. This ease of producing affordable, one-off shapes with adaptive moulds has been well-received in the architectural and construction industry for concrete façades.
This technology is also currently being used in the construction of Kuwait International Airport’s new terminal, where 40,000 unique concrete panels – all curved – will be manufactured. Curve Works was the first company to spot the potential of the Adaptive Mould for processing plastic and composite materials. Innovation in the process While the Adaptive Mould is an innovation in itself, Curve Works uses the mould to create new processes that could not otherwise exist or would be too expensive to carry out. Thermoforming
one-offs or low-series products provides the perfect example. Take the production of curved Plexiglass windscreens. Typically, a Plexiglass plate is heated in an oven to thermoforming temperature. At this stage, the plate becomes more of a ‘pancake’ as it is transported from the oven and above the mould. The plate is either lowered onto the mould or the mould raised to deform the plate. Vacuum is then applied and the formed product allowed to cool. The larger the product, the more risky the transport process due to the weight of the plate. In addition,
the cost of a mould can be detrimental for prototyping or lowseries windscreen production. Curve Works takes advantage of the Adaptive Mould by preparing the Plexiglass plate cold and flat on the mould. Infrared heating is applied to bring the thermoplastic to temperature and the mould activated to form the shape. Such a simple process allows for especially large panels to be formed safely in a single shot. CREATION OF NEW PRODUCTS The technology has allowed Curve Works to realise new products. To take the
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THERMOFORMING NEWS UK-BASED THERMOFORMING EQUIPMENT MANUFACTURER RIDAT RECENTLY DELIVERED A VACUUM FORMING MACHINE WITH DUPLEX HEATER TO SAS CREAPLAST NEAR DREUX, FRANCE, WHICH IS A PART OF MARIE-LAURE PLV MERCHANDISING GROUP. 3D Core Kits as an example, these products target a number of markets but it is in the forward-thinking highperformance marine sector where it has been embraced most. High performance yacht hulls are made primarily of a composite sandwich construction; a structural core in the middle with carbon fibre skins. For those yachts using structural foam core, there are two ways to place this rigid material into the curved hull mould during manufacture: kerfing, or scoring, sheets of foam core through the thickness to allow it to shape more easily; and heating each sheet in an oven and thermoforming it into shape by applying ballast to press it into the mould. Both techniques have their downsides; the first requiring more resin or adhesive to fill the kerfs and adding to the
While the Adaptive Mould is an innovation in itself, Curve Works uses the mould to create new processes that could not otherwise exist.
overall weight, and the second requiring more skill, as well as being a lengthy process. Curve Works offers the boat builder kits of preformed structural foam core, manufactured in a similar process to their own thermoforming processes but with springback correction and accurate cutting to ensure a perfect fit. The springback correction can only be possible with an Adaptive Mould because it can be given a different shape to the final hull form. While there are a number of benefits to the 3D Core Kit, the most attactive to the boat builder is the savings in the build time. An 80ft (~25m) hull would normally take five weeks to form and place the structural core; this is reduced to a single week with the 3D Core Kit. ADAPTIVE MOULD FOR RAPID MANUFACTURING In the end, the Adaptive Mould is a new and complementary addition to the technologies that form the ‘Rapid Manufacturing’ group. Not only suitable as a tool during the thermoforming processes, but many different materials can be processed on it as it is, after all, a mould. Only far more flexible, and reusable.
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RIDAT DELIVERS VACUUM FORMING MACHINE TO FRANCE
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rank Zimmerman, Industrial Director of Marie-Laure PLV Merchandising, said: “We urgently needed to replace ageing vacuum formers with equipment that provides flexibility in operation and meets the strictest standards. Ridat’s Model 4030AVF offered us the perfect solution and provides us with superior performance at a competitive price. We were so pleased with our first Ridat vacuum former that we ordered a second within 60 days of the first delivery.” The new order will have additional bespoke functionality, including a sheetfeed product removal facility. Founded in 1982, Marie-Laure PLV is a French company specialising in merchandising displays and projects. The company employs more than 450 people in France and has three production plants, including SAS Creaplast, where the new Ridat thermoforming
machine was commissioned. Ridat is a leading UK manufacturer of thermoforming equipment with more than 60 models and more than 50 years’ manufacturing experience. Its impressive product range and highspecification machinery offer many features included as standard. The Model 4030AVF industrial vacuum forming machine includes automatic sag control, photo-electric safety curtain, quick cooling, bubble facility, quick mould changes and a user-friendly micro-processor system that assists
with fault rectification, as well as top and bottom heating with PID control for accurate zone temperature control. The equipment was fitted with plug assistance to facilitate material distribution. www.ridat.com
We were so pleased with our first Ridat vacuum former that we ordered a second within 60 days of the first delivery.
SATATUOTE INVESTS IN KIEFEL’S SPEEDFORMER TECHNOLOGY FINNISH THERMOFORMED PACKAGING EXPERT SATATUOTE OY HAS CHOSEN A KIEFEL SPEEDFORMER KMD 78 POWER MACHINE.
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atatuote is a manufacturer specialised in PET, PS and PP packaging for the food and medical sectors. Sustainability in packaging design,
processing of recycled materials as well as energy efficiency in production are important to the company. An important requirement for Satatuote was being able to use existing production tools. The forming, punching and stacking stations of the Speedformer KMD 78 Power are designed to use existing RDK tools without necessitating any modifications. In addition to tool flexibility, the KMD 78 Power’s
proven Speedformer technology and excellent co-operation with Kiefel’s sales partner and tool specialist Techno Tool were critical in Satatuote’s choice. KIEFEL GmbH develops and produces high quality machines for processing plastic films, with customers including well-known manufacturers from the automotive, medical engineering, refrigerator and packaging industries. Kiefel has a global presence with sales
and service branches in the US, France, the Netherlands, Russia, China, Brazil, Indonesia and India, as well as sales partners in more than 60 countries. Kiefel owns the automotive specialist KIEFEL Automotive s.r.o.
based in the Czech Republic, the Dutch thermoform toolmaker Kiefel Packaging BV, and the Austrian company KIEFEL Packaging GmbH, a supplier of tools and automation solutions.
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PIPE & PROFILE NEWS UNI-BELL PVC PIPE ASSOCIATION BRINGS TOGETHER THE PVC PIPE AND FITTING MANUFACTURERS OF THE WORLD AT THE 47TH ANNUAL MEETING, WHICH WILL TAKE PLACE IN SAN DIEGO, US, FROM 11-13 MARCH.
