EPPM 15.4 by EPPM Magazine

May 2013

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in this issue

editorial editor david gray david.g@rapidnews.com editorial assistant mark wynne mark.wynne@rapidnews.com

production art samantha hamlyn production peter bartley production tracey roberts

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MACHINERY

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SHOWCASE: TEMPERATURE CONTROL

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ISSN No - 2052-3912 MAY 2013 • WWW.EPPM.COM • 3

4 • WWW.EPPM.COM • MAY 2013

John Ellis, Segment Manager Polycarbonate, Bayer MaterialScience

Clive Maier, Owner and Director, Econology Ltd.

Nigel Brown, Founding MD, Frontier Aerospace

Dr Martin Kay, Chief Consultant, Pira International

Vicki Sayer, Regulatory Manager, Colormatrix

Charmaine Bowers, Operations Manager, Polymer Training & Innovation Centre

Pipe Extrusion Recycling Micro Manufacturing Home Appliances

Automotives & Compounds

Mark Bonifacio, President, Bonifacio Consulting Services

Andy Bone, Sales Director, Formaplex

Andrew Smith, Head of Manufacturing, Numatic International

Wire & Cable

Aerospace Biopolymers

Alex Collins, Director, Vannplastics Ltd.

Regulation & Compliance

Andrew McArthur, Engineering Manager, IKO

Jonathon Short, MD, ECO Plastics Ltd.

Jon Herbert, Director, FS Cables

Biopolymers/Materials Science

Simon Chidgey, Director, M&H Plastics

General Industry Insight

Paul Maley, Senior Mechanical Engineer, Selex Elsag

James Goddard, Honorary Lifetime Member, Plastics Pipe Institute

Dr Terence A. Cooper, CEO, ARGO Group International

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

Advisor for the German & Scandinavian Speaking Countries

Film & Sheet Extrusion Recycling

Martin Marron, MD, Biffa Polymers

Graeme Diston, Senior Injection Moulding Engineer, Bausch + Lomb

Education in the UK & Ireland

Construction

Graham Pickwell, Technical Adviser, Polymer Training & Innovation Centre

Medical

Barry Assheton, Sales Director, CRDM

Mould Making

John Bunker, Member, Worshipful Company of Horners

Packaging

Omer Kutluoglu, CEO, 2K Manufacturing

Medical

Rapid Prototyping

Blow Moulding

Recycling

Injection Moulding

David Gray, Editor

John Sturgess, Director, MG Stuma

Andrew Feilden, Principle Consultant, Smithers Rapra

Wood Plastic Composites

When you first join the plastics industry, whether you’re supplier side or processor, technician or salesperson, marketing or engineering, there are a few things that everybody gets briefed on in their first week. Typically, if the field is injection moulding, lots of simplified diagrams and animations of polymer being fed or dosed into the machine and melted down before being forced into a mould, to give the basic understanding of the technology. We all did it once. Some are just 16 when they learn the ropes; others are going on 60. Well, there’s something else that everybody finds out about, maybe not in the first week, but certainly in the first year. The K Show. If you enter the business right at the start of the K cycle, your colleagues will probably still be buzzing (and possibly wobbling) from the previous show. Join in year two of the three year cycle, and you might find that people around you sporadically mention the show, fearful that hotels close to Messe Duesseldorf are already booking up fast (everybody wants to be close to the action). And if you join in a K Show year, a couple of months prior to the show, as I did back in 2010, you might just find that your standard initiation to that company (gathering stationary, setting up an email account, generally finding your feet) goes out of the window. And with good reason. Planning for a show the size of K is no mean feat. I’ve been planning since late last year, I suspect many readers have started even earlier. The (Images copyright hotels are just one thing. When Messe Duesseldorf). you get on–site, you have just a few days, if you’re lucky, to try and get round 17 halls (depending on what you’re there for). I’ve always adopted a very ‘loose’ approach to planning my shows, as I find that meetings so often overrun. But I suspect I’ll need more than a few contingency plans at K this year. Anyway, if I were to give a theme to this issue of EPPM, ‘planning for K’ would be it. This is the first of our traditional series of K Show issues. Over the last 15 years this magazine has reported on K for five cycles, and this year we plan to make our coverage as genuinely useful, relevant and helpful as possible. The media machine has already started to turn its cogs and we have the first stand announcements from just a handful of exhibitors who have already declared their offerings at the show. I expect that over the next three issues, the ‘K Preview Section’ will grow and grow as we become inundated with news about product launches and new partnerships. I just hope my forward-planning pays off!

Plastics for the Environment

K 2013: The First Impression

General Industry Insight

“

from the editor

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

Dr Gerd Schmaucks, Independent Consultant

cover story

Distribution portfolio continues to

E X PA N D ALBIS UK is a fully owned subsidiary of ALBIS GmbH which is one of the leading European distributors and thermoplastic compounders. ALBIS operates on an increasingly global scale with a plant in China currently under construction complementing facilities in Europe and the USA along with one of the strongest distribution networks in Europe. ALBIS UK has added a number of key products to the portfolio so far in 2013 widening its already ‘famous names’ product offering even further, and thus giving customers even more choice. In January NAS (SMMA) and Zylar (MBS) were added to ALBIS UK’s already extensive range of Styrolution products. The SMMA grades are known for their water clear color and desirable touch and feel. The impact modified (MBS) grades also offer clarity with practical toughness for those applications requiring resistance to breakage. Customers will now have ALBIS as a one-stop-shop for the whole range of Styrolution’s Specialty portfolio. ALBIS also provides local compounding, allowing them to offer customers smaller order sizes and special colours. In April the Catalloy range of products from Lyondellbasell were added into ALBIS’ portfolio. Catalloy resins are Thermoplastic Polyolefins that come directly from the reactor. They cover a whole range of properties from very soft without the use of plasticisers to very stiff. Application areas include building and construction, automotive, film and polymer modification. The range includes established brand names such as Adflex, Hifax, Softell and Adsyl. They can be used on their own or to enhance the properties of other materials via blending or compounding processes. Additionally ALBIS UK are now distributing Sipolprene from SIPOL in Italy. This a TPE-E / COPE . An elastomeric polymer, semi crystalline with excellent mechanical and impact strength coupled with flexibility.

ALBIS has a market leading range of polymers for healthcare applications

ALCOM light diffusion products are widely used in many lighting applications.

Own Compounds – Exciting new development: ALTECH NXT PP ALBIS is a leading compounder with an increasingly global reach. With the opening of the Chinese factory in July ALBIS will provide compounding capability to its customers in Europe, Asia and the Americas. Responding to trends towards lighter and more fuel efficient cars ALBIS has added ALTECH NXT PP to its range. Available in a 30% glass and mineral filled version and also 35% and 50% glass filled versions this range of products is aimed not just at the automotive market but also where similar properties to nylon or PP modified with long glass fibres are required. Applications are seen in the power tool, furniture and domestic appliance markets. With lower density than nylon, processing benefits such as no drying and lower processing temperatures this product provides cost effective solutions as well. Commenting on this product range Ian Mills, Managing Director of ALBIS UK said “We are seeing a high level of interest in ALTECH NXT from various industries including the automotive sector.

New to the ALBIS range ALTECH NXT PP helps reduce weight in cars. It’s first commercial applications are now running and we are confident that this product range will bring an excellent range of benefits to our customers.” ALBIS UK has been established almost fifty years and continues to develop its business to improve service and offerings to its customers. With a strong field sales and technical team ALBIS is continually investing in its technical knowledge and ensuring that its manufacturing business unit operates to the highest possible standards. Accreditations achieved include TS16949, ISO14001, OHSAS18001 and Investors in People. The group invites readers to visit at PDM on stand D0009 in June.

ALBIS UK Tel: +44 1565 755777 Email: albisuk@albis.com Web: www.albis.com

MAY 2013 • WWW.EPPM.COM • 5

MACHINERY

PO pipe extrusion line said to offer significant savings Extrusion machinery specialist battenfeld-cincinnati recently joined forces with partner companies Labotek and SABIC to demonstrate the latest version of its PO pipe extrusion line at an open house event held at the group’s site in Germany. The line is reported to consume at least 30% less energy than a predecessor model. 75 visitors were given demonstrations on the ways to run a pipe extrusion line in an ecological and economical way. With an annual production time of 7,000 hours, about €300,000 can be saved in electricity costs alone if a pipe extrusion

line is equipped with certain components, claims battenfeldcincinnati. The example used during the event was a co-extrusion line producing a twolayer pipe for pressure pipe applications, which reached an output of 750kg per hour and a line speed of 0.93 meters per minute. The group’s uniEX 35-30 and solEX 7540 extruders were used, as well as the helix 250-3 VSI-T+ pipe die with an EAC (efficient air cooling) internal cooling system, and the “Green Pipe” downstream equipment. uniEX single screw series extruders are equipped with AC motors using aircooled frequency converters. Models from the solEX series use an AC motor with a water-cooled frequency converter. battenfeld-cincinnati has also revised its helix VSI-T pipe dies in an effort to reduce energy consumption. The core component of the new helix 250 VSI-T+ 3-layer pipe die is a cooling basket installed between the spiral mandrel and the lattice basket. The EAC internal cooling system blows in cold air for internal pipe cooling and subsequently transfers heated air to the Labotek material drying system. The sagging effect (uneven wall thickness distribution) is significantly reduced, especially in large-diameter pipes, claims the company.

The third key component is the “Green Pipe” downstream equipment with built-in cooling system. This system uses frequency-controlled vacuum and water pumps. The cooling system also operates with a water volume flow cut by almost 90%, a reduction which is achieved by pumping the cooling water into the last tank and then passing it on from one tank to the next in the opposite direction to the extrusion process. With those amendments, battenfeld-cincinnatti is claiming that energy cost savings of at least 30% can be achieved. Labotek a supplier of drying systems for the plastics industry has worked with battenfeld-cincinnatti to develop an EAC variant of its combination dryer, which was demonstrated at the open house in operation with the line. The drying system operates with two separate drying zones. The hot air drawn from the pipe die is blown into the top zone. The bottom zone is laid out as a conventional drying zone with a dry air system to ensure the necessary degree of dryness for the material. The dryer

consumes no more than 11 kW for drying 1,500 kg/h of granulate. SABIC has developed a new PE compound designed for energy-efficient pipe extrusion. Vestolen A-Rely 5924 R 10.000 was used to produce the pipe during the open house demonstration. Compared to a conventional PE-100, it is said to require measurably less energy for melting and processing in an extruder. battenfeld-cincinnati Web: www.battenfeld-cincinnati.com Labotek Web: www.labotek.com SABIC Web: www.sabic-europe.com

Blown film gauge control claims to enable greater output Addex Inc., a global supplier of blown film equipment and components, has released an automatic external gauge control (EGC) system for blown film extrusion lines. The new Tandem external gauge control (TEGC) system combines the gauge control efficiency of Addex’s EGC air ring, with a bubble stabilising lower air ring which reportedly achieves 15% to 30% greater output compared to Addex’s standard EGC system. “The Tandem EGC is the culmination of extensive development work and is yet another example of how Addex works continually to devise unique products that help processors increase yield and realise major raw material savings,” said Rick von Kraus, President of Addex Inc. The lower single-lip air ring sits on the die and matches the die’s diameter. It is fed by a blower about half the size of the blower needed for a typical air ring. The blower gently cools the bubble and stabilises it before entering the realm of the upper, dual-lip automatic gauge control air ring which is located above it. The more stable bubble allows for higher output without jeopardising the gauge control function. 6 • WWW.EPPM.COM • MAY 2013

The upper EGC air ring is 50mm bigger than the die size. Therefore, a 400mm die employs a 400mm single-lip air ring located on the die and an 450mm EGC air ring situated on top (as shown in photo). The larger diameter for the upper air ring, which is equipped with the gauge controlling features, is needed to accommodate for the blow up ratio. The remaining components of the Tandem EGC system are the same as those of the standard EGC system. The standard unit is an automatic system that reduces film thickness variations by up to 70%, typically resulting in a 5% to 6% raw material savings. Addex simplified the original air ring structure by moving the electronic circuit board from outside of the air ring into the plenum area. This integration offers simplicity, enabling the user (end user or OEM customer) to rely on its own control panel if desired. