EPPM 14.2

March 2012

Volume 14 | Issue 02

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MACHINERY

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SHOWCASE: EXTRUSION

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SPOTLIGHT: AUTOMATION & ROBOTICS SPOTLIGHT: PROCESS CONTROL & MONITORING

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MATERIALS

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SHOWCASE: MEDICAL POLYMERS

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EVENTS - NPE PREVIEW

pages 24–29

A look ahead at what’s in store in Orlando

THE GREEN ROOM

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REGULARS: Latest news roundup Industry news

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SHOWCASE: BIOPOLYMERS

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CLASSIFIEDS

pages 34–35 EPPM 3

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EPPM 4

John Ellis, Segment Manager Polycarbonate, Bayer MaterialScience

Clive Maier, Owner and Director, Econology Ltd.

Aerospace Biopolymers

Alex Collins, Director, Vannplastics Ltd.

Sourcing & Manufacturing

Andrew McArthur, Engineering Manager, IKO

Nigel Brown, Founding MD, Frontier Aerospace

Dr Martin Kay, Chief Consultant, Pira International

Jan Herring, Strategic Sourcing Leader, Nokia

Charmaine Bowers, Operations Manager, Polymer Training & Innovation Centre

Pipe Extrusion Recycling Micro Manufacturing Automotives & Compounds Home Appliances

Graeme Diston, Senior Injection Moulding Engineer, Bausch + Lomb

Mark Bonifacio, President, Bonifacio Consulting Services

Andy Bone, Sales Director, Formaplex

Andrew Smith, Head of Manufacturing, Numatic International

Wire & Cable

Simon Chidgey, Director, M&H Plastics

Jonathon Short, MD, ECO Plastics Ltd.

Jon Herbert, Director, FS Cables

Biopolymers/Materials Science

Paul Maley, Senior Mechanical Engineer, Selex Elsag

General Industry Insight

Martin Marron, MD, Biffa Polymers

James Goddard, Honorary Lifetime Member, Plastics Pipe Institute

Dr Terence A. Cooper, CEO, ARGO Group International

Ken Braney, 2010-2011 President, Society of Plastics Engineers

Advisor for the German & Scandinavian Speaking Countries

Film & Sheet Extrusion Recycling Mould Making Packaging

Barry Assheton, Sales Director, CRDM

Graham Pickwell, Technical Adviser, Polymer Training & Innovation Centre

Medical

Injection Moulding Recycling Blow Moulding

John Bunker, Member, Worshipful Company of Horners

Medical

Rapid Prototyping

Omer Kutluoglu, CEO, 2K Manufacturing

Education in the UK & Ireland

David Gray, Editor

John Sturgess, Director, MG Stuma

Andrew Feilden, Principle Consultant, Smithers Rapra

Construction

NPE 2012 — located in Orlando for the first time — has been marketed by its organisers as ‘The Return of the Machines’. This (slightly ominoussounding) title suggests that, if nothing else, NPE will be noisy.

At Fakuma last year, much to the amusement of my colleagues, I dabbled in video journalism — never again.

Trying to capture decent audio on an interview with a technician or engineer is hard work when they’re demonstrating the latest (and very loud) incarnation of a manufacturing cell, complete with integrated automation and the parts produced falling in their hundreds into a cardboard bin on the floor. Add to this two dozen people gathered round discussing the merits of the machine, and a neighbouring company on the next stand with an equally large, equally loud demonstration, and you’ve got yourself five minutes of footage which requires the viewer to be trained in lip-reading for maximum enjoyment.

So yes, it’s safe to say NPE will be noisy, with a substantial increase of live machinery demos predicted by the SPI. But from the hundreds of press releases I’ve received since January, the quality of the demonstrations will be well worth the requirement to shout for much of your visit.

The Wittmann Battenfeld booth will be larger and more diverse than in 2009, including six integrated turnkey moulding cells up to 1,000 tonnes, complete with robots, temperature controllers, dryers, loaders, and downstream automation, along with web-based support service.

Engel has reported that it will display 33 per cent more equipment this year. Engel North America President Mark Sankovitch said: “All of our equipment at NPE 2012 will be in operation, including part moulding, downstream processing, and automated part handling. A machine in operation allows visitors to see for themselves that the specifications quoted — cycle times, energy usage, and so forth — are achievable in operation, not just on paper.”

Sumitomo Demag brought only three machines to NPE 2009 but will be exhibiting twelve at NPE 2012, all of them running. “We’re making a major investment in NPE2012 because of the improved economy, everything Orlando has to offer and the need for our industry to come together and strengthen its capabilities,” said Jim Mitchell, Executive Vice President.

So that’s a small selection of some of the ‘celebrities’ of the show. But we’ve covered as many of the key exhibits as we possibly can in our preview, starting on page 24. I hope you find this issue helpful when you’re at NPE — the magazine will be on-site at the entrance and on the EPPM stand (10062) so make sure you drop in and pay us a visit!

Wood Plastic Composites

Welcome to the NPE Special Edition...

Plastics for the Environment

from the editor

General Industry Insight

“

Our Editorial Advisory Board is compiled of a cross-section of the plastics industry, including processors, consultants, technicians and key industry figures.

Dr Gerd Schmaucks, Independent Consultant

cover story

IPR – The PET Machinery Specialist Continues to Diversify Internationally UK-based International PET Resales (IPR) has supplied PET machinery, consultancy services and moulds to 104 countries at the last count. Over the years — and the directors have been specialists in PET now for something like 20 years — they have witnessed boom cycles from various regions, from the old Soviet Union, the Balkans, the Middle East and Asia.

“Recently we have seen renewed interest from South America”, said Van Bommel, IPR’s Spain-based Sales Director “but our principal business remains in Europe where we have developed integral relationships with nearly all the main manufacturers”.

That said, the marketplace for the PET container and beverage market in Europe is now very mature and so IPR has had to be increasingly creative in order to achieve new sales.

Examples of this include targeting specialist container manufacturers such as their recent investment in shot bottle tooling and partnering with blow moulders and end-users to supply the emerging nutraceutical business.

“One such customer”, said IPR Technical Director, Kevin Gallagher, “is Dragon Nutrition, an arm of J Donohoe Beverages of Enniscorthy in Ireland, who have developed an award winning range of shot bottles, known as ‘Little Dragon’ that aspires to provide targeted supplement drinks for sports and health conscious individuals”.

Another example would be a turn-key project which the group has recently undertaken for Complete Core Business Solutions of Abercynon, South Wales. In this case, PET Resales supplied the blow moulding equipment, the preforms and the caps to develop a specialist container to dispense a formulated salt based product known as Ezi-Melt.

Other projects in the pipeline include the hole-in wall supply of wide mouth container blowers (new and used) to protein powder manufacturers, whereby the group set up the manufacturers with the equipment to blow wide mouth containers, and deliver the preforms and caps on amortised supply contracts — and in so doing cut down on the logistical costs of transporting large containers whilst allowing the customer to have ‘switch-on, switch-off capacity’.

IPR will have a booth at NPE in Orlando this year (Booth 8945, West Hall Level 2) to introduce its container solutions to the North and South American marketplace.

IPR have developed integral relationships with nearly all the main manufacturers and many converters worldwide.

Packaging and the bottling industry is a particularly large market for IPR.

“NPE is an ideal base to meet up with our clients from Central and South America and we have several meetings lined up and one contract to ink with an established customer in Colombia”, said Commercial Director, Anthony Thompson.

“Outside of the UK, and to some extent Europe, our challenge is the financing of such hole-in-wall projects as we can only manage a finite number of partnerships, and so we are seeking a financial backer or institution that has appetite for these type of assetbased lends, which is no easy feat in the current market”, said Thompson.

Aside traditional dealer sales, and the aforementioned foray into specialist container manufacture, IPR has increasingly become involved in selling machinery via on-line auction platforms and private treaties.

“Partnering with on-line auction outfits was a natural next step for us”, said Thompson, “fostered by the belief that we knew we could do a lot better than most of the companies that have tried (and in the main failed) to sell PET equipment successfully via this route”.

“We started out years ago as disposal agents for insolvency practitioners here in the UK and so have always been familiar with the requirements and processes of controlled disposals” said Gallagher. That experience enabled the Directors to secure a contract with Schmalbach-Lubeca to clear from site the assets from its acquired Johnson Controls facilities in the USA and Europe.

“No mean feat, as there were multiple sites to clear and a tight schedule” said Gallagher. “In fact I recall taking a flight a day for a month just to see all the sites”.

That experience is paying dividends in the present as IPR presses on with the auction sales for clients in Sweden and Ireland, and is in advanced discussions with finance companies to extend their modus operandi.

“Clients benefit because we can offer a service to accurately evaluate their machinery pre-sale, and assuming we get the go-ahead, we send in a team to

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disconnect, remove and load up machinery. We can effectively undertake a complete sweep-clean operation so that the building can be reinstated for the property landlord, or positioned for resale” said van Bommel.

Thompson continued: “As an established international trading company we also have the technical competency to ship machinery around the globe and manage the sometimes complex fiscal transactions involving letters of credit and the like. You have to appreciate that we have been doing this sort of thing for a number of years so it is nothing new, only the advertisement of this fact is new as we look to raise our profile”.

International PET Resales Ltd. Tel: +44 845 128 5501 Tel: +34 676 986962 (Spain) Email : sales@petmachinery.com Web : www.petmachinery.com

MACHINERY

Single Minute Exchange of Dies (SMED) Drives Demand for Automated Mould Transfer Systems A key element in achieving Single Minute Exchange of Dies (SMED) is the speed at which moulds can be transferred to the moulding machine. Mould transfer systems provide fast, economical and safe handling methods for all sizes of mould. Speeding up mould changes often represents one of the best opportunities to increase the flexibility, productivity and, most importantly, the profitability of the moulding shop.

Stäubli, the specialist in quick mould change solutions and clamping systems, also manufactures mould transfer systems, suitable for all applications from lightweight moulds producing small electrical components through to large heavy moulds typically used for car bumpers or dashboards; significant reductions in changeover times have been achieved using transfer systems, in some applications by over 70 percent, even where quick mould change systems have already been installed.

Transfer tables and systems can be tailored to all types of application, they are not just suited to the heaviest larger moulds but do frequently provide an efficient and effective system for handling smaller moulds too.

Mobile systems can provide service to a number of machines or be dedicated to a single machine; operation can be manual or automatic, each designed to match with the existing workshop layout, work practices and tooling.

All Stäubli transfer systems are fitted with roller tables to easily move the mould either manually or power driven,

eliminating the handling problems commonly encountered with moulds, improving operator safety and protecting moulds and their connectors from damage. Incorporating a mould preheating station in the changeover cycle further reduces changeover time.

A very cost effective layout is positioning one transfer system between two machines; the two-directional loading table serves both machines and provides maximum flexibility and efficiency for each production cell.

Where automatic mould changing is required then positioning a transfer system on each side of a machine is ideal and provides the fastest method of mould changing. On one side, the mould from the previous production run is unloaded, while simultaneously on the opposite side the new mould is loaded.

A further step towards complete automation, that is often included in new

installations, is the use of rail carts; a rail mounted loading/unloading table transfers moulds from the storage area direct to the moulding machine incorporating, if required, a preheating station. Rail carts can service several or even an entire line of machines. More versatile are moveable carts permitting free movement of moulds between several machines and storage areas.

Adjustable height mechanisms built into the cart ensure adaptability to different machines or storage areas while mould locking devices on the cart ensure safe and secure transfer.

Maintenance and repair of moulds also needs to be fast and efficient to avoid production delays. Within Stäubli’s range are maintenance stations fitted with turnover mechanisms that provide a safe and secure platform, holding the mould in the correct position for the work required.