Molecor participates in 47th annual Uni-Bell meeting Uni-Bell PVC Pipe Association, the authoritative source of information on PVC pipes in the US, fosters the application and development of increasingly efficient manufacturing systems. Ignacio Muñoz, CEO of Spain-based pipe manufacturer Molecor, will participate with a presentation on the company’s latest innovations and will highlight the wide range of products that Molecor manufactures with its exclusive technology, the ecoFITTOM PVC-O fittings and the TOM Oriented PVC pipes. Molecor produces PVC-O pipes and fittings through Molecular Orientation, a process that greatly enhances the PVC’s physical and mechanical properties, obtaining a laminated structure more resistant to impacts and fatigue. With more than 20,000km of pipes
installed worldwide, the TOM pipes and the ecoFITTOM fittings manufactured by Molecor are presented as the Oriented solution for the uniformity and integrity in the water networks for the conveyance of water under pressure. Presentations cover topics ranging from market assessments for PVC pipe, vinyl resin and related chemicals, to sustainability, technology, legislative affairs and product certification. Participants come from around the world and include pipe and fitting manufacturers, resin and additive providers, equipment manufacturers, affiliated associations, and non-profit certification agencies. Speakers include academics, business analysts, engineers, municipal officials, taxpayer advocates, and public affairs specialists.
Sikora uses measuring techniques to their full potential WITH THE X-RAY 6000 PRO MEASURING SYSTEM FROM SIKORA, QUALITY CONTROL OF HOSES AND TUBES IS DONE FAST AND PRECISELY, DIRECTLY IN THE EXTRUSIONLINE.
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ithin milliseconds, an X-ray image of the product is generated showing all measuring values (diameter, ovality, wall thickness and eccentricity) on the EcoControl 6000 processor system monitor. Sikora continuously optimises the performance of the measurement solutions, enabling the operator to fulfil its potential. Since the early 1990s, Sikora has offered X-ray technologies in combination with processor systems for the quality control of cables. In 2004, these technologies were transferred to the hose and tube area. While processor systems of the first generation were limited to four measuring values, the operator now receives a far more sophisticated display due to higher processor performance.
NEWTUBE The X-Ray 6000 PRO is combined with the EcoControl 6000 display and control system, a powerful processor system with a vertically mounted 22” TFT monitor, which shows the measuring values numerically as well as graphically as trend and statistical data. The physical model enables the visualisation of the wall thickness at any position over the total circumference of the hose or tube. For example, as an alternative to the standard display of eight measuring values, a visualisation of 12 or more is possible. The operator selects how many points and at which position the values are being displayed. Furthermore, the processor system is used for an automatic control of the line speed,
thus guaranteeing compliance with given specifications, as well as the highest performance for maximum process optimisation and productivity. The X-Ray 6000 is available as an alternative to the X-Ray 6000 PRO. This measuring system focuses on single-layer products wherein the product data is displayed on an integrated 7” monitor at four measuring points. In combination with an EcoControl 6000, 1000 or 600 processor system, a line control regarding line speed or extruder rpm can also be realised.
GERMAN MACHINERY MANUFACTURER KRAUSSMAFFEI GROUP HAS BEGUN CONSTRUCTION OF A NEW PRODUCTION PLANT AT AN EXISTING LOCATION IN HAIYAN, CHINA.
KRAUSSMAFFEI BEGINS CHINESE PLANT CONSTRUCTION
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he new intelligent manufacturing unit will cover 1.3 million square feet and is expected to double production
capacity by 2020. The new plant will build all primary plastics processing machinery such as injection moulding machines, and pipe and profile extruders. It will also supply fully automated turnkey systems with integrated robots and smart technology.
KraussMaffei currently manufactures 120 units of injection moulding machinery, 16 units of reaction process machinery and 122 units of extrusion machinery per year at the site, which will serve as the operating headquarters of KraussMaffei Group
in China. KraussMaffei Group has been mainly engaged in plastic pipe and profile extrusion equipment since its establishment in Haiyan. Over the past decade, the group has expanded to meet the needs of Chinese and overseas markets.
KraussMaffei was acquired by ChemChina in 2016 and listed on the Shanghai Stock Exchange in 2018.
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PIPE & PROFILE
A NEW LEASE OF LIFE FOR OLD WASTE LAUNCHED IN JANUARY AS AN AMBITIOUS JOINT PROJECT BETWEEN SOME OF THE MAJOR HOUSEHOLD NAMES IN THE PLASTICS INDUSTRY, THE ALLIANCE TO END PLASTIC WASTE HAS COME AS A WELCOME DEVELOPMENT FOR THE US-BASED PLASTICS PIPE INSTITUTE, INC. (PPI), WHICH BELIEVES THE INITIATIVE WILL HELP SOLVE SIGNIFICANT PROBLEMS ASIDE FROM THAT OF PLASTIC WASTE.
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ere PPI President Tony Radoszewski shares his thoughts on what the alliance can do not just for the planet, but for the communities and businesses upon it, as well as for the vital infrastructures connecting them. Of the companies involved in the formation of the alliance, 12 are PPI members, and they have taken what Radoszewski describes as a “quantum leap”. “With the formation of the Alliance to End Plastic Waste, the industry is driving forward a major initiative that has set realistic and obtainable goals. The PPI’s membership also sees another benefit, which is an increase in the supply of recycled high-density polyethylene (HDPE) resin. One of our members reports using more than 400 million pounds a year of recycled material.” GOING UNDERGROUND Primarily used for underground storm water infrastructure management and agricultural drainage projects, some HDPE pipe can be made using more than 40 per cent recycled HDPE resin that was originally used in more common applications. “For decades, our members have been capturing the value of discarded plastics by using it to make plastic pipe,” Radoszewski adds. "Plastic milk bottles and detergent bottles have been recycled and incorporated into agricultural drainage pipes since the 1980s. Today, we are working with research firms and the American Association of Highway Transportation Officials (AASHTO) to
produce storm water drainage pipe incorporating post-consumer recycled plastic for use in highway culverts. “Our industry currently processes 25 per cent of all post-consumer HDPE bottles – mainly from liquid detergent products – and converts them into products used in underground infrastructure. These bottles and containers that originally had a 60-day shelf life are now converted into a product with a 100-year service life.” ONE PLAYER’S PROBLEM IS ANOTHER’S OPPORTUNITY The question of whether there is enough to meet demand, however, remains, and while this continues to be a problem for pipe manufacturers, it presents an opportunity to bring the goals set out by the Alliance to End Plastic Waste to the next level. Furthermore, it answers the question of what to do with that surplus waste due to the success of the alliance and its projects. “Think about it,” Radoszewski continues. “To make one standard 20-foot length of 48-inch diameter HDPE pipe containing 40 per cent recycled HDPE resin, between 1,600 and 2,200 discarded bottles would
To make one standard 20 foot length of 48 inch diameter HDPE pipe containing 40 per cent recycled HDPE resin, between 1,600 and 2,200 discarded bottles would be required.
be required. Most storm water drainage projects using this type of pipe run in the thousands of feet, sometimes even miles of pipe. This is how the plastic pipe industry uses an enormous number of post-consumer plastic bottles and puts what was formerly a solid waste issue to good use. “Additional infrastructure is necessary worldwide to improve and increase the collection and supply of recycled plastics. Both of these issues combine to bring a holistic approach that leads to a sustainable solution. We believe that is the prime directive of the alliance.” Radoszewski and his fellow PPI members are enthused by the alliance and the intrinsic partnerships with innovative, market-leading organisations; he is optimistic that the project will take sustainability to the next level by including old waste in a new lease of life, and in a way that can still be of true service to communities.
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PIPE & PROFILE
WHEN MICHAËL VAN DER JAGT, CO-FOUNDER AND CEO OF THE NETHERLANDS-BASED START-UP PARX PLASTICS – ALONGSIDE CO-FOUNDER AND CTO MICHELE FIORI – RECOGNISED THE NEED FOR PLASTIC PIPING WITH ANTIBACTERIAL AND ANTIMICROBIAL PROPERTIES IN 2008, HOW COULD HE HAVE KNOWN THAT IT WOULD LEAD TO A WORLD TECHNOLOGY AWARD AND SHARING A STAGE WITH ELON MUSK AND JANE GOODALL IN 2014?
Piping up
S Michaël van der Jagt, co-founder and CEO of Parx Plastics
uch solutions were not suitable for large-scale application or adoption at the time due to the possible harmful effects on humans and the environment. Following four years of stringent research in biomimetics, with the aim of creating a biocompatible technology that inhibits bacterial proliferation on the surface of plastics, Van der Jagt and a team of just 11 researchers – with varying skills in nano- and bio-tech, and chemical, physical and microbial analytics – patented the Saniconcentrate solution to give plastics a certified antimicrobial quality. By using zinc (the second most abundant trace element in the human body) in lieu of heavy metals or nanomaterials, plastics
can now be counted among the naturebased solutions in industries where environmental and sanitation-based issues are abundant. As well as contributing to the strength of hair, nails and the eyes, the body also uses zinc to improve wound-healing and reinforce the immune system. Integrated into the very fabric of plastic, it has a similar function that disables bacteria and prevents it from migrating or leaking out into the environment – “an immune system for plastics”, as Van der Jagt put it. EPPM wanted to find out more about how biomimetics and biochemistry-inspired plastics manufacturing is contributing to the improving performance of plastics
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PIPE & PROFILE
in health, hygiene, and the environment, as well how stakeholders such as Parx Plastics are rising to the challenges. SKYPING FOR PIPES From a humble-looking office near the centre of Rotterdam, Van der Jagt revealed a pipe that had been used to drain water from a UK supermarket freezer for just six months. Clogged with biofilm and riddled with microbes, the discarded pipe appeared to have no further function left in the world – except perhaps following a heavy, thorough cleaning using harsh chemicals. Alongside it, another pipe, which had been used for the same purpose but for twice as long, was clear and immaculate but for a drop or two of residual water. The latter, the Parx BioPipe, had of course been treated with Saniconcentrate zinc technology. Integrated into ABS and PE at just 3%, the zinc renders the plastic antimicrobial and antibacterial to the power of Log3 (i.e. 99.9%) and higher according to ISO 22196, all without the need for harsh chemicals or metals, including silver. Such properties are vital to food and hygiene markets with Parx Plastics’ contribution described as a ‘truly revolutionary technology’ as it does not deteriorate over time. “All supermarket trials have taken place in the UK,” Van der Jagt said, “and all have returned with positive feedback. Not only does the technology exponentially improve hygiene and environmental standards, maintenance and the need for excessive cleaning using harsh chemicals is reduced
to a bare minimum, saving time and expense. Furthermore, the zinc protects the polyurethane from corrosion, and therefore from leakage, preventing any potential accidents and injuries.” THE HYPE AND THE PIPE Recognition for the multi-layered benefits of the Parx BioPipe came from both sides of the Atlantic in 2014 with Van der Jagt collecting the World Technology Award for materials with long-term significance, as well as Parx Plastics being named among the top three start-ups in Europe in the same year. In 2016 the company took another step towards banishing clogged drain pipes to the annuls of history through a collaboration with UK-based plastics development company Bio Products Group. The joint project saw the first supermarkets fitted with BioPipe parts with swab samples taken every three months, which showed a significant and continuous decrease in bacteria count throughout the duration of the trial. The internal walls of the BioPipe appeared clean, smooth and without any slime throughout as revealed by Van der Jagt. Bio Products Group CEO Robert Stewart said: “Our challenge was to create a permanent solution to an old problem – bacteria found in most systems that form biofilms and slimes which cause blockages leading to leaks from the systems. The fact that Parx technology uses a key element found in our everyday diets and can be used with ABS, PP and PE – the three essential plastics for our Internal wall of the Bio Pipe (left) 12 months after installation versus the internal wall of a standard pipe six months after a deep clean.
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products – was a perfect match. It has delivered the results we wanted and the results we promised our customers. Also, the support mechanism Michael and the Parx team has given us through product testing, product development and contacts to manufacturing and new markets, we couldn’t have asked for a better partnership.” Alongside the all too common health and safety issue of water leaks, other significant impacts include service and maintenance costs, equipment downtime, loss of sales and increased labour hours through de-stocking/re-stocking each system. Stewart confirmed that the BioPipe, alongside the BioPad and BioHose solutions which were also created using Parx Technology, has helped reduce the growth of bacteria by up to 99.9%, and the amount of all water leaks by 93%. “Best of all,” Stewart continued, “we have created a permanent solution for our users which only requires regular pre-planned maintenance.” The projects undertaken so far have saved up to £20,000 (~€17,500) per customer in just six months. Small wonder then that more and more end-users are showing interest, and that through the combination of such recognition, successful partnerships and positive test results, both companies are hard at work trying to meet the now worldwide demand from supermarkets interested in utilising the BioPipe. With potential applications ranging from food packaging and waste reduction, to water infrastructure and the health sector, the new decade is set to be busy and successful, with challenges and victories in both companies’ pipelines.
DRIVEN BY INNOVATION There is no substitute for the experience we’ve gained by rolling up our sleeves and working through improvements at every stage of thermoforming technology for over six decades. From process design through putting high-output machinery on the floor, innovation is in our DNA.
PIPE & PROFILE
DAVIS-STANDARD, LLC, HEADQUARTERED IN PAWCATUCK, CONNECTICUT, US, IS A GLOBAL LEADER IN THE DESIGN, DEVELOPMENT AND DISTRIBUTION OF EXTRUSION AND CONVERTING TECHNOLOGY. ITS SYSTEMS SUPPORT MANUFACTURING APPLICATIONS AND CUSTOMERS IN EVERY MAJOR INDUSTRY.
Standard deliver ERNST GEIDER Davis-Standard
JOE WNUK Davis-Standard
A
s well as its manufacturing and technical facilities in the US, Davis-Standard operates in Canada, China, Germany, Finland, Switzerland and the UK. Maillefer, a Davis-Standard company, is a global leader in wire, cable, pipe and tube production technologies. Known for its commitment to costeffective, environmentally friendly engineering systems that offer a high ROI, eppm editor Rob Coker reached out to Davis-Standard’s Vice President for Pipe, Profile and Tubing, Joe Wnuk, and subsidiary company Maillefer SA’s Technical Sales Director, Ernst Geider, for a chat about pipes and profiles, materials and manufacturers, and economics and the environment. WHAT CHALLENGES HAS THE 21ST CENTURY PRESENTED FOR PIPES AND PROFILES SO FAR, AND WHAT STRATEGIES DOES THE COMPANY HAVE IN PLACE TO MEET THEM? The economy has been solid, which has both driven robust infrastructure activity worldwide and forced plastic component and pipe producers to expand their product range – for example, to develop new components to accommodate
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customers. Agility, time to market, and technology innovation are all important considerations for machinery suppliers. At Davis-Standard and Maillefer, we have R&D capabilities in the US, Europe and China to support customer innovation and product development year-round. Our goal is to help customers optimise their investment while having options for improving productivity and meeting changing demands such as those presented by the 21st century so far. Sometimes this may mean using a new feedscrew design, for example, or upgrading control systems or replacing a gearcase. If they need a new extruder or additional downstream equipment, we have manufacturing processes in place to enable a fast turnaround. Whatever the case, we strive to be ready at all times. WHERE IS THE PART OF PLASTICS IN PIPE AND PROFILE LIKELY TO GO DURING THE FORTHCOMING DECADE? Everything is currently geared toward reducing the impact on the environment and maximising efficiency. Expanding the scope of resins used in processes is therefore essential, as is developing new components that are better and stronger. It is equally as important for equipment technology to offer sustainability in terms of energy consumption and waste reduction, while also addressing space limitations. A recent customer replaced an older profile line with a more energyefficient dual-strand line to double their outputs without additional space. The same sentiment is also visible in the automotive industry. While the number of vehicles is increasing, there is mounting pressure for responsible fuel consumption, environmentally friendly energy sources,
lighter vehicles, more technology and higher safety levels. The result is a growing range of tube constructions, custom-engineered for automotive manufacturers to serve specific markets. Emissions standards will continue to require the use of low permeation fuel tubes, while electric vehicles will continue to depend on cooling tubes to keep batteries at optimal temperatures. HOW IS DAVIS-STANDARD CONTRIBUTING TO SOLUTIONS DEVELOPMENT AT THE COMMUNITY LEVEL AND ON THE INTERNATIONAL STAGE (E.G. IN DEVELOPING COUNTRIES)? We have outstanding technical partnerships worldwide, and our commitment to R&D has been instrumental in developing real-world solutions. We also understand that what works in North America may not be the best solution for developing countries. Having facilities and representatives in every major market has helped us identify region-specific requirements and to hone our technology accordingly in terms of applications, machinery requirements, and production rates. We seek to support profitability and growth for the longhaul by supplying equipment that yields quality products at a competitive price, no matter where the customer is located. HOW ARE CHANGES IN POLICY/ PUBLIC ATTITUDES AFFECTING THE INDUSTRY? Environmentally friendly practices, recycle and reclaim efforts, energy conservation,
and smart technology are front and centre. Producers expect and demand process improvements that focus on machinery efficiency, reduced scrap, tighter tolerances, flexibility for producing components in all weights and sizes, and more.
have the capacity to extrude smooth and corrugated tubes with up to six layers. That flexibility, combined with the possibility of swapping layer positions, is giving manufacturers more choices to meet the standards in place in different regions.
Smart equipment design is integral to changes in policy and attitudes. We always seek new ways to support market-specific resourcefulness and took advantage of the IoT to create the DS Activ-Check system for continuous extruder monitoring from hand-held devices for this purpose. Machine operators are now alerted to issues before they happen, and they can now also collect operational data that can lead to significant cost-cutting opportunities. This also helps processors avoid unexpected downtime and discover ways to improve existing processes.
IN WHAT WAYS ARE YOU CO-OPERATING WITH OTHER INDUSTRY/ACADEMIC PARTNERS TO STAY ON TOP OF DEVELOPMENTS? We are fortunate to have some of the industry’s leading profile and tubing extrusion experts working at Davis-Standard and Maillefer. It is not uncommon to have one of our process engineers presenting a technical paper at a conference or symposium. We offer extrusion seminars, training and process tuning services using our lab lines at our various facilities, perform machinery consignments with universities, and regularly promote educational topics through our DS Connect Blog, the Maillefer blog, on social media, and on our website. We firmly believe in collaboration with industry leaders and raw material suppliers to promote best practices and new developments.
Maillefer’s multi-layer tubing production line with a multi-layer crosshead at the centre is another excellent example of how smart equipment is helping industry adapt to new public attitudes and policy demands. Using an array of five or six single screw extruders, processors now
Extrusion cell for manufacturing six-layer automotive fuel and vapour return tubes
WHILST BROWSING THE EPPM ARCHIVES, I DISCOVERED THIS SUCCINCT CONTRIBUTION FROM DAVIS-STANDARD IN SEPTEMBER 1999’S INAUGURAL ISSUE AND INVITED JOE WNUK TO COMMENT ON THE PAST 21 YEARS IN THE COMPANY, AND OF WORKING ALONGSIDE EPPM – ED.
I
n reflecting on the past 21 years at Davis-Standard, I would say we’ve done an exceptional job of building equipment that meets the production demands of a competitive marketplace while addressing industry trends of improved safety, operational efficiencies, environmental sustainability and processing versatility. It’s not enough to build an extruder that outlasts the competition and provides years of reliability. Processors need machines that adapt to their business and provide an excellent return on investment. Every development we make in our R&D labs and every product we offer is geared toward optimising performance and supporting the customer’s bottom line. Our recent branding strategy is a reflection of this; we truly want to partner with customers for the lifecycle of their equipment. Our one-stop parts and service centre for maintaining, reconditioning and retrofitting machinery is an essential part of this philosophy. We also want to help customers take advantage of IoT and smart factory solutions for better manufacturing practices. Our slogan – ‘Where your ideas take shape’ – is genuine. We want our customers to know that. Our congratulations to eppm for 21 years of writing about our industry. Davis-Standard aims to provide you with even more exciting stories in the years to come! Cheers to your staff on a job well done.
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TECNOMATIC
INDUSTRY 4.0
AVANT-GARDE FEATURES BOOST PRODUCTION OF PLASTIC PIPES EXTRUSION PLANTS.
T
he global market is constantly evolving. Therefore, each company should have a department dedicated exclusively to R&D on a full-time basis to keep abreast of the numerous ongoing upgrades.
can be easily analysed thanks to the efficiency indicators (KPIs), which are accessible from any PC, smartphone or tablet and can be queried at any time or at established intervals, from anywhere, due to Cloud technology.
This is one of the challenges that Tecnomatic wants to add to its ‘must do’ list, and focusing on Industry 4.0 is and will continue to be one of the major objectives of this department.
Pipe manufacturers are always striving for optimum performance and output whilst simultaneously trying to limit the different kinds of costs and waste. The PIPE 4.0 software is able to achieve this by:
Constant technical improvements are essential in the field of extrusion and combined with Industry 4.0 will leverage the full potential of pipe extrusion. The ‘Fourth Industrial Revolution’ is having a very strong impact on the ways companies manage industrial processes, and Tecnomatic is actively participating in it; in fact, in addition to introducing a new control system in 2018, characterised by the latest-generation hardware and software, Tecnomatic has been able to bring to the market the most sophisticated and modern system, following meticulous, close-knit teamwork. This dedicated software, called PIPE 4.0, facilitates all preventive maintenance and records machine efficiency. As well as enabling manufacturers to monitor all production activities, it also provides precise and timely data on order management, production phases, and estimating and calculating costs. Data
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• Predictive lines management, which maximises lines utilisation and minimises unplanned downtime; optimises maintenance activities planning and scheduling; reduces failures and downtime; and generates alerts and recommendations (prediction model). • Process management and control, which minimises production variability and improves quality by addressing production on the most efficient lines according to the kind of pipes produced. • Energy management, which reduces costs through monitoring for line and process. • Production analysis, which monitors lines, processes, people and products on a continuous real-time basis, and displays KPIs and usage reports. • Production simulation, which includes manufacturing and downtime planning and cost forecasts.
• Production forecasting, which adjusts production schedules in line with changing customer needs and raw material availability. • Safety management, in which connected technologies can help companies in continuously monitoring and recording products and quality for each produced lot, as well any generated waste (records of dimensional changes, temperature instability, breakdowns). Currently, Tecnomatic’s PIPE 4.0 system is the most cutting-edge software for plastic pipes extrusion. Certain that it will be essential to better face the ongoing Fourth Industrial Revolution, Tecnomatic has already made it available on the market. Positive customer feedback relating to improved plastic pipes extrusion, due to better monitoring and management, is what gives Tecnomatic the certainty that it is heading in the right direction.
EPPM_April_May_2019_issue .pdf 1 20/03/2019 15:29:15
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AUTOMATION AND ROBOTICS
ABB’S FAUSTO BELOTTI REVEALS HOW AUTOMATION IN THE PLASTICS INDUSTRY WILL CHANGE THE WAY WE PRODUCE AND USE PLASTIC.
REVOLU T O N
A
BB, along with its Austrian subsidiary Bernecker & Rainer Industrie-Elektronik GmbH (B&R), will feature its automation and motion drives and motors applications during the K 2019 event in Dusseldorf, Germany, in October. K is the number one global exhibition in rubber, plastic and plastic machinery and ABB has agreed with major OEMs in these sectors to join them in showcasing their automation products. With automation, the IoT and greater connectivity transforming the ways in which industry operates, eppm caught up with Fausto Belotti, the Global Segment Manager for Rubber and Plastic at ABB, to discuss what automation means for plastics specifically and how plastics is leading the way for other industries when it comes to catching up with trends, demands, machinery, and environmental issues. Fausto Belotti Global Segment Manager, ABB
HOW IS AUTOMATION CONTRIBUTING TO CHANGING DEMANDS IN THE PLASTICS INDUSTRY? The market in plastics has changed from high volume batch production, with machines set up to run uninterrupted for long periods, to small batches. Producing smaller batches creates the need for more frequent machine set-ups. It means that the new imperative for machine builders is to design equipment that can be re-set quickly to match production demands. ABB has responded to this challenge by developing automation products and drives that can easily be reconfigured to suit changing production needs. One approach is by embedded product macros that are prepared in advance to change the setup of the machinery. Reconfiguration can be done locally, i.e. beside the machinery, and remotely with what we call the ‘networked machinery automation and drives’ system, which enables production to be controlled remotely using the internet. IF THE INDUSTRY IS MOVING ON FROM HYDRAULICS, WHAT ARE THE MAIN ADVANTAGES OF ELECTRICAL MACHINERY? The main advantage of electrical machinery is less maintenance. There is
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also the possibility of easily modifying production profiles because everything can be done with digitalisation, including controlling processes remotely. Furthermore, there is an improved efficiency of the complete production chain. Efficiency means that production uses less energy and greater productivity means reducing process costs. Another important point is, of course, the impact on the environment. Full hydraulic systems require regular maintenance and there is the challenge of correctly handling the oil waste. HOW QUICKLY ARE INDUSTRY PLAYERS AND STAKEHOLDERS CATCHING UP WITH INDUSTRY 4.0? HOW QUICKLY IS IT GAINING MOMENTUM? I will start by saying that the rubber and plastic sectors – certainly more plastic than rubber – are historically always ready to adopt new technology. This is a good place to start because history has shown that the plastic industry is prepared to move forward rapidly. That doesn’t mean from monomer to polymer, I mean that even since the 1960s the industry has embraced new technologies, including mechanical processes, thermohydraulics, bio-plastics to address recycling, full automation, and the IoT and Remote Condition Monitoring as provided
We cannot do without plastic – it’s like going back to travelling by horse now we have cars. by our ABB AbilityTM platform. Industry 4.0 is revolutionising the ways in which we work. It’s pushing us towards the change from high volume production based on standard machinery to machinery customisation. For each automation solution, customers have different options and different specifications. What we want to offer to our customers is a ‘pre-design concept’ that can be finalised by the OEM. This is based on patterns already identified through experience drawn from our extensive customer base, which has helped create what is effectively a ‘master model’. In this master model, we can define the variables of the process and all relevant customisations required and identified by the OEM and the system integrator to meet the specific needs of the equipment end-user. HOW DOES THIS ‘MASTER MODEL’ THEN CONTRIBUTE TO AN AFTERSALES SERVICE? With a master model you can prepare and predict from the very beginning how you will need to manage your machinery fleet over time according to the defined working profile and load; you can predict and prevent maintenance before machinery stops working and reduce the downtime rate; this enables you to maintain the highest level of productivity. When you start to design the machinery according to this master model, you will be able to offer end users insight into how, over the next five years, maintenance can be planned and scheduled to ensure the best productivity and product quality, as well as output reliability. Again, these activities can be done locally or remotely
plastics. This is already visible in the market. A lot of businesses and OEMs are coming up with new machinery for recycling and are moving to new technology such as biologically recyclable plastics.
within a networked automation and drives system. WHAT CHANGES CAN AUTOMATION BRING ENVIRONMENTALLY? I am really happy to say that in plastics again we will see a big revolution. We cannot avoid the environmental concerns relating to plastics, and it is clear that the industry has made mistakes in creating these problems. What I have understood whilst travelling around the world and meeting many plastics operators, is that the message, politically, was at first a sort of ban on plastic; then there was a move to try to get to recycling; now we are moving in the direction of biological plastics. So, what is happening now in the market? Let’s start with one baseline: We cannot do without plastic – it’s like going back to travelling by horse now we have cars. However, the impact of plastic is there and is visible. We have to clean what has happened and then we have to prepare for greater recycling and for biological
WHAT WILL BECOME OF AUTOMATION AND CONNECTIVITY IN THE FUTURE? WHAT DOES INDUSTRY 4.0 LOOK LIKE FROM HERE? This trend will continue, I think, to gain control of the production of every single line or plant – or more than one plant – by matching the best efficiency in terms of productivity with demand and production. The point is to be able to match all your sales demands in different locations, or even regions, and match them with the right MES system to adjust production so that it meets the market demand as fast as possible, especially in minimising the distance and time between demand and supply. The challenge of simultaneously and flexibly managing different production units, and matching them as closely as possible to the market demands, requires remote automation solutions, and especially the IoT in Industry 4.0 – and this has been a key driver in the development of ABB AbilityTM. I believe these trends will be visible in the plastics industry in 2019, and then one-byone other industries will follow, e.g. metal forming and paper converting. I expect the textile industry will also go in this direction, but plastics are leading the way.
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AUTOMATION NEWS WITTMANN BATTENFELD’S AUTOMATION SOLUTIONS FOR SKILLS SHORTAGES.
Robo-sapiens
T
he production sector suffers from skilled labour shortages in most industrialised countries, and growing populations could augment the issue. Numerous projects are on hold or have otherwise been removed from many European agendas simply because they cannot be realised due to a lack of long-term technical capacities. When planning injection moulding projects, for example, technical feasibility is not the only issue. Increasingly, capacities for reliable production in an often insufficient pool of expertise must also be considered. KISS AND RUN The principle known in the Anglo-American region by the acronym of KISS (keep it simple and stupid) is becoming significant in Europe. For the injection moulding industry, KISS indicates an increasing need to invest in production cells which include intuitively operated, self-learning
control systems such as Wittmann Battenfeld’s B8 system with its HiQ software packages. Just as important is which robot can take care of fast parts removal and support high-speed downstream finishing. Robots equipped with the R8 and R9 control systems are ideal for these purposes as linear axes are used for basic, quick and easy extension and retraction movements within the mould space. For additional functions outside the mould space, they are combined with compact rotation axes. In contrast to working with articulated robots, the operator is not required to alternate co-ordinates systems or concern themselves with collisions caused by multi-axis movements. Although the R9 robot control system allows manual selection of desired movement co-ordinates, the robots’ main axes are nevertheless orientated within the Cartesian co-ordinate system. Again, in contrast to articulated robots, the risk of collision can be substantially reduced; from a skills perspective, training expenses can too because the R8 and R9 systems include preparing, editing and operating input
assistants. Wittmann robot control systems provide two user levels as standard: QuickEdit enables the operator to change selected commands and programming templates; and TextEditor enables complete programming freedom. Any sequence and function can be applied directly to the robot before interfacing with the program simply by pressing a key. QuickEdit enables inexperienced operators to create programs in simple steps using pictures and animations, whilst the control system proposes the sequence and explains the correct input. This method is primarily used for simpler applications such as ‘pick and place’ functions or parts removal with sprue picking and depositing. For more complex tasks, TextEditor is available with the option of generating illustrations and templates in QuickEdit for this type of application, and users can add animations. The Wittmann Group has brought connectivity – and the advantage plastics processors have been looking for in the integration of injection moulding machines, automation and auxiliary equipment – to all product lines.
HEMMER OF THE GODS:
COMAU’S HEMMING PROCESS
C
omau is taking a quantum step forward in digital-enabled solutions for lightweight vehicle manufacturing with its new robotic roller hemming process. Fast, flexible and extremely precise, Smart Hemmer is a compact, symmetrical roller hemmer able to hem any complex joint. Suitable for electric, hybrid and traditional lightweight vehicles, it is designed to allow players in the automotive industry to join dissimilar materials using a cold process. Head of Process Technologies Giovanni Di Stefano said: “Comau’s newest hemming solution features a revolutionary design that renders it extremely fast and efficient for lightweight and e-vehicle manufacturing, while eliminating the costly attributes of the product as well as the
associated production process. The Industry 4.0-compliant solution allows automakers to innovatively join components together with full in-process monitoring of the joint.” Smart Hemmer addresses the dual market requirements of increased efficiency and accuracy. Featuring two flexible rollers, in which the linear roller can automatically disengage when encountering obstacles, the Smart Hemmer performs curved path hemming and manages complex angles as part of a continuous process. Smart Hemmer can also maintain a constant hemming thickness even when encountering multiple layers of dissimilar materials. The result is an Industry 4.0-compliant hemming head offering high reliability, inherent flexibility and complete process control while ensuring geometric uniformity of the assembled parts. Field-tested and validated by major European automakers, Smart Hemmer is a standardised product that can be applied to all vehicle architectures and complements the complete array of similar technologies developed by Comau in the cold joining environment.
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You will receive your victory within 6 and your duo within 12 work weeks*. * Delivery times quoted here may differ depending on the actual order. Please note the terms of the sale: www.engelglobal.com/fasttrack
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AUTOMATION AND ROBOTICS
AUTOMATIC ACADEMICS WITH GROWING INTEREST AND THE WORLDWIDE PUSH IN STEM SUBJECTS, ROBOTICS AND INDUSTRY 4.0 GENERALLY, EPPM ASKED COMAU’S ACADEMY DIRECTOR EZIO FREGNAN ABOUT THE E.DO EXPERIENCE INITIATIVES, AND WHAT THEY MEAN FOR HUMANS AND ROBOTICS. HOW DID THE E.DO EXPERIENCES COME ABOUT AS AN OUTREACH INITIATIVE? Comau’s main asset is its people and their skills. Comau developed e.DO – a small, modular, versatile and interactive, open-source robot – to support and stimulate students’ involvement and creativity in school and extracurricular activities. Thanks to its technical characteristics and potential use in teaching, e.DO helps students learn STEM subjects in a simple, intuitive and entertaining way, and encourages them to explore robotics by acquiring basic operating and programming skills. Since 2017, over 6,000 primary and secondary pupils have attended learning centres featuring e.DO, organised by Comau in conjunction with schools and educational foundations. The success of pilot projects encouraged Comau to develop a teaching programme. There are now six different e.DO Experiences targeting the learning needs of different users. These are e.DO Learning Center, e.DO Learning Lab, e.DO Robotics Licenses, e.DO Programs, e.DO Events and e.DO Corner. All are based on the teaching method promoted by the Comau Academy and built around three fundamental concepts: Action Driven Content, Action Driven Relationships and Action Driven Learning. Respectively, and according to Comau’s experience and teaching method, all types and levels of skill can be learned: through formal or spontaneous acquisition
of content and notions; through social interaction and shared experiences; and through direct action or ‘learning by doing’. IN WHAT WAYS DO THEY BENEFIT COMMUNITIES, AS WELL AS THE BUSINESS, ECONOMY AND INDUSTRY? Thanks to global collaboration with leading technical institutes and universities, Comau provides a wide range of training courses. Since 2012, Comau has trained more than 12,000 people of all ages from all over the world, involving more than 320 subject matter experts from inside and outside the company. Moreover, the Comau Academy has provided technical and managerial training for employees for over forty years, and began tailoring the activities of its ‘Learning Factory’ to benefit customers outside the company. The Comau Academy now places its experience and knowhow at the disposal of others to promote the development of a ‘culture of automation’ among students, professionals, manufacturers, and public and private organisations. The academy’s training programmes help develop the technical and managerial capacity companies need to overcome challenges and seize opportunities, with particular reference to Industry 4.0 and digital transformation. HOW DOES COMAU ASSUAGE ANY FEARS THAT ROBOTICS IS ‘TAKING OVER’ FROM SKILLED MANUAL LABOURERS? Comau’s approach to Industry 4.0 – dubbed HUMANufacturing – describes the factory as a place where the operator is at the centre of the production system and works with robots and other industrial machines in a safe and synergistic way. Continuous technological innovation can help overcome new challenges that characterise Industry 4.0 and digital transformation, but this process
cannot overlook the value of people and their professional and cultural skills. Because, and only thanks to human experience, it’s possible to realise the technological solutions needed to achieve transformation and progress. Our e.DO Experiences fully reflect this vision, turning e.DO into a robotics ambassador. Robotics is fascinating technology capable of stimulating the curiosity and attention of students and enabling them to achieve learning targets more effectively. The use of robots in schools reinforces essential skills both in robotics and STEM subjects, and integrates them with soft skills and business culture in an interdisciplinary context. The e.DO Experience is an innovative platform that offers a pragmatic approach to subjectbased learning, reinforcing transversal skills, encouraging involvement and strengthening the link between academic and life skills in the real world. HOW MUCH MORE COULD THE TECHNOLOGY ADVANCE IN THE COMING DECADE, AND WHAT COULD THIS MEAN FOR THE FUTURE OF THE INDUSTRY? The world of robotics is experiencing a revolution equivalent to that seen in information technology in the 80s and 90s, when computers turned from sophisticated and complex machines into simple, accessible tools. Due to this revolution, Comau is committed to the development of a new and open industrial automation, characterised by the design of easyto-use products and systems. Until recently, robots have been considered difficult to operate and program without special skills. e.DO is conclusive proof that this is no longer the case and that robots can be used intuitively, even with younger children. We can look forward to a prosperous future for robotics, provided that we seize all the opportunities presented by innovative technologies and digital transformation.
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AUTOMATION AND ROBOTICS
PROCO MACHINERY UNVEILS NEW LAY-FLAT TOOLING ROBOT SYSTEMS PROCO MACHINERY HAS BEEN SERVING THE PLASTIC CONTAINER INDUSTRY FOR OVER 35 YEARS; A LEADING MANUFACTURER OF AUTOMATION SYSTEMS FOR THE BLOW MOULDING INDUSTRY, THE CANADA-BASED COMPANY SHARES ITS LAY-FLAT TOOLING EXPERTISE AND ITS USE OF ROBOTICS.
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roco Machinery Inc., a leading manufacturer of automation systems for the blow moulding industry, has launched a unique lay-flat packing technology which allows blow moulders to pack plastic bottles on their sides, as opposed to placing them with necks up or down. The new tooling technology makes innovative use of collaborative robot automation systems from Universal Robots, based in Boston, US. Proco Machinery is working closely with Universal Robots to offer a complete downstream automation solution for the blow moulding industry, according to Siva Krish, Vice President of Sales for Proco Machinery: “We have a very niche market, and we work with a lot of companies in the packaging industry that have complex manufacturing requirements.”
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Proco’s new lay-flat tooling innovation helps blow moulders and brand owners maximise product capacity for a given container. The company has developed two sets of tooling for two different applications – one for straight neck-toneck packaging in the box and another for offset neck orientation from row to row. This potentially allows a blow moulder of bottles to pack 270 bottles in a box instead of 250, resulting in maximised capacity and tremendous savings on freight cost. For Proco’s unique layflat system, the company designed a solution to counter the cobot’s inherent desire to resist force. “You need a small bit of clearance between the box and the bottle, so the tooling arm goes in and comes out,”
Krish explained. Ultimately, the design of the bottle determines how Proco customises the robot’s packing routine. “Every bottle and every pack count, and every production line will be completely different,” he added. The lay-flat technology gives blow moulders more flexibility and widens the scope of containers that can be packed automatically. The bottom line is that blow moulders and brand owners can benefit from an attractive ROI when incorporating Proco’s innovative lay-flat tooling technology. Proco Machinery has developed several options for packing bottles including a patent pending end-of-arm tooling specifically designed for PET bottle applications. Proco is incorporating collaborative robotic automation systems in a range of products, including its collaborative robotic ‘Half-Cube Palletizer’ system and the Robo Packer case packer. Both new products are attracting broad interest in the packaging market due to the need for greater efficiency and automation. These systems are being designed in such a way that they complement the production line and provide simplified operation, a smaller footprint, reduced bottle handling, and enhanced efficiencies. Proco Machinery, based in Mississauga, Ontario, has been serving the plastic container industry for over 35 years, providing labour-saving automated machinery and equipment throughout the US and Canada. The company manufactures a complete line of Robopik Take-out systems, Automatic Deflashers, Ultra Test Leak Testers, Flame Treaters, Dome Spin Trimmers, Robotic Packaging systems (case packers), and the Multipak Palletizer Packaging System.
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AUTOMATION AND ROBOTICS
MORETTO 4.0
F
ITALIAN AUTOMATED SYSTEMS PRODUCERS MORETTO S.P.A SHOW HOW LOOKING TO THE FUTURE HAS KEPT THEM AT THE CUTTING-EDGE OF DIGITAL INDUSTRIAL DEVELOPMENT.
or almost 40 years Moretto has researched, developed and produced automations for plastics processing. The result of continuous technological investment and innovation, Moretto’s solutions are distinguished by efficiency and low energy consumption, inspired by Industry 4.0, and based on respect for environmental needs. Injection, extrusion and PET processing are characterised by specific complexities and high levels of performance, in which production and energy efficiency play key roles. Moretto’s goal is to help the industry through knowhow, innovation and high-precision machines. At the heart of the Moretto R&D department and inspired by Leonardo da Vinci, the LEONARDO supercomputer develops simulations of mathematical calculation to finite elements, fluid dynamics, thermodynamics, electromagnetism and sound analysis. Equipped with Star-CCM+ software, a Siemens Industry Software developed by NASA and used in Formula 1, LEONARDO is a powerful installation allowing Moretto to expand its scientific knowledge by examining a wide range of physical phenomena, providing unprecedented support in the continuous development of the next generation of products. The Moretto 4.0 Project includes an impressive plan of expansion and production re-engineering. In 2017 Moretto made important acquisitions of production spaces and now has five factories and over 75,000m² of
production space in Padua, Italy. Work is underway to establish a new production area of 20,000m², which will host ‘Moretto of the Future’: a new training centre, showroom, and development hub for efficient production using digitalisation and advanced logistics. SMART MACHINES The Moretto 4.0 Project aims to combine technological and digital leadership to develop systems capable of automatically adapting output to the needs of the market, predicting breakages or downtime, and providing real-time remote support. These smart machines are required mainly by the automotive, medical and packaging sectors. The Moretto Object Windows Integrated Supervisor (Mowis 3), for example, is the advanced supervision and management system developed for the integrated control of the entire supply chain in plastics processing plants. It allows the interconnection of machines, processes and departments, and overcomes the limits of traditional supervision by adapting to the quality, production efficiency and management needs of each customer. With a modular software and unique, self-configurable interface that simplifies immediate factory status checks, Mowis 3 also features integrated management and global factory control; safe, direct and integrated data interchange; a unique, simple and self-configurable interface; material, finished product and batch traceability; IP automatic recognition; OPC UA technology; tailor-made solutions; and E-Service. Each Moretto product is designed and connected to Mowis. The ambitious Eureka Plus drying system, concluded after more than 15 years of research, studies, and simulations, has been described as the most advanced lowconsumption drying system available. Processors that have adopted it have enjoyed an average 56 per cent reduction in energy consumption compared to conventional drying systems.
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The Moisture Meter Manager (MMM) marks a genuine Industry 4.0 revolution in drying processes. A unique, in-line, resin moisture sensing and drying system control, which guarantees production certification with maximum energy efficiency, MMM is absolutely accurate due to the exclusive ‘Power Peak technology’. The delta measurement between initial and final moisture of the granule in the hopper’s inlet and outlet allows the system to manage the dryer’s working conditions, maximising process performance. By targeting granule moisture levels and handling internal and environmental variables, the MMM creates an on-demand drying process and scans the material every two seconds to provide grain quality reports with regular frequencies for each piece or sample. Another example of exclusive 4.0 patented Moretto technology is KruiseKontrol, a device which manages the material speed in conveying systems, eliminating angel hair, dust, friction stresses and pipeline wear. Moretto introduced KruiseKontrol in 2008 and received much criticism from competitors, in 2017, however, and following a lawsuit brought by a German brand that had opposed the patent, KruiseKontrol was recognised by the EPO as “the only automatic and intelligent plastic material conveying system in the world”. Capable of automatically adjusting the transport conditions for various plastic materials, KruiseKontrol guides the granule to the target destination at optimum speed. Moretto looks to the future by investing in innovation, energy saving and sustainable projects. The intent is to sublimate the irreplaceable raw material and focus on eco-sustainable activities and new materials. The Be Tomorrow Project, developed to foster environmental awareness, information and responsibility, is a long-term project oriented to safeguard the world of tomorrow for our children.
CLASSIFIEDS
JAN/FEB 2019
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3D PRINTING INNOVATO MATERIAL RS AND S SCIENCE COLLABO GIANTS RATE TO PUSH BOUNDAR IES
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COLUMN
EUREKA Dr Fanya Ismail, Founder and CEO of SGMA, Sol-Gel Coatings and Advanced Materials, has created a coating for food and drink packaging that removes the need for plastic. Ismail has created environmentally friendly coffee cups with smart coatings using the sol-gel process, which is used to make disposable coffee cups waterproof without plastic. Ismail, who is originally from Kurdistan, is now working with some of the largest coffee cup manufacturers in the world to implement this. Having studied chemistry in the Kurdistan Region, Ismail earned her Master’s degree and PhD at the University of Manchester. As part of its ‘Women in Innovation’ campaign, she was one of nine women to win funding from Innovate UK. Speaking to The Manufacturer, Ismail said: “The sol-gel technology is well-known in both industry and academia. What makes our technology
HAVING STUDIED CHEMISTRY IN KURDISTAN, DR FANYA ISMAIL EARNED HER MASTER’S DEGREE AND PHD AT THE UNIVERSITY OF MANCHESTER, UK. NOW FOUNDER AND CEO OF SGMA, ISMAIL HAS CREATED A COATING THAT MAKES PACKAGING WATERPROOF WITHOUT PLASTIC.
Dr Fanya Ismail, Founder and CEO of SGMA, Sol-Gel Coatings and Advanced Materials
different is that we introduce materials at a molecular model which makes the end product unique; it has never been done before.”
UK-BASED ENTREPRENEUR CREATES COATING THAT NEGATES THE NEED FOR PLASTIC
SOL-GEL SISTER The barriers affecting the growth of sol-gel may be due to the fact that it is still not treated as a technology and is often overshadowed by the developing interest in nanotechnology. “There has been a lack of
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investment in researching the basic science resulting in diluted benefits, imposed limitations on current applications and restricting the future full potential of this technology,” Ismail continued. “Despite the draw-backs and lack of recognition, the future of industry might see an increase in the visibility of sol-gel in the worldwide technological arena … Aspects such as fast-cured
materials and functionalised additives, along with multifunctional coatings and sol-gel-based products that could be used as a single step solution in industrial assemblies, may well be the main drive to witness increased visibility.” If more women took part in entrepreneurial activity, more than £180bn (~€210bn) could be delivered to Britain’s economy, according to a Deloitte survey. The Women in Innovation campaign began in 2016 when Innovate UK revealed that just one in seven applications for funding came from women. “The manufacturing and chemical industries are male-dominated,” Ismail said. “When you go to any event, if you just look around you can count the number of women. Many entrepreneurs give up, especially females, because they don’t feel confident; my confidence came because of my expertise.”
What makes our technology different is that we introduce materials at a molecular model which makes the end product unique; it has never been done before.
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STONE ISLAND Stone Island collection embraces the world’s natural wonders with earthy and enigmatic tones evocative of lush forests, deep canyons, vast deserts and mystical caves. New technologies push consumers to a narrow, chaotic lifestyle with less time to interact with each other and the diverse natural world. Connecting with the tangible beauty of the outdoors and disconnecting from the intangible digital world is essential for happiness, well-being and a quality life. The grounded and mysterious colors and solid, darker striations of this collection play into our fascination with the exotic and wild aspects of nature.
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