Stäubli specialises in mould handling, clamping and connection solutions with years of experience analysing the critical parameters that need to be considered at each stage to reduce mould changeover times to a minimum. As manufacturers of all of the connection and clamping products needed to reduce mould change times as well as mould transfer systems, the group is ideally placed to objectively analyse requirements and recommend the best solution. Stäubli’s team expertise and knowledge is available right from the initial design stage onwards to ensure that the installed systems are effective, easy to use and will only require minimum maintenance.

Stäubli Connectors Division Tel: +44 1952 671918 Email: connectors.uk@staubli.com Web: www.staubli.com

Universal Converting Equipment Cuts Energy Use in Slitter/Rewinders UK group Universal Converting Equipment has introduced a package of energy consumption reducing features into its range of slitting and winding machinery.

Technical Director, Dave Ward, explained: “We design our machinery to be as frugal as possible with energy and have identified significant areas where energy savings can be made: in some cases functionality and performance has been increased as a positive side effect. One of the ways we achieve this saving is by using the latest high efficiency (Efficiency 1) AC motors, with the most up to date AC Vector Drives. Commonly we design regenerative motors rather than more traditional pneumatic brakes so rather than braking energy being lost (as heat) it is turned into electricity and used by other systems within the machine. In EPPM 6

some applications the brake energy is enough to reduce power consumption of the machine by 40 percent or more. Our machines intelligently turn off unused systems (how often do you walk past machines with hydraulic packs (sometimes on guiders) that are running whether the machine is in use or not) and avoids fan systems that run even when not required. Wherever possible we have engineered hydraulic systems out of our equipment. Even our touch screens are set to go into power save mode when not used for a period.”

Universal Converting Equipment Tel: +44 1473 403333 Email: info@universalconvertingequipment.com Web: www.universalconvertingequipment.com

MACHINERY ROUNDUP Arburg Trials Video Recording of Production Set-Up to Find Time Savings When it comes to setting up machines and systems, much is often done “as it always has been”. This means that habitual behaviours are propagated, even though it would perhaps be better and faster if done differently. In order to identify and subsequently implement optimisation measures for daily work, video analysis of set-up processes can prove useful according to German injection moulding specialist, Arburg.

An important aspect here is that employees are not criticised, but are brought on board to benefit from their extensive specialist knowledge. This allows potential improvements to be identified, which help to not only speed-up, but also facilitate set-up work.

Arburg is one of the first companies to incorporate this method of analysis in its production environment and is working extremely successfully with video analysis in order to further enhance production efficiency. Use of this investigative method began back in 2010, with selected groups within the production department receiving preliminary basic training in the use of video analysis. On a selected day, the video films were first shot with external assistance and subsequently given a systematic evaluation. Workshops on set-up time optimisation were first held in production before being extended to various sectors in assembly. Between five and six employees are invited to take part in each session: at least two operators, managers and production planners. The two operators then team up for the actual compilation of the analysis video. One films what the other is currently doing. This material then forms the basis for analysis and subsequent development of appropriate activities. The agreed steps are more likely to be put into practice when video analysis is used than without this audiovisual aid. When the films are screened, many otherwise unnoticed things become apparent.

Video recording of all the processes is particularly important for the introduction of SMED or “Single Minute Exchange of Die”, which aims at performing die changes within singledigit minute times. The objective of this process for the reduction of set-up times with regard to production machines or production lines (including material provision or parameterisation of the production units etc.), is to minimise plant downtime over the long term.

For this purpose, it may be necessary to carry out sequentially-performed processes simultaneously. Here, video recording and evaluation can provide valuable assistance. Once the videos have been shot, the set-up operations are analysed during a discussion between the operators and their line manager on the basis of the filmed images. Torsten Schmid from Production Planning at Arburg, places particular emphasis on the spontaneous nature of this exchange: “Many ideas are a direct result of these discussions. Most of them come from the operators themselves. This effectively weakens arguments like: ‘but we’ve always done it this way’.”

Eight of the 14 intended workshops

have already taken place. At these, the operators' initial scepticism gave way to an overwhelmingly positive assessment of the results. The Rotational Production, Non-cutting Production (Coating and Sheet Metal Processing), Grinding and Special Machines departments have already worked with video analysis. Cubic Production and Assembly are set to follow.

Arburg Tel: +49 7446 330 Email: contact@arburg.com Web: www.arburg.com

Shooting the process on location: while Emanuel Armbruster's actions (centre) are filmed during work, Torsten Schmid (left), and Reiner Huss explain the processes.

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MACHINERY ROUNDUP Glaroform Teams up with Beck Automation for In-Mould Labelling Technology Swiss IML (In-Mould-Labelling) specialist Beck Automation AG and mould specialist Glaroform AG teamed up recently to demonstrate the manufacture of thin-walled cups of highly transparent polystyrene decorated on both sides.

Beck offers users of IML a QA inspection module with camera supervision.

The high speed of the automated equipment was the result of the interaction of a production cell consisting of a Ferromatik Milacron F160 machine and a mould made by Glaroform. The F160 was filling the 4impression Glaroform mould with a shot weight of 41 g. Each thin-walled cup had a wall thickness of 0.5 mm and weighs 10.25 g.

Glaroform injection moulds are designed by the company's experienced specialists who pay attention to maximum cooling near the contours to achieve short cycle times. Special tooling steels suitable for high-gloss and high-quality polishing are used for these IML thin-wall applications. The fully balanced and thermally tuned hotrunner system developed by Glaroform resulted in a remarkably high shot-weight repetition accuracy. The detail of the mould was also impressive, and attention had been paid to ease of handling. Urs Harder, Sales Manager of Glaroform, commented: “With this in mind we use low-wear and selflubricating sliding and guide elements.

Apart from this we take care to optimally centre the mould parts and make them

readily accessible. The highly stable and rugged execution of the entire mould guarantees a high availability and a very long useful life.”

The Beck automation unit fed the labels from the label magazines horizontally, inserting them from the side in the cavities and removing the finished cups from the mould. The system then stacks

the cups on a conveyor. Beck Automation developed for the first time a ‘reject’ switch which can be integrated together with the camera inspection module or on an IML system. The QA module automatically detects and separates any nonconforming products from the flow of good parts. The big advantage of this system is that only the

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one “bad part” has to be separated, and not the complete shot. When necessary the system can easily be changed over to other IML parts or another set.

Glaroform AG Tel: +41 55 618 45 30 Email: info@glaroform.ch Web: www.glaroform.ch

MACHINERY ROUNDUP New Needle Valve Range for Injection Moulding

The new needle valve range Z107900/… from hot runner specialist Hasco features “the latest sealing developments and a rugged adjusting mechanism” according to the company.

The specifications for developing the new components focused on ease of assembly, service-friendly operation, a high level of flexibility and modular design. As a result, the amount of maintenance for the customer has reportedly been reduced to a minimum.

The modularity of the sub–assemblies guarantees optimum availability of the individual components. Every drive unit is equipped with a special adjusting mechanism that balances out the centre misalignment through heat expansion.

Needle assembly is also very easy and is carried out from outside via the platen.

The subsequent fine adjustment of the needle position when warm, is performed with a conventional screwdriver.

For the hydraulic operation, two different housing variants have been produced, each in three sizes and two stroke lengths for different needle diameters.

Z107900/… is intended for integration into the platen and contains the plunger and a housing with correspondingly high surface quality for the desired freedom from leakage.

This inner plunger together with the adjusting mechanism is also used for the second housing variant Z107920/… as a flange version on the hot runner, in combination with a spacer and cooling plate. This allows fully wired and piped systems to be produced. Opening of the hydraulic system for assembly/dismantling of the valve needles is not necessary with either system. Consequently, the conditions are always clean in the event of servicing or repair.

The pneumatic drive solution Z107910/... has a built-in cylinder in the clamping plate, and also uses the modular interior components for the adjusting mechanism. The units are available in four sizes with different needle diameters and variable stroke. In addition, the possibility exists with this design to block the plunger with a locking edge washer. Should a cavity become defective, the individual cavity can thus be closed down without interrupting the entire production process.

The new needle valve range is rounded off by an extensive selection of accessories, e.g. new spacers for heat insulation, high-precision valve needles and valve needle guides to seal off against the melt stream.

Thermal Diffusivity Measurement Service Goes Online Independent Materials testing laboratory Gammadot Rheology has refurbished its Rapra-developed Thermal Diffusivity apparatus with a view to bringing the measurement service online by the end of the month.

The equipment provides thermal diffusivity data as a function of temperature in both the solid and melt phase (temperature range: -50°C to 350°C), though the aim is to further expand its capabilities to enable the direct measurement of thermal conductivity by the end of the year, (thermal conductivity is currently

calculated from the relationship of thermal diffusivity, specific heat capacity and density).

The apparatus will become a key part of Gammadot Rheology’s flow simulation data production suite, providing accurate thermal data across a wide temperature range for use in injection moulding simulation packages such as Moldflow, Moldex3D and Sigmasoft3D. Gammadot Tel: +44 1939 291677 Email: enquiries@gammadot.com Web: www.gammadot.com

Hasco Tel: +49 2351 957 503 Email: alampe@hasco.com Web: www.hasco.com EPPM 9

MACHINERY ROUNDUP Battenfeld-Cincinnati Saving Energy All Along the Line In pipe, profile, sheet and film extrusion, the energy costs constitute three to five per cent of the total costs, and consequently they are often the decisive factor in the cost-efficiency of the process. The extruder itself is considered the largest energy user in every extrusion line. This is why Austrian extrusion specialist, battenfeld-cincinnati, has reportedly equipped all of its extruders with maintenance-free, energy-efficient AC motors as standard. Tests have shown that torque motors offer a further increase in efficiency thanks to their high performance coefficient. This concept is already being applied in modern highspeed extruders. It should be remembered though that the operating range is a decisive factor for both motor types. The nominal operating point where the drive yields its maximum efficiency should always be targeted.

Optimised screw geometries for every application also contribute to saving energy on the extruder, as does tempering of the processing unit. Here, the machine manufacturer relies on concepts that are highly flexible, provide excellent contact with the barrel and offer a large surface for optimised heat dissipation.

However, optimising only the extruder is not sufficient for sustainable energy consumption cuts on the entire extrusion line. So battenfeld-cincinnati offers an energy monitoring system to ascertain exactly how much energy each component of a complete line consumes. The system measures all

energy flows in the line and compiles an energy distribution chart. Thus processors get an accurate overview of how much energy is being consumed at each point. This enables reliable comparisons on the basis of which practicable energy saving measures can be devised so that the production process becomes more efficient.

In other news, the first die from a new PVC extrusion die series made by battenfeldcincinnati has impressed its long-standing customer InstalPlast Lask of Poland, with an improvement in pipe quality. After the leading pipe manufacturer had tested the prototype of the spider 200-3 die for six months, they decided to buy it because of the enormous benefits. “We have now been using the new die in regular production for three months and are extremely satisfied with the significant advantages compared to the feedblock-die combination we used previously. Its easy handling attributes together with optimal pipe quality are particularly impressive,� Robert Stasiak, Managing Director of InstalPlast summed up.

InstalPlast has been using the new die to produce 3-layer foam core pipes ranging from 32 to 200 mm in diameter on an existing co-extrusion line. In this line with its two reliable parallel twin-screw extruders from battenfeld-cincinnati, the new spider 200-3 die has replaced the feedblock-and-standard-die combination used previously.

The design of the new die is really something out of the ordinary.

Regardless of their viscosity, the two melts for the inner and middle layers are both fed into it centrally via a newly

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developed distribution system. In contrast to conventional dies, where the melt for only one layer could be fed in centrally, this is now possible for two layers for the very first time. Only the melt for the outer layer is fed in laterally via a side-fed distributor laid out as a coat-hanger model. To compensate for differences in viscosity, the outer layer can be centered separately from the other layers of melt.

Battenfeld-Cincinnati Tel: +43 1 61006 128 Email: steger.c@battenfeldcincinnati.com Web: www.battenfeld-cincinnati.com

SHOW

EXTRUSION Fast Roll Change Brings Flexibility to Sheet Production Recently a polyolefin sheet manufacturer took the decision to purchase its third PE/PP sheet extrusion line from battenfeld-cincinnati of Austria. The highlight of this equipment, which has just been commissioned, is a polishing stack with a high-speed roll change device, which gives the sheet manufacturer more flexibility.

The processor specialises in the

production of PE and PP sheet with thicknesses ranging from 1 to 15 mm, which is mainly used for thermoforming applications. For example, wheel cases or other casing parts for the automotive industry are made from this sheet, as well as sandboxes and plant containers for gardening and leisure-time activities, and transport equipment and technical parts for the packaging industry. The

client uses extrusion lines from battenfeld-cincinnati to produce the sheet. With these, the sheet is extruded in widths of up to 1,700 mm, partly in multi-layer versions.

At the customer’s request, battenfeldcincinnati equipped the newest line, which was installed in Autumn 2011, with a special polishing stack for high-speed roll change. Thanks to the fast roll

change system, the time required for product change-over has now been halved compared to conventional systems. Surface treatments such as matte finish or leather graining can now also be applied much more efficiently.

Another important aspect in sheet production is ensuring gentle and homogeneous plasticising. In this line, this is taken care of by a 120 mm single-screw extruder equipped with a barrier screw with mixing section. The

TransXL Adds to Range with 240 for Sale TransXL International Limited, one of the largest used sheet line dealers in Europe, has recently purchased a 2400 mm Kuhne/Reifenhauser Co extrusion sheet line to add to its extensive range of sheet lines currently available for sale ex-works from Swindon UK. The 2400 mm line is ideally suited for the manufacture of ABS, PS and PE, with sheet thickness ranging up to 12 mm thick. The end products would be typically used for thermoforming applications both for the sanitary and automotive markets, but can be used in other markets. The line is fitted with a gear pump, thus giving greater quality and dimensional stability to the finished product.

This line was strategically purchased to replace the 2300 mm Welex line which was sold at the begining of the year. TransXL continues to offer a wide range of sheet lines with widths ranging from from 650 mm to 2400 mm.

The line comprises: • 150 mm Kuhne main extruder • 33D vented, Maag square type 703 melt pump

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WCASE

EXTRUSION New Line For Thin Wall Micro-Bore Tubing and Fine Wire Jacketing Applications

1-120-35B extruder also comes with a screen changer, melt pump and compounding device. The line speed of 300400 kg/h can be reached in processing virgin material as well as 100 percent reclaim from the thermoforming process. battenfeld-cincinnati Tel: +43 1 61006-293 Email: lebic.j@battenfeldcincinnati.com Web: www.battenfeld-cincinnati.com

At the recent MD&M show in Anaheim, USA, extrusion equipment group, American Kuhne, featured a running microextrusion line including its 13 mm gearless modular microextruder with pressure control, B&H Tool BH25 MicroCrosshead with spiral deflector, three foot precision water bath, Conair Medline puller/cutter and Zumbach ID/OD/WALL system. The system

included American Kuhne’s newest AKcess Level II control system which incorporates a 19-inch widescreen that can be mounted anywhere on the line.

The AKcess Level II control system features 3D graphics and includes mobile access via iPhone, iPad, Android and other tablet devices.

American Kuhne offers modular extruders that enable barrel and screw

00 mm Sheet Extrusion Line

• 48 mm Kuhne single screw coextruder • 2300 mm wide die head • 2400 mm x 510 mm Reifenhauser type Mirex-W 3 roll stack • Kelviplast temperature control units • Cooling conveyor with edge trim knifes • Cooling table support/elevating device • 2400 mm wide haul off • Discharge table Transxl International Ltd Tel: +44 1793 827666 Email: sales@transxl.co.uk Web: www.transxl.co.uk

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modules to be changed quickly and easily. Modular Microextruders are offered in 13 mm and 16 mm sizes.

American Kuhne Tel: +1 401 326 6205 Email: smaxson@americankuhne.com Web: www.americankuhne.com

MATERIALS SPOTLIGHT eppm

AUTOMATION & ROBOTICS

Engel Austria is celebrating the A THOUSAND delivery of its ENGEL VIPER 1,000th viper robot. In ROBOTS NOW future, the IN USE robot will be used to handle inserts and prefabricated parts in hybrid applications at Seletec Plastics Products in the Austrian town of Uttendorf.

Seletec has been using injection moulding machines from Engel since the 1980s, with the focus switching to automation in its new projects. That’s why an Engel viper 40, the anniversary edition robot, was delivered to the Pinzgau region as part of a complete package that includes an Engel duo 650 injection moulding machine. “With pressure continuing to build on costs, those of us in western Europe can no longer afford to work without automation”, said Gerald Rauch, Head of Sales and Development at Seletec.

“Automation guarantees stable processes, which raises productivity and enhances our production quality.”

The new large-scale machine will be used to make technical parts for a wide range of application fields, including housing components with metal

The thousandth Engel viper robot is handed over.

An Engel Viper robot in action. threads. “When several inserts are placed into a mould at once, the speed of the robot is what counts”, stressed Rauch. “We also look for fast cycle times and maximum precision in our handling operations.”

The Engel viper robot is the ideal machine for these requirements thanks

to its innovative software packages: vibration control, mass identification and efficiency control. These software packages eliminate the structure-borne vibration of the robots — even with longer axis dimensions — and optimise their movement and dynamic values.

This ensures high tracking and

EPPM 14

positional accuracy and minimises cycle times. The viper robot also adjusts its movements to the respective manipulation weight and avoids unnecessary wait times outside of the machine.

Since Engel supplies both injection moulding machines and robots, full integration of the two control environments is offered. “Operating the robot is simplicity itself”, said Rauch.

“Our staff were comfortable with the new system by the second day of training — they can control the robot using the familiar commands on the machine itself.”

Engel viper robots are available in six sizes with nominal load-bearing capacities of six to 90 kg. Since the viper series was launched, Engel has significantly increased its sales in the field of linear robots. This is partly due to the fact that the linear machines are sold not only in a package with injection moulding machines, but also as replacements for old equipment or use with injection moulding machines of other brands.

Engel Tel: +43 50 620 0 Email: sales@engel.at Web: www.engel.at

MACHINERY SPOTLIGHT eppm

PROCESS CONTROL & MONITORING

Film extrusion machinery group Brückner Servtec’s BIRT software MMS EXCELLENCE (Manufacturing AWARD FOR Management BRÜCKNER System) SERVTEC’S MMS received the “BIRT Excellence Award” at the recent Actuate Customer Day in Frankfurt, Germany, in the

Manufacturing category. BIRT is an opensource-software project for the development of reporting and businessintelligence applications. Participants of the project are, among others, IBM and Actuate Corporation. The panel appreciated the innovative application, developed by Brückner Servtec, which provides decision makers with selected Key Performance Indicators (KPIs) of production plants. These KPIs are available on mobile devices such as the iPhone and iPad. The award is presented to companies with outstanding solutions

in business reporting and performance management.

Within his presentation “KPIs on smartphones — trend or necessity?”, followed by a live demo session, Wolfgang Zintz, MMS Key Account Manager at Brückner Servtec, focused on the advantages and benefits of the solution in a real customer situation. Zintz concluded that due to the fast worldwide development of mobile applications, production data on smart phones or tablet PCs will neither be a trend nor a necessity, but simply a matter of course.

Wolfgang Zintz, MMS Key Account Manager Brückner Servtec (left), accepted the BIRT Excellence Award from Pete Cittadini, CEO Actuate (right), for the innovative MMS application.

The global film industry faces new challenges in the trade-off between price transparency, small lot sizes, short delivery times and increasing output of modern stretching lines.

Nowadays, the permanent availability of reliable data becomes a must in efficient decision making.

Brückner Servtec GmbH Tel: +49 8662 63 9252 Email: annemarie.heigl@brueckner.com Web: www.brueckner.com US moulding group RJG’s advanced NEW CONTROL process SYSTEM FROM monitoring THE STATES and control NOW BOASTS system has been USER-FRIENDLY modified INTERFACE and is now even simpler to use, according to the company. The new touchscreen friendly eDART interface still enables the user to minimise the inherent process variation that is common in moulding facilities and allows production of repeatable parts with superior quality.

By controlling the process and implementing part containment, RJG says that users can guarantee that no bad parts will be shipped to customers.

Some key advantages of the eDART System are: • Digital smart sensors • Simplified graphical analysis • Part containment to ensure no bad parts ship to the customer • Faster sample rates, all-owing for real time operation • Single unit or networking ability The new eDART System will be available for viewing at NPE 2012, on booth 2883.

RJG Tel: +1 231 947 3111 Email: kara.eskeli@rjginc.com Web: www.rjginc.com EPPM 16

Industry News

Printing Machine Group Kammann to Hold 2012 Open-House in New Headquarters Many readers will remember printing machinery specialist Kammann’s 2010 Open-House event. In the mean time another two years filled with intensive development work have passed and Kammann has now announced its 2012 Open-House which is to be held from April 16-20 2012 at the group’s new headquarters in Bad Oeynhausen, Germany.

In 2010 the K15 CNC series was presented the first time to visitors from the glass and plastic container industry.

Many of these visitors are now reportedly using this technology to great effect. According to Kammann, customers are able to take advantage of its capabilities and generate profitable business in the packaging industry.

Whether lipstick covers, threedimensional shaped cosmetic jars, convex baby milk bottles, heavy vodka bottles or flexible tubes — thanks to its precision and production speed the K15

CNC has made its way into a wide range of applications.

At the 2012 Open House Kammann is going to present the brand new K15 CNC-XS (X-Small) with six stations, designed, for example, for two-colour printing, as well as the huge K15 CNCXL (X-Large) with twenty stations for up to eight-colour UV decoration. Hot-foil application, visual inspection, tilt axis printing, new feeding technology and

Managing Directors Mr Matthias Graf (left) and Dr Christian Maas (right) demonstrate a Kammann K15 CNC machine.

SPE Announces 8th European Thermoforming Conference The Society of Plastics Engineers — European Thermoforming Division has released details of the 8th European Thermoforming Conference to be held in Venice from April 26–27 2012 at NH Laguna Palace Hotel, Mestre, Venezia.

The conference agenda will include presentations from experts in the thermoforming industry and lively debates in workshops about technical and commercial issues. Moreover, the event provides the opportunity to meet colleagues and customers from the industry around the world.

The conference is to be complimented by an informative and comprehensive exhibition (table top displays) of the latest relevant product developments and services offered by a variety of leading suppliers to the thermoforming industry. This will also be held in the NH Laguna Palace Hotel.

Thermoformers are invited to participate in the 4th European Thermoforming Parts competition. The essential points of the competition are the designorientated application of materials and the successful combination of technical innovation and design quality.

The award winners will be presented at the 8th European Thermoforming Conference.

Society of Plastics Engineers Tel: +32 3 541 77 55 Email: spe.etd@skynet.be Web: www.e-t-d.org EPPM 17

many other novelties will be rounding out the event. Kammann encourages readers to mark their calendars and contact Wilhelm Glauber (details below) to register and get access to the future in container decoration.

Kammann Tel: +49 5734 5140 5201 Email: glauber@kammann.de Web: www.kammann.de

New Installations

Automotive Hose Inspection System Commissioned A leading manufacturer of PTFE hose used in the automotive industry has integrated a vision inspection system designed by Olmec-UK Ltd into its extrusion line at its UK manufacturing facility. Capable of continuous inspection of the hose travelling at speeds up to six metres per minute, the vision system is linked to a novel failure mechanism which catastrophically destroys defective product by puncturing the hose at the point any defect is detected so that it will later fail a high pressure test.

The vision system features 4 cameras arranged at 90 degrees to each other with the tube travelling through the centre so that the entire outer surface of the tube can be imaged. This allows

high-speed detection of flaws such as foreign matter, cracks, burrs and blistering, overcoming limitations presented by human inspection and pressure leak detection. It can inspect both virgin PTFE and carbon-lined hoses. Different diameter tubes may be inspected without setup changes.

The system is fully integrated into the extrusion line control system and features a simple-to-use intuitive graphical interface. All defects are detected, whether cosmetic or likely to cause failure and identified accordingly.

Defect location reports can be produced, or the tube automatically punctured at the defect point. The tube will then fail at the high pressure testing

stage allowing the defective region to be cut out.

The new vision system has replaced manual inspection of the hoses and resulted in a significant improvement in the quality of the product reaching the customer. Robert Pounder, Technical Director at Olmec-UK, said: “The system we have developed has potential for applications in many different industries.

It can be used wherever 360 degrees inspection of hose, pipe or tubing is required.”

Olmec-UK Ltd Tel: +44 1652 631960 Email: enquiries@olmec-uk.com Web: www.olmec-uk.com

Jenco Motor-Less Vacuum Hopper Loaders Impress Javelin Plastics

PTi Completes Installation of Dryer-Less PET/PLA Sheet System

Jenco, a UK supplier of materials handling equipment has made major advances with its new stainless steel range of motor-less vacuum hopper loaders.

UK injection moulder Javelin Plastics recently took an order of the hopper loaders. Simon Pepper, Technical Manager at Javelin described them as “Very nice, small and compact,” going on to say that they were: “not noisy due to being motor–less, very easy to use — a very tidy unit. I wasn't sure about the motor-less route, but so far I am glad Jenco pushed me this way.”

This motor-less vacuum loader solves many problems with customers that have dusty regrind. There are no blocked filter issues, thus eliminating costly electric motor replacement. In addition to this it will convey free-flowing

Processing Technologies International (PTi), a leading global manufacturer of high-performance sheet extrusion machinery, has completed the installation of its unique “dryerless” twin-screw sheet extrusion production system at company headquarters in Aurora. The production-scale demonstration line is up and running. Several customers have already conducted successful product trials utilising this technology.

“The launch of this unique technology is of major significance for our customers who now have an eco-conscious manufacturing solution which delivers major energy savings and cost reduction,” explained Dennis Paradise, PTi’s Senior VP. of Sales and Marketing.

“Moreover, it is the only full-scale “dryerless” twin-screw sheet extrusion demonstration system available for trials in North America.” PTi has invested over $3 million to install the unit for its customers.

The demonstration line will be available to sheet manufacturers for product evaluation using their own virgin and recycled materials. Paradise noted that customers have the ability to run production-scale trials instead of scaling up from a small lab-scale pilot line that can often result in inaccurate estimations and unfavourable results. The production-scale line eliminates the uncertainties associated with a scale-up from a small lab line. Ultimately, it will give customers a proof-of-production result, according to Paradise. Potentially, companies will be able to produce

powders with ease.

It operates in the same way as a conventional electric vacuum loader and comes with a six-year warranty.

Jenco Ltd Tel: +44 208 501 5522 Email: sales@jenco.co.uk Web: www.jenco.co.uk

EPPM 18

samples at sufficient volumes for test marketing programs — a capability not typically possible with pilot-scale equipment, he added.

The production-scale unit, which is capable of processing rates in excess of 900 kg per hr, runs a variety of resins including post-consumer and industrial PET/PLA. The energy-efficient process relies on Italian group Luigi Bandera’s patented High-Vacuum Twin-Screw Extruder (HVTSE)* technology, which allows PET to be processed without the need for raw material drying and crystallising. It employs a single atmospheric and dual high-vacuum, vent system with a co-rotating twin-screw extruder. This novel approach allows moisture and other volatiles to be removed as part of the extrusion process. In the case of recycled PET, the need for re-crystallisation of the material is also eliminated. The energy savings from the elimination of drying and crystallization can approach 30-35 percent versus the conventional method.

PTi Tel: +1 630 585 5800 Email: dparadise@ptiextruders.com Web: www.ptiextruders.com

MATERIALS

End the “Milky Drag” When Purging High Clarity Resins Black PC to Clear in the first Shot with New Dyna-Purge C CJP Sales Ltd, based in the UK, has introduced another new and improved purge in the Dyna-Purge product range.

Dyna-Purge has taken on board customer feedback and developed a purge that is formulated to purge high clarity resins such as PET, GPPS, PC, SAN, and PMMA. The new Dyna-Purge C is a clear, non-abrasive, non-chemical compound which contains a proprietary additive that expands in the barrel, and allows the purge to reach all those areas of the machine where materials tend to get stuck. The carrier matrix then flushes away impurities, previous resins, and prevents any “milky drag” or residue.

The new Dyna-Purge C has proven to be excellent when changing to a clear or transparent material and can purge through hot runner systems. It covers a wide range of temperatures, from 193°C to 310°C (380°F to 590°F) and there is no need to change any machine settings — add new Dyna-Purge C as it is and

easily purge to a clean finish.

Dyna-Purge has a low “cost per purge”, as only small quantities are required to be fully effective.

CJP Sales Ltd provides a full purging program that includes assisted trials, where the company listens to the customer and evaluates the purging issues; the group then explains exactly what Dyna-Purge can do to remedy these problems. CJP provides a full and comprehensive purging procedure for the user to get the absolute best from Dyna-Purge. CJP Sales Ltd also provides samples for the user to evaluate and see it in action before purchasing.

Dyna-Purge is a registered trademark of Shuman Plastics, Inc. CJP Sales Ltd Tel: +44 1656 644907 Email: sales@cjpsales.co.uk Web: www.cjpsales.co.uk

Trelleborg Tooling Block Boosts E-Go A high performance epoxy tooling block from engineering plastics specialist, Trelleborg Offshore, has been used in the development of a new Single Seat De-Regulated (SSDR) class aircraft designed by UK-based light aircraft company, e-Go aeroplanes.

Trelleborg provided its EP678 tooling block to help with the development of the ‘e-Go’ aircraft, which was the winning design in a competition held by the Light Aircraft Association (LAA) to develop aircraft that meet the new deregulated rules in the UK. The SSDR class demands a weight of less than 115 kg.

Tony Bishop, CEO at e-Go Airplanes, said: “In 2007, following an announcement by the UK’s Civil Aviation Authority of the new class of aircraft, the Light Aircraft Association (LAA) launched a competition for new designs in this category. We designed the e-Go project to be exciting, efficient, easy to fly, ecological and ergonomic and entered it into the ‘state-of-the-art’ category of the competition.

“We originally entered the competition for the challenge and to realise our longheld ambitions to design a complete airplane, therefore we were over the moon to find out that we had won and overwhelmed with the immediate

Velox Launches New Products for Plastics in Healthcare

demand for our design — we quickly got serious about building it, flying it and commercialising it.

“Trelleborg Offshore has sponsored the development of this project by generously providing half-size boards of its EP678 tooling block to make the patterns for all the composite work.

When building the e-Go, we require accurately machined patterns with an excellent surface finish and temperature stability as we have to be able to make the composite components quickly, efficiently and with an excellent finish; Trelleborg's epoxy blocks are ideal for this and we are really happy with the results. Thanks to global support from companies such as Trelleborg Offshore,

we are on track to make our dream aircraft a reality.”

The program has now reached the prototype phase and patterns are currently being machined at a number of CNC shops. Moulds and parts are then built at the e-Go Centre from composite materials, mainly pre-impregnated carbon. The first prototype flight is planned for Summer 2012 and production is expected to commence soon after. The company’s aim is to manufacture 30 aircraft in the first year.

Velox, the Hamburg-based materials distribution specialist, has launched two new TPU solutions for medical and healthcare applications, produced by The Lubrizol Corporation, Cleveland, USA. Several grades of pre-coloured Isoplast thermoplastic polyurethane (TPU) resin are offered in white for non-implantable applications. Adding colour during polymerisation prevents additional heating and diminishes variability. This helps reduce scrap, eliminate defects and offers more consistent batch-tobatch melt indexes.

The second development is Velox’s Hydrophobic Tecothane Soft technology; this new low density hydrophobic thermoplastic polyurethane (TPU) technology eliminates the need for plasticisers to produce softer grades. In addition, these TPUs exhibit low tack with use of significantly reduced amounts of lubricant. This soft TPU polymer can be used instead of silicones. The technology may be extruded or injected moulded utilising traditional processing equipment.

Trelleborg Tel: +44 1695 712000 Email: offshore@trelleborg.com Web: www.trelleborg.com/en/offshore

Velox Tel: +49 40 369 688 47 Email: bastiansen@velox.com Web: www.velox.com

EPPM 19

MATERIALS ROUNDUP Milliken Nucleating Agent Helps SEM Plastik Win Clear Cup Contract for Milkshakes Leading Turkish sheet extrusion and thermoforming company, SEM Plastik, is using a newly formulated polypropylene to fullfil an important contract for highclarity, high-stiffness polypropylene cups for milkshakes at a global fast-food company in the country. The improved properties of the material are largely due to the incorporation of Hyperform nucleating agent HPN-600ei into the material. Hyperform Nucleating agent HPN-600ei is a high performance additive manufactured by additives specialist Milliken & Company.

SEM Plastik’s customer had been using imported milkshake cups in 16- and 32ounce sizes, but was unhappy with the overall quality, especially clarity. Yavuz Eroglu, Owner and General Manager of SEM Plastik, says the customer was also looking for a lighter cup that would provide environmental as well as economic benefits. “We already had contacts with Milliken, so we worked together on the project with them together with an important Turkish polymer supplier to satisfy all its requirements,” he said.

The project began around the middle of 2010, and the new grade is now almost ready for full commercialisation. SEM Plastik has been using trial product quantities for several weeks, and is targeting annual production of around 6.5 million cups. It is also making the domed lids for the cups.

Eroglu said that by using the new grade, SEM Plastik has been able to cut the weight of the cups by close to ten per

cent with no loss of mechanical properties. Thermoforming cycle times are believed to be between eight and twelve percent lower.

“All our major customers have a strong focus on environmental issues as well as costs,” Eroglu said. “So the weight reduction is very important to them because it brings benefits all along the production chain, from less use of nonrenewable resources to reduced emissions of vehicles supplying the cups to outlets.” He also noted that people actually using the cups appreciate the new product too: “When the customer grips the cup, they have a more solid touch,” he said.

Polypropylene nucleated with HPN600ei presents a cost effective alternative to PET and polystyrene (PS).

Cups are highly transparent and have an excellent visual appearance, rather than the yellowish appearance that results from the use of sodium benzoate, the conventional nucleating agent in PP. The Hyperform HPN-600ei nucleating agent increases the crystallisation temperature of polypropylene, and thus allows converters to operate at higher line speeds. They may, in fact, achieve output rates on thermoforming equipment to levels normally only achievable with other plastics. The PP parts can be made with the same wall thickness as other materials. So because the material is less dense, processors use less material, gaining further cost savings.

Milliken Account Manager, Aytül Demirel Dündar, said: “It is a very open-minded processor, and is very receptive to new ideas and innovations.” SEM Plastik is one of a growing number of companies now benefitting from the use of the Hyperform HPN-600ei nucleator: “We have seen rapid adoption and significant growth over the last two years,” she said. “Demand for thermoformable PP sheet is forecast to grow at about 5 per cent per year. Consumption of HPN-600ei will far exceed that growth rate.”

SEM Plastik is one of Turkey’s largest thermoformed packaging producers.

Much of its production is done in-line

EPPM 20

with sheet production, with complete inline trim recycling. One line, producing some three million PP cups a day, is among the biggest packaging thermoforming lines in Europe. The company also has substantial injection moulding capacity for production of disposable cutlery and related products.

Major customers include Coca-Cola, Nestlé and Unilever. It is Turkey’s biggest exporter of disposables, supplying to customers in 76 countries.

Milliken Tel: +32 9 265 1136 Email: veerle.dewolf@milliken.com Web: www.milliken.com

MATERIALS ROUNDUP Victrex Peek Offers Aerospace Industry a Lightweight Metal Replacement

Evonik's Vestamid Now in Over 400 Offshore Pipes Vestamid NRG 1001, a highperformance polymer from the plastics division of Evonik, has been used in a total of over 800km of pipeline since its release. The polyamide 12 made by Evonik Industries has gone into the making of more than 400 unbonded flexible pipes to service the oil production industry.

Together with pipe processor Wellstream International Limited, Evonik conducted intensive testing to demonstrate compliance with international standards API 17J for flexible risers and ISO 13628-2. The tests allegedly proved strong creep performance, ductility, thermal

expansion, methanol compatibility, and hydrolysis resistance.

The moulding compound has since been used commercially for the manufacture of flexible pipes.

Specially developed Vestamid NRG combines its technical advantages with consistent product quality, and good processability, thus reducing setup times, scrap and the risk of extrusion faults.

The new name, Vestamid NRG, represents a range of polyamides employed primarily in the energy sector.

Victrex Polymer Solutions, a manufacturer of high performance polyaryletherketones (PEEK) and a major supplier of thermoplastics to the composites industry, will showcase its latest product at the JEC Composites Show in Paris, from 27-29 March 2012.

Durable, thin walled Victrex Pipes, based on Victrex PEEK polymer, are the latest innovation from the group. Victrex Pipes offer a range of properties including chemical, corrosion, abrasion and permeation resistance at high temperatures, in a flexible format. For the aerospace industry, Victrex Pipes are reported to offer weight savings of up to 68 per cent compared to stainless steel. Additionally, they are inherently halogen-free, with low levels of smoke and toxic gas emissions.

Also at the Victrex booth will be PEEK polymer APTIV films, which are designed to reduce weight and improve performance in numerous applications.

The films are available in a range of thicknesses and widths. They provide permeation barrier properties with low moisture absorption as well as flame, smoke and toxicity performance. APTIV film laminates meet FAA requirements for radiant panel testing and specialised burn-through barrier systems.

In the form of granules, powders, film and filaments they provide optimum impregnation and performance at the fibre-matrix interface. Examples include multi-axial fabric laminates, and unidirectional (UD) tapes and sheets.

Their advantages reportedly include reduced manufacturing and maintenance costs, longer service life, good recyclability, processability and performance when compared to metals, thermosets and most other thermoplastic materials. Up to 50 per cent in weight reductions can be realised over metals and metal alloys, with more than five times the specific strength of typical metals and alloys used in aerospace applications, according to the company.

Victrex Tel: +49 61 92 96 49 27 Email: cbutz@victrex.com Web: www.victrex.com EPPM 21

Evonik Tel: +49 2365 49 9227 Email: thomas.lange2@evonik.com Web: www.vestamid.com

SHOWCASE MEDICAL GRADE POLYMERS Low Friction Acetal Resin Chosen for Drug Injection Device High performance polymers group, DuPont, recently unveiled a new application for its DuPont Delrin SC699 acetal resin. The UnoPen, a disposable, variable-dose injector pen for insulin and other therapies, is manufactured by the company Ypsomed AG of Switzerland.

The DuPont material, which is supplied with extensive regulatory compliance for use in healthcare applications, is used to mould the pen’s dose dial sleeve. Its low-friction behaviour facilitates use of the pen by diabetes patients who are required to administer daily injections of insulin either by themselves or with the help of a healthcare professional. Further attributes of this grade of Delrin in the application include its mechanical properties and the compatibility of the material with laser marking when using a masterbatch.

The UnoPen is a disposable pen designed for the manual injection and delivery of insulin or other drugs from a

pre-filled glass cartridge. A principal feature of the device is its ease-of-use based on a well-proven ‘dial and inject’ handling concept, in which the dose dial sleeve — the component moulded from Delrin SC699 acetal resin and located between the housing and the piston rod — plays a key role. It is used by the patient to set the required dose of insulin to be injected and interacts mechanically with the piston rod to dispense the required dosage.

“The friction properties of Delrin SC699 acetal resin used for the dose dial sleeve are fundamental to the pen’s ease of use. If friction between the parts of the pen is kept to its minimum, then the patient will need a minimum of force to dose or inject the drug,” explained Stefan Burren, Manager, Product Development at Ypsomed. “We tested many polymers that are currently available on the market for this component, but none fulfilled the

Quadrant Introduces Sterilisable Polypropylene for Medical Applications Medical parts fabricated from Quadrant’s Proteus LSG HS PP heat-stabilised polypropylene withstand repeated steam and autoclave sterilisation cycles, according to the company.

Quadrant says that this is possible because the material has a deflection temperature (HDT) of over 149˚C under 0,455 MPa load (66 psi). The material is highly resistant to cleaning agents, disinfectants and various solvents, making it a suitable material for surgical trays, caddies and instrument components used in various life science applications. Such parts are often difficult to produce by injection moulding, owing to their complexity and the need to use high viscosity resin.

“Uncompromised quality is key in the medical industry,” said Stefan Willing, Global Market Segment Manager, Life Science Industry, at Quadrant. “Materials with excellent cost-performance ratio are the future in a more and more sensitive medical and life science industry. In addition, proof of biocompatibility and controls are prerequisites for sustainable material qualifications. Proteus LSG HS PP meets all these requirements.”

Quadrant’s Proteus LSG HS PP will be available in plate form; the production process includes a proprietary heattreatment phase. This increases the HDT, improves machinability and optimises dimensional stability. The material is reported to be a highly cost-effective alternative to polyphenylsulfone (PPSU)

DuPont Tel: +41 22 717 54 19 Email: remi.daneyrole@dupont.com Web: www.dupont.com

Teknor Apex Expands Range of Medical Vinyl and TPEs

in applications where less temperature resistance is required, but resistance to repeated sterilisation cycles is still needed.

Quadrant LSG stock shapes are tested and evaluated for biocompatibility according to ISO10993. This offers the designer increased safety, approval facilitation, as well as reduced cost and time–to–market.

Quadrant produces machinable semifinished parts for life science applications in a range of advanced engineering materials in addition to heatstabilised polypropylene.

Quadrant Tel: +41 62 885 84 43 Email: sigrid.dopfer@qplas.com Web: www.quadrantplastics.com

requirements as well as the DuPont material.”

Delrin SC699 acetal resin has been modified for exceptional low friction performance and is suitable for high volume manufacture. It has been specifically developed for parts requiring high precision moulding in the healthcare industry and is supplied with the relevant regulatory compliance (FDA

and EU food compliance, production according to GMP standards, testing against USP Class VI and ISO 10993–5 and -11). The material is compatible with laser marking, by use of an appropriate masterbatch, for indication of the dose settings. As with other grades from the Delrin product family, the material is reported to exhibit outstanding properties in terms of strength and stiffness, permitting the snap-fit assembly of the component, as well as ensuring reliable and durable mechanical performance in use.

Teknor Apex Company, a producer of medical-grade compounds, has expanded its offerings to device manufacturers in both vinyl and thermoplastic elastomers (TPEs), the company announced recently.

Advances by Teknor Apex for medical manufacturing include BioVinyl flexible vinyl compounds with bio-based plasticisers. Teknor Apex has begun development of flexible vinyl compounds that incorporate phthalate-free Dow Ecolibrium bio-based plasticisers, which are manufactured using plant by–products from The Dow Chemical Company. In uses like tubing and pouches, Teknor Apex expects that these compounds, under the new BioVinyl brand, will provide the performance advantages of vinyl, have a smaller carbon footprint than alternative plastics like polyolefins or polyurethanes.

The group has also developed new assembly technologies for TPE tubing.

Three new patent-pending systems for use with tubing made from Medalist medical elastomers enable common-size TPE infusion tubing to bond securely with conventional connectors. The systems include room temperaturecured adhesives, light-cured adhesives, and solvent bonding. Commercially available adhesive and solvent systems used with PVC tubing either do not enable most TPE tubing to achieve sufficient bonding strength or do not permit sufficient work time for ease of

EPPM 22

assembly. These new systems achieve bonds exhibiting a retention force significantly greater than the minimum required by device manufacturers, and they include a slow-setting option to allow precise assembly control.

“In light of recent regulatory pressures, medical device manufacturers are seeking the path of least resistance in selecting plastic raw materials without sacrificing performance and without straying far from historical economics,” said Peter M. Galland, Medical Industry Manager for the Vinyl Division of Teknor Apex. “Teknor Apex has addressed these market needs by developing a complete and broad-based array of solutions that includes a very diverse portfolio of vinyl options and a fastgrowing family of TPE alternatives to PVC.” Teknor Apex Tel: +31 46 70 20 950 Email: info@teknorapex.com Web: www.teknorapex.com

Industry News

PolyOne GLS Appoints Velox as Distributor for Western Europe PolyOne GLS Thermoplastic Elastomers, a global leader in high-performance, custom-formulated thermoplastic elastomer solutions (TPEs), recently announced the appointment of Velox GmbH as a distributor of its products in Western Europe.

With this agreement, PolyOne combines its expertise in application development and value creation with Velox’s extensive reach and service excellence in order to improve the ability to collaborate with customers.

Velox, the first European TPE distributor

appointed by PolyOne since its acquisition of GLS, will increase the resources available to help customers select and optimise their use of PolyOne’s extensive TPE materials portfolio, including Dynaflex, Versaflex, Versalloy, Dynalloy and OnFlex products.

Walter Ripple, General Manager for PolyOne GLS Thermoplastic Elastomers, said, “Velox understands our products, solutions, and customisation services.

We look forward to building upon this strong foundation to jointly provide improved service to customers and

explore new opportunities for GLS TPEs in Western Europe. Working together, we can help customers develop and commercialise their products quickly and cost-effectively to accelerate time to market and help customers achieve business success.”

François Minec, General Manager for Velox GmbH, said: “We are pleased to have earned the confidence of PolyOne, as demonstrated by this appointment as a preferred distributor. We believe our experience, broad geographical presence and years of work with GLS

TPEs will help PolyOne enhance its customer relationships and expand its market reach.

The distributor appointment was established in December 2011 and is aimed at significantly increasing the presence and penetration of GLS TPE products in a range of markets across Europe.

Novodur by A. Schulman, a large European customer base will be able to access an even broader range of properties and applications in the area of ABS. In this context, the distribution series will comprise:

• Low-emission emission grades for automotive interiors.

• Chemical-resistant types.

• Extrusion types.

• Compositions for medical engineering and contact with food.

• Customised special grades.

Velox Tel: +49 40 369 6880 Email: info@velox.com Web: www.velox.com

A. Schulman to Distribute ABS Grades from Elix Polymers Distributor A. Schulman and supplier Elix Polymers have entered into a new distribution partnership. A. Schulman has taken over distribution of the ABS types from Elix, which are currently marketed under the trade names of Lustran and Novodur, in Germany, Switzerland, Austria, the Benelux countries, France, Great Britain and Scandinavia.

A. Schulman is a leading international compounder and distributor of engineering compounds, thermoplastic elastomers, masterbatches, standard

thermoplastics and special powders domiciled in Akron, Ohio, USA and has more than 50 sales offices and production facilities around the world.

Elix Polymers S.L. is an independent manufacturer of acrylonitrile butadiene styrene (ABS) and styrene acrylonitrile (SAN) with a registered office in Tarragona, Spain.

The alliance formed between these two strong partners opens up new opportunities in the plastics market.

Thanks to the distribution of Lustran and

• ABS natural and precoloured ABS grades.

• ABS/PC blends and high heat resistant grades.

• Electro plating grades and flameretardant types.

Elasto Appoints Mimox as Distribution Partner in Switzerland Elasto, a leader in the development and manufacture of custom formulated thermoplastic elastomer (TPE) compounds, has appointed Mimox as its distribution partner in Switzerland and the Principality of Lichtenstein.

Mimox, based in Zurich, has over 30 years experience in the Swiss plastics sector, working as the distribution partner for several leading chemical speciality manufacturers. Mimox will be responsible for the market development and sales of Elasto's range of Dryflex and Mediprene TPEs in Switzerland.

Per G. Hellberg, Managing Director, Elasto commented: “With a growing customer base in Switzerland we felt the time was right to appoint a local partner.

With a strong Swiss medical manufacturing sector, we have seen increasing demand for our Mediprene

range of TPEs for medical device applications. This partnership offers our customers the local sales coverage, stock inventory and support of Mimox with intelligent material solutions and technical expertise provided by Elasto.”

Dryflex TPEs are used in a wide range of applications including; soft-touch grips, caps and closures, toys, automotive interior and exteriors and construction profiles. Mediprene compounds are sterilisable with gamma, and representative grades have passed cytotoxicity tests according to ISO 10993-5 and biocompatibility tests according to USP Class VI. Elasto Tel: +46 532 607500 Email: info@elasto.se Web: www.elastotpe.com

Evonik Industries to Increase Global Methyl Methacrylate Production Capabilities Evonik Industries, one of the leading suppliers of methacrylate chemistry, is increasing the production capabilities of its methyl methacrylate plants throughout the world, to meet the rising demand.

Evonik will increase its production capabilities of methyl methacrylate through de–bottlenecking and plant expansion projects in their existing plants in Europe, Asia, and the United States in 2011 and 2012. Upon completion of the projects, Evonik industries will be able to produce approximately 50,000 additional metric tons of methyl methacrylate.

Thomas Müller, Senior Vice President & General Manager Acrylic Monomers, said of the previously announced expansion of the methyl methacrylat capacity: “We are reacting timely to support the growth of our customers.” methyl methacrylate is primarily used for Polymethylmethacrylate resins and surface coatings.

Evonik Tel: +49 6151 18 4614 Email: andrea.schaeuffele@evonik.com Web: www.evonik.com EPPM 23

A. Schulman Tel: +49 2273 5610 Email: aschulman@de.aschulman.com Web: www.aschulman.com

NPE PREVIEW

NPE 2012: The Return of the Machines as

NPE Moves to Orlando No trade show comes close to NPE for sheer dynamism, with aisle after aisle of working plastics equipment filling the halls with clamour and action. While some of this was lost at NPE 2009 as the recession took its toll, the excitement will come back in full force this year. According to the SPI: The Plastics Industry Trade Association, NPE 2012 will mark “The Return of the Machines.”

Produced by SPI, the triennial NPE international plastics exposition will take place on April 1-5 in Orlando, Florida, after 40 years in which the show was held in Chicago. “The improved economies and logistics of the new venue have encouraged many NPE 2012 exhibitors to purchase more exhibit space and bring more machinery to the show, much of it to be operated on-site,” said Gene Sanders, SPI Senior Vice

President of trade shows and conferences. “Contributing to this enhanced commitment by exhibitors is the steadily improving manufacturing sector of the U.S. economy.”

The show is on track to be substantially stronger than the last NPE in 2009, according to the SPI. Thus far 1,830 companies have purchased 83,890 m2 of exhibit space at NPE 2012, and commitments by more companies can be expected before opening day, according to Sanders. The exhibit space total thus far is one-fifth greater than the amount actually occupied at NPE 2009.

Sanders cited reports from three exhibitors of injection moulding systems and a fourth company specialising in auxiliary systems as representative of the positive response to NPE 2012 from machinery companies, showing how the

greater scale of exhibits can increase the return on trade show investment for attendees.

“We know moulders want to see equipment making parts, touch the controls, witness tangible differences from what they already have, and experience for themselves what they otherwise might only see in a brochure,” said David Preusse, President of Wittmann Battenfeld, Inc. “At the same time, since our company handles large projects such as new molding plant launches, NPE2012 will give us an

opportunity to show that we can produce a state of the art molding shop in only eight setup days.”

German Injection Moulding at its Best in The States German injection moulding specialist, Arburg, will present a total of six exhibits in Orlando. The focus will be on the subject of efficient production. One of the highlights on the 500 m² exhibition stand, (number 3729) in the West Hall, will be the US premiere of the new Edrive series, with which Arburg has expanded its electric machine range.

The stand will also feature electric and hybrid exhibits from the highperformance Alldrive and Hidrive series, as well as a vertical machine. There will be demonstrations involving the production of moulded parts for the automotive, medical technology, electronics and packaging sectors. The Selogica control system will also be on show, providing impressive evidence of its benefits in increasing efficiency.

The new Edrive series has expanded Arburg’s electric machine range. The Allrounder E machines cover a range of clamping forces from 600 to 2,000 kN. The appearance of the Allrounder 370 E at the NPE show will mark the US debut of the new series. The Edrive machines are primarily designed for the efficient production of standard items, such as technical moulded parts, making them an energy-efficient electric alternative to basic hydraulic machines.

With a total of three high-performance machines, the electric Alldrive series will be prominently represented. The exhibits will offer impressive proof of their capabilities in a range of different applications, with clamping forces from 350 to 2,000 kN. The smallest electric Allrounder 270 A with a clamping force of 350 kN operates with the Arburg micro-injection module, which combines an 8 mm injection screw with a second screw for melting the material. The electric Allrounder 520 A with a clamping force of 1,500 kN operates with a 32-cavity mould and produces

syringe barrels in a cycle time of 6.5 seconds. In order to meet the requirements of the medical technology sector, the exhibit will have a completely encapsulated, stainless steel clamping unit.

The electric two-component Allrounder 570 A with a clamping force of 2,000 kN will be equipped for processing liquid silicone. Integrated in a production cell, the machine will produce a sophisticated hard/soft component from PBT and LSR for the automotive sector.

For the packaging sector, an IML system will be presented that produces two finished buckets with handles in a total cycle time of only 4.85 seconds. The plastic parts will be produced on an Allrounder 720 H with a clamping force of 3,200 kN, representing the hybrid Hidrive series, which is predestined for high-speed thin-walled applications. The

total weight of the two items is 62 g and the material throughput is approximately 50 kg/h.

Automation plays an important role with regard to production efficiency.

Accordingly, all exhibition machines operate with robotic systems. One of the highlights will be the fully automatic encapsulation of cables with a production cell built around the Allrounder 375 V vertical machine. All parts handling is dealt with by a six-axis robotic system, which the machine operator can program himself using an implemented Selogica user interface. In addition, the robotic system is linked directly to the Selogica machine control system. Online communication extends far beyond the Euromap interface and offers functions such as the synchronisation of movements and simplified machine start-up. The

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advantages of this solution are shorter set-up and cycle times.

Arburg will not only be looking at the multi-faceted topic of production efficiency on its exhibition stand at NPE. During Antec 2012, which is held in conjunction with NPE, managing director Helmut Heinson from Arburg’s German headquarters sheds light on the developments of the plastics industry, the relevance of an efficient production and influencing factors as part of a keynote speech. In addition, Martin Neff, head of the Arburg Technology Center Midwest, Elgin, IL, will illustrate a wide variety of injection moulding’s savings potential in an expert presentation.

Arburg Tel: +49 7446 330 Email: contact@arburg.com Web: www.arburg.com

NPE PREVIEW Elastomer Technology Delivers Optimum Grip Even When Wet Kraiburg TPE, a leading supplier of thermoplastic elastomers (TPEs), has launched a new elastomer technology which results in TPE materials with optimum grip even in the presence of moisture for a range of consumer, industrial and medical applications. Wet Grip technology, offered under the Thermolast W trade name, boasts up to three times the coefficient of friction (COF) of conventional TPEs for both dry

and wet applications with no negative impact on physical and rheological performance. The technology will be on display at NPE. The Wet Grip technology, based on styrenic block copolymers (SBS), is permanent and incorporated throughout the matrix. It does not migrate to the surface and dissipate over time and has no negative impact on processability in multi-component injection moulding or extrusion processes.

Kraiburg has the ability to adapt the technology to its broad portfolio of Thermolast branded SEBS elastomer compounds.

“We’ve developed a oneof-a-kind material solution that gives products a firm grip even when wet,” said Keith Dunlap, Kraiburg TPE’s Director of Sales and Marketing for Americas. “This is a major development for consumer product companies who want to have a competitive advantage, enabling them to make products that are safer and easier to handle.”

Kraiburg’s technology can be used to eliminate the tackiness found in prior competing material solutions which use tackifiers to achieve the wet grip, or it can be used along with tackifiers to

improve COF performance. Kraiburg TPE Thermolast W — Wet Grip compounds also can be made to adhere to a range of engineering thermoplastics including acrylonitrile-butadiene-styrene (ABS) and polycarbonate (PC).

Kraiburg expects the Wet Grip technology to be adapted for a range of hand-held uses for diverse markets including sporting goods, lawn and garden, and watercraft. Possible uses for Wet Grip could potentially include antislip mats; tool handles; fitness equipment; serving trays for caterers; orthopedic aids such as crutches; medical, dental, and surgical instruments; kitchen utensils; children’s toys; and a range of household goods.

Wet Grip compounds are available in 2560 Shore A hardness and meet FDA approvals. Along with the unique Wet Grip performance, Thermolast W compounds also provide standard performance advantages such as smooth surface, optimum sealing, versatile bonding, high transparency, and easy colouring.

Kraiburg has teamed up with a global partner to launch the new technology and is currently working to make it available to other global OEMs and processors.

Wet Grip compounds are currently manufactured at Kraiburg TPE’s facilities in the US and Germany.

its comprehensive Thermo Scientific material characterisation solutions.

Material characterisation solutions analyse and measure viscosity, elasticity, processability and temperature-related mechanical changes of plastics, food, cosmetics, pharmaceuticals and coatings, chemical or petrochemical products, plus a wide variety of liquids.

Molecor, a pipe technology specialist from Spain will present its new technology for the production of PVC-O pipes at booth 40033. Additionally, the group will present a conference entitled: “New full dry system developed for bioriented pipes brings excellent opportunities for PVC-O” as part of the SPE Antec 2012 Educational conferences being held during the exhibition.

Molecor is specialised in molecular orientation applied to pipeline solutions which improves the physical performance of other alternative solutions for water transportation under pressure.

Molecular orientation is a physical process which modifies the molecular structure of plastic, where amorphous PVC-U structure is re–organised into a layered structure, improving the impact resistance of the pipes. Enhancing the strength of the pipe allows the user to reduce the consumption of raw material.

Molecor Tech has developed an air based technology in which no water is involved, which makes a safer, cleaner, more efficient and more profitable process, according to the company.

Among the PVC-O pipe improvements, one of the significant developments is the socket. Its manufacturing process is carried out at the same time as the rest of the pipe, with the same molecular orientation process. Furthermore, it is efficiently designed to allocate the tightness ring, making the pipe installation faster, increasing the pipe installation performance and guarantying the preservation of hydraulic resources.

Molecor is currently working on different joint systems to be adapted to other already existing market solutions, higher range of diameters and pressures, and new applications of molecular orientation knowledge to other supporting products for pipeline networks.

Thermo Fisher Scientific Inc. Tel: +49 721 4094 Email: petra.roth@thermofisher.com Web: www.thermoscientific.com/mc

Molecor Tech Tel: + 34 902 566 577 Email: pilar.sanz@molecor.com Web: www.molecor.com

Kraiburg TPE Tel: +1 678 584 5020 Email: info-america@kraiburg-tpe.com Web: www.kraiburg-tpe.com

Parallel Co-Rotating Extruder for R&D to Make Debut in Orlando Thermo Fisher Scientific Inc., a leader in serving science, will introduce the new Thermo Scientific Process 11 twin-screw extruder, the latest model in a suite of stand-alone compounding systems, to the public at NPE 2012 for the first time.

The parallel co-rotating extruder will be showcased on booth 5555.

“When developing new polymeric compounds or food formulations, performing time and material intensive experiments on production scale extruders can significantly increase costs and thus put these projects at risk.” said Karl Gerhard Hoppmann, Vice President and General Manager of Thermo Fisher Scientific’s material characterisation business. “Using the new Process 11 extruder, only 20 g of material is needed to conduct experiments and carry out an array of trials in a cost and labour effective manner. In addition, results that are relevant to production conditions can be obtained due to the full scalability of the Thermo Scientific standalone compounding systems.”

Features and benefits of the new Process 11 include: • Minimised sample material usage.

• Throughput 20 g/h to 2.5 kg/h.

• Small footprint benchtop design, easily transportable.

• Segmented screw design with removable top half barrel.

• Easy-to-operate touchscreen with integrated feeder control.

• Geometrically scalable screw and barrel design across portfolio.

The Process 11 extruder provides a user-friendly operation via a touchscreen with integrated feeder control and easily removable product contact parts. The compact monocoque design minimises the usage of lab space and is ideal for fume hood applications. The screw elements and barrel design scale geometrically across the whole suite of extruders and thus allow easy process scale-up.

Thermo Fisher Scientific, one of the pioneers in rheology, successfully supports a wide range of industries with

Molecor Technology Aims to Revolutionise the US Water Industry with PVC-O Technology

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NPE PREVIEW Low Ovality Technology: Redefining the Installation of Large Diameter HDPE Pipe Low Ovality Technology from UK group Pipe Coil Technology Limited (PCT) will be on display at NPE. The technology allows large diameter HDPE pipe up to DN315 to be coiled as free standing coils or reeled onto drums. There are still many pipe manufacturers who continue to manufacture large diameter HDPE in the traditional 12 or 20 metre ‘stick’ lengths regardless of its final use. This is not only highly inefficient to store and transport but also drastically decreases the overall integrity of the installed pipeline, as butt welded and electro fusion joints are still the most common inherent failure in a pipe designed to last 100 years.

Low Ovality Technology not only reduces transport costs by maximising the amount of coiled pipe per load but also greatly increases the integrity of the finished pipeline. For example, DN160 pipe can be coiled in 900 m lengths allowing for a much quicker installation time, by removing up to 73 butt welds per 900 m coil, and with less joints the pipeline’s integrity is significantly increased. For larger projects, 4600 m of DN160 can be put on a reel increasing the efficiency of modern ploughing technologies. With new ploughing technologies and the need for longer continuous lengths and larger diameters in coil form, Low Ovality is well positioned to remove the constraints of butt welding backlogs and joint failures during the installation and life time of the

pipeline. Reels of this size would require an escort on highways, however, the cost savings made through a much more efficient installation process far outweigh the additional transportation costs and with fewer joints, maintenance costs of the pipeline are also considerably reduced.

Even with pipe sizes that can already be

coiled with standard coiling machinery, Low Ovality can make a big difference to profit margins through its ability to supply longer lengths of coil within existing coil dimensions, increasing the pipe length per truck and so reducing overall transportation costs. Transporting thinner walled pipes in coil format also becomes a possibility with low ovality as

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it is capable of coiling pipes with standard dimension ratios up to 21 and 26 whilst maintaining coil and pipe stability.

PCT Ltd Tel: +44 191 295 9910 Email: chris.spratt@pipecoil.co.uk Web: www.pipecoil.co.uk

NPE PREVIEW Davis-Standard Covers Every Base for Extruders and Extrusion Equipment US extrusion specialist Davis-Standard will bring a host of extrusion machinery and ancillaries to Orlando in April, on stand 5945. The group will exhibit a range of its extruders including a groove feed extruder, a new high-speed extruder, a MAC extruder, a direct drive medical extruder and a Super Blue extruder.

Representatives will demonstrate a 50 mm 34:1 L/D (length to diameter) groove feed extruder designed for bimodal PE100 and other polyolefin materials. This

Davis-Standard’s high-speed extruder has a high volume feed section and electrically heated/air-cooled system for demanding processes.

The Davis-Standard 12-inch Triple Lip Air Ring on display at NPE offers several advantages including effective and fast gauge control.

extruder features a low melt temperature, high output design with a new feedscrew for even greater mixing and homogenisation. In addition to the 34:1 L/D barrel assembly, this extruder has a 4:1 L/D intense cooled groove feed section. This machine will be running as part of the geothermal HDPE pipe extrusion system at the company’s exhibit.

A 75 mm 40:1 L/D high-speed extruder will showcase a high volume feed section and electrically heated/air-cooled system. This extruder is targeted for use with PS and PP resins for sheet and inline thermoforming. In these applications, a 75 mm high-speed extruder is able to produce the equivalent throughput of a 150 mm machine while still providing excellent melt temperature and pressure stability.

The adjustable HPE-H extruder will be shown in a 25 mm model with direct drive AC vector motor capabilities and an available Servo option. The compact HPE-H is designed for quick delivery and offers processors high torque capability and an extensive list of options. It will also be used to demonstrate the DS-eTPC touchscreen controller for extruder and line control.

A 90 mm 30:1 MAC extruder with a slimmer design will also be shown. This version of Davis-Standard’s highperformance, air-cooled extruder is engineered for nine-layer co-extrusion film arrangements.

Additionally, a Medical Extruder Direct Drive (MEDD) will be shown. This new extruder features a direct drive motor for more energy efficient operation.

Advantages include linear movement, a replaceable feed section liner and a Windows 7 PLC control system. The MEDD also features interchangeable 25

Techne Industrial Fluidised Baths Offer “Fastest and Lowest Cost Plastic Extrusion Tool Cleaning System”

Industrial Fluidised Baths remove all polymers and hydrocarbon-based products from tooling, components and parts.

Cleaning time is dramatically faster than with oven methods, while the risk of tool damage from scrapers, brushes or blow torches is eliminated. The typical cleaning time is as fast as 20–30 minutes.

Temperature control specialist, Techne Industrial has previously supplied hundreds of customers who manufacture plastic extrusions, including tubes, pipes, rods, sheets, films, fibres, electrical cables and other extruded shapes. There are seven models available from the IFB-51 with a working size of Ø 259 mm x 305 mm deep up to the IFB-131 which is Ø 450 mm x 1200 mm deep. Complete systems including baskets, extraction fans, fume scrubbers and afterburners are also available.

Techne Fluidised baths offer safe,

The running geothermal pipe extrusion system at Davis-Standard’s booth #5945 will feature a groove feed Thermatic extruder. mm 24:1 L/D to 19 mm 24:1 L/D barrel assemblies for material versatility.

Finally, completing the lineup of extruders, the group will bring its ‘Super Blue’ extruder. This will be shown in a 90 mm model. The Super Blue was reportedly designed for a quick delivery and rugged design that is energy efficient and easy to maintain. Standard machines can be delivered as quickly as one to two weeks, according to the company. Advantages include an increased torque capacity to handle high viscosity resins and custom options.

A newly introduced hand-held computer tablet will be another highlight for the group. Called the DS-Tablet, this portable operator interface offers a wireless touchscreen option to processors using the EPIC III (iFIX) supervisory control system.

With a 264 mm screen and rugged design for industrial environments, this Windows-embedded tablet allows operators to access and control functions from outside typical OCS (Operator Control Station) locations.

A 300 mm triple lip air ring for blown film extrusion will be exhibited in conjunction with a Vertex die at the group’s stand.

The triple lip provides fast gauge control via the manipulation of all three airstreams. When used in conjunction with Davis-Standard’s dies, processors can reportedly achieve especially high internal and external cooling rates and superior film quality.

Davis-Standard Tel: +1 860 599 1010 Email: info@davis-standard.com Web: www.davis-standard.com

Wittmann Battenfeld to Demonstrate ‘Entire Moulding Plant’ at NPE

efficient and cost effective cleaning of tooling, components, systems and parts (dies, breaker plates, nozzles, tools, tips, spinnerets, extruder screws, manifolds, etc). These baths will remove all polymers, including plastic, paint, epoxy, rubber and adhesives, as well as other hydrocarbon-based products such as oils, fluids, grease, lubricants and coatings.

Parts immersed into a fluidised bath are cleaned by the high temperature typically 450°C (but can be used up to 600°C) environment within a bath media of fluidised aluminium oxide that instantly starts to degrade plastic to carbon, which then leaves the bath as CO2. This instant heating and minimised quenching results in shorter cleaning times than those of ovens, and when paired with the even and consistent heat of the bath, results in greatly reduced metal fatigue and tool damage.

Techne Industrial will be exhibiting the IFB-51 system at Booth 8942 at NPE 2012.

Wittmann Battenfeld claims it will be ‘bringing an entire moulding plant’ to booth 2843 at NPE 2012. The company will display six operating moulding machine workcells with integrated robots, automation and auxiliaries.

“We know moulders want to see equipment making parts, touch the controls, witness tangible differences from what they already have, and experience for themselves what they otherwise might only see in a brochure,” said David Preusse, President of Wittmann Battenfeld, Inc. “At the same time, since our company handles large projects such as new moulding plant launches, NPE 2012 will give us an opportunity to show that we can produce a state of the art moulding shop in only eight setup days.”

Techne Industrial Tel: +44 1785 812121 Email: ralph.westbrook@bibbyscientific.com Web: www.techne-calibration.com EPPM 28

Specific products on display include: • Injection moulding machines ranging from 5 to 1,000 tonnes clamp force, including the Micro, Servo and Macro Power Series.

• Robots and automation featuring the new R8.2 robot with Smart Removal, Eco-Mode, and Smart Start features, for the fastest and most efficient parts removal.

• Temperature controllers, featuring the New Tempro D series and high temperature water controllers • Blenders including the new B14 Series.

Wittmann Battenfeld Tel: +1 860 496 9603 Email: sonny.morneault@wittmanngroup.com Web: www.wittmann-group.com

NPE PREVIEW PolyOne to Make a Green and Colourful Appearance at NPE

Thermoforming for Cups, Yoghurt Pots and More Kiefel, a member of the Bruckner group for extrusion technology, will present its Thermorunner KTR 6 L Speed with a high-speed demonstration producing drinking cups from PP material using a cuptool.

The machine can be used to produce yoghurt pots, drinking cups, cups for use with snap-on lids or plant-pots, at ‘optimum production rates with minimum costs’, according to the company.

Integration of the inline stacking

system KIST 78/56 with vertical stacking, also developed by Kiefel, is also available for use with the KTR 6 L. The KTR 6 L is designed on a modular basis. It can then be expanded with downstream equipment for complete packaging solutions.

The Speedformer KMD Series of automatic pressure forming machines will also be on show.

The design, drive technology and the Simotion Control System of Siemens reportedly offer faster and more precise movements for the

PolyOne, a leading US developer of plastic additives, will be a key exhibit for many visitors to NPE. One of its latest developments is its newly acquired company, ColorMatrix. Acquired back in 2011, ColorMatrix has long been a leader in liquid colorants and other additives. One product which the group brings to the PolyOne table is HyGuard, an oxygen barrier technology for PET packaging with full recycling capability, high performance product protection and controllable shelf life management.

According to the group, this is the only oxygen barrier technology to be endorsed by the APR (Association of Postconsumer Plastics Recyclers) for its recyclability. HyGuard has recently received FDA approval for use in standard food and beverage containers, including hotfill applications.

Also on display will be Excelite, a liquid foaming agent for PVC digital sheet. This technology has been designed to offer more consistent cell structure and smoother surface finish for printed sheet.

In other news, PolyOne and biomaterial specialist, Archer Daniels Midland, have a pipeline of new bioplasticiser technologies in development. The two companies will launch an initial commercial offering called reFlex 100 at NPE. This material is a high solvating plasticiser that may have the potential to replace, in whole or in part, butyl benzyl phthalate (BBP) or other high solvating plasticisers. Applications include toys and other consumer goods that need to be non-phthalate, flooring, carpet backing, and other building and construction end uses. reFlex has been produced on a large, commercial scale, and is now available for sampling or sale, according to PolyOne.

PolyOne Tel: +1 440 930 1000 Email: info@polyone.com Web: www.polyone.com EPPM 29

Speedformer machines.

Typical applications of the KMD Speedformer include trays and containers, hinged packaging, blister packs, tub lids and sorting elements.

Kiefel Tel: +49 8654 780 Email: kiefel@kiefel.de Web: www.kiefel.de

THE GREEN ROOM

Is This the ‘Greenest Ever’ Refillable Bottle?

Specialist plastics packaging technology business, Petainer, has developed its ‘greenest ever’ refillable bottle — further improving the sustainability of what is already one of the most environmentally-friendly forms of beverage packaging.

The new bottle is manufactured using more than 25 per cent post-consumer ‘one-way’ recycled PET but has the same performance characteristics as a refillable bottle made entirely from virgin material.

Nigel Pritchard, Group Chief Executive of Petainer, said: “This is a very exciting development. Refillable bottles are already the beverage packing system with one of the lowest environmental footprints. This massive advance in the use of recycled material makes refillable bottles even more ‘eco-nomic’.

“They are ‘eco-friendly’ because they use up to 90 per cent less virgin material per filling. This performance is improved even further by the introduction of postconsumer recyclate, which means that the bottles now require less energy and other resources to manufacture.

“They are also economic in the traditional sense because the environmental benefits translate into lower costs. As the cost of PET resins inexorably increases, the economics of refillable bottles using recycled material become even more compelling.

“We believe these new containers have a good claim to be considered one of the world’s most sustainable forms of beverage packaging. This will become even more the case as commodity resources become scarcer, costs rise and environmental impacts come more to the fore.”

Petainer is now working with bottled water companies, carbonated drinks producers and brewers across Europe to put its new ‘greener’ refillable bottles into use.

Research has demonstrated that refillable bottles — which are returned to the retailer by the consumer once emptied, then sent to the beverage manufacturer for washing and refilling — have a lower carbon

materials in both types of bottle. It has demonstrated that one-way bottles can be manufactured from 100 per cent recycled material.

Petainer’s latest developments in manufacturing technology allow more than 25 per cent of postconsumer waste from used PET bottles to be included in refillable bottles. The company is now working on improving the use of post-consumer recyclate even further.

The ‘greener’ bottle’s performance is identical to the performance of conventional refillable bottles. It gives the same number of ‘round trips’, has the same topload strength which allows it to be stacked in the same way as other refillable bottles, and provides the same level of retention of CO2 in carbonated soft drinks.

The technology can be applied both to bottles manufactured in Petainer’s own plants in Sweden and the Czech Republic and also to bottles blown from Petainer-supplied preforms.

Nigel Pritchard added: “This bottle-to-bottle recycling, added to the existing environmental and economic benefits of refillable bottles, makes a strong case for fillers and brewers to consider switching to refillable bottles. We are already seeing a number of customers and countries considering the introduction of refillables.”

A company using one-way bottles can spend around four to five times as much on packaging as a company that bottles the same quantity of beverage in refillable bottles, which it needs to replace only once in every 20 trips. The total PET used per filling is 90 per cent lower for the refillable container, which is improved even further with this development in the use of post-consumer recyclate. footprint than one-way bottles that are thrown away after use. This is the case even if one-way bottles are recovered for materials recycling.

Petainer, which manufactures both refillable and oneway bottles in PET, is a leader in the use of recycled

New Granulator for Thermoformers: Skeleton and Production Waste Processing Granulator Strips of foil or sheets are punched out in the thermoforming process when producing packaging products such as cups. This thermoplastic punched skeleton waste can reportedly be handled easily by the new M 1200/300 granulator from German group Hellweg, and processed into re-usable regrind material.

300 series thermoform granulators are fitted at the rear with special feeding equipment for material in thickness up to 5 mm. Feeding punched skeletons or complete sheet into the granulator grinding chamber is controlled by frequency or dancer arm systems in order to adjust and synchronise intake rate to the feed rate of the production machine to compensate for fluctuations. At the front of the granulator there is a chute for manual feeding or an intake chute with conveyor belt connection.

The machines are equipped with a stiff torsion-resistant

rotor, in open or closed design, which is produced from one solid piece of metal. This ensures quiet running at high rotation speed without any imbalance. Depending on the purpose, the rotors are fitted with three or five rows of blades.

Versions with working widths of 650 mm or 1,200 mm are offered, along with a rotor diameter of 300 mm and power rating between 7.5 kW and 30 kW. Throughput depends on the screen mesh size used and amounts between 400 and 1,200 kg/h.

Hellweg Tel: +49 24 71 42 54 Email: info@schneidmuehlen.de Web: www.schneidmuehlen.de EPPM 30

Petainer Tel: +46 510 54 56 00 Email: enquiries@petainer.com Web: www.petainer.com

SHOWCASE BIOPOLYMERS European Bioplastics Announces 7th Annual Conference

FKuR’s Bioplastic Progress Leads to New Applications Bioplastics specialist FKuR Kunststoff GmbH presented a broad range of biodegradable, biobased and natural fibre reinforced compounds at the recent Ecopack 2012 show.

“During recent months we have concentrated our development work on new formulations for injection moulding and film applications”, said Patrick Zimmermann, Director Marketing & Sales at FKuR. “These intelligent and tailor-made compounds, made from renewable resources, enable our customers to explore new applications and markets”, he explained.

Besides its exisiting product lines Bio-Flex and Biograde, FKuR presented its new custom-made green polyethylene compounds with the brand name Terralene, which are based on Braskem’s Green PE. Furthermore, as Braskem’s European

distributor, FKuR introduced pure Green PE for the first time at a European trade show. In contrast to traditional polyethylene the ethanol used for Green PE is derived from Brazilian sugar cane rather than from crude oil. Through the use of this renewable raw material, each tonne of Green PE is able to capture up to 2.5 tonnes of CO2 from the atmosphere, thus helping to reduce greenhouse gas emissions. Green PE and Terralene are 100 per cent compatible with conventional polyethylene having identical properties. It is also possible to recycle both materials in the same recycling stream.

FKuR Tel: +49 2154 92510 Email: info@fkur.com Web: www.fkur.com

European Bioplastics, the association of the bioplastics industry in Europe, has announced the 7th European Bioplastics Conference to take place from 6-7 November 2012 at he Maritim proArte Hotel in Berlin.

“More investments, more (commodity) products, and an increasing interest in the industry — the steadily growing market visibility puts bioplastics onto the agenda of brand owners, consumers and decision-makers,” commented European Bioplastics Chairman Andy Sweetman. “Bioplastics are clearly moving from niche to mainstream.”

The 7th European Bioplastics Conference is the pre-eminent international industry event in Europe offering a unique information platform for industry trends and innovations in material and application development.

Participants can expect a newly diversified conference format as well as an improved mix of expert presentations

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meeting their individual needs and interests.

Excellent networking opportunities and a comprehensive product exhibition: building on last year’s success of the record exhibition, the 7th Conference is set to offer even more exhibition space, exclusiveness and networking areas.

In 2011, over 420 experts from around the globe came together at the 6th conference and impressively showcased the conference’s tremendous effectiveness in networking and information exchange.

For this year’s event, registration opens in April 2012. The call for papers will be published soon.

European Bioplastics Tel: +49 30 28482 358 Email: conference@europeanbioplastics.org Web: www.conference.europeanbioplastics.org

Industry News

Preparing for REACH 2013 in the Plastics Industry On 31 May 2013, the REACH registration deadline will be upon us, meaning that companies wishing to register their products for REACH compliance need to be making the necessary changes now. For polymer suppliers and their clients, this may well involve altering the way safety data sheets (SDSs) are distributed, as well as a host of other administrative responsibilities.

Malcolm Carroll, Director of REACH Delivery, a company specialised in bringing regular updates on REACH compliance to a global audience of manufacturers offers his thoughts on the change, and gives some suggestions for companies who wish to make the transition a little less bumpy...

At the European Commission’s REACH Registration conference in September last year a new campaign — ‘REACH 2013 — ACT Now!’ — was launched by the ECHA. This campaign was aimed at manufacturers, importers and downstream users to focus their attention on the 31 May 2013 REACH registration deadline and urge them to start preparing now.

Last year, we saw manufacturers, importers and distributors of over 1,000 tonnes register their chemicals with the ECHA successfully. We have moved on however, and in 2013 companies will be required to register all phase-in substances above 100 tonnes a year which are manufactured or imported in the EU. This time around, many more SMEs will be affected by REACH including companies in the plastics industry. For many companies, complying with the regulations will prove challenging and time consuming. SMEs are less likely to have experience of the REACH process; they have budget constraints and tend to have fewer resources to handle the complexities and administrative challenges involved.

Manufacturers and importers that will be affected by REACH need to start planning ahead. One of the ways they can gear up for 2013 now is to address the new rules concerning the way Safety Data Sheets (SDSs) and associated documents are sent to customers as there are big changes required under REACH. Under REACH, any company importing and distributing chemicals to and within the EU now needs to ensure the direct delivery of SDS and associated documentation to customers. REACH wants to promote the consistent use of safety data sheets within organisations to ensure that everyone involved with the chemicals is using them correctly and safely. Therefore, companies are also responsible for keeping SDS and their customers up to date if there are any changes or clarifications.

Understandably, for most companies the new requirements will be considered an administrative and logistical challenge,

Already affecting the chemical industry, by 2013 REACH will begin to have a real impact on the plastics industry. as well as a potentially costly exercise.

Traditional methods of sending SDSs by email or post may not be considered robust enough to stand up to regulatory scrutiny so new ways of sending SDSs to customers and ensuring they are kept up to date are needed.

One way round this is to automate the entire SDS delivery process using REACH Delivery, a new industry-wide SDS delivery service. This secure online service enables the electronic delivery, receipt, control, update, audit and tracking of SDSs in line with REACH. It automates the entire SDS delivery process including the monitoring, tracking and reporting on all documents that are sent to customers and provides a delivery status that is ideal for auditing purposes. If there are any changes or clarifications to the SDS, then the new version is sent to customers and it replaces the previous version automatically. This means organisations no longer have to worry about out of date version being in circulation and managers can be confident all employees are using the most up to date SDSs at all times.

The system also stores all documents in

an electronic database, allowing users a single consistent point of access for the latest version of a SDS. The service is simple to access and operate, and importantly, it is cost effective.

Companies can use REACH Delivery free of charge by registering for a free (low use) account and upgrade to the paid service at any point when their volumes increase. The service operates on a ‘many-to many’ basis, allowing companies, no matter where they are located, to be able to manage and automate the sending and receiving of SDS, and other documents and messages, within a fully secure and audited environment. It is international and multi-lingual as well as being easy to use.

In addition to the fact that REACH affects companies throughout the world, similar legislation is now being considered in other countries, most significantly in the USA. REACH Delivery has been designed to meet the requirements of new international legislation as and when it is required. The system already functions on an international basis. NonEU firms can use it to comply with REACH by securely delivering SDS to

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their customers in Europe. They can also use it outside of Europe and in their own countries, as it supports the delivery and receipt of SDS and any other documents worldwide, or to distribute SDS throughout their company.

There is no doubt that REACH compliance is a hugely complex issue for companies — particularly those smaller companies who are now gearing up for 2013 registration. However, automating the sending of SDS in line with REACH is one way of alleviating some of the supply chain challenges and reducing the administration and costs involved and most importantly, ensuring compliance in this area. There seems little point in jeopardising all the hard work that has gone into registration by failing to comply with these regulations.

One thing is certain, these challenges won’t go away. According to the Chemical Logistics 2020 Report published recently by Cefig and Deloitte, the chemical industry will see even more complex supply chains in the future and it also highlighted the industry’s continued focus on sustainability; safety and security could lead to even more regulations. So, this is one area where regulatory challenges can be easily and cost effectively solved ahead of 2013.

Malcolm Carroll, Director of REACH Delivery REACH Delivery Tel: +44 1442 450 460 Web: www.reachdelivery.com

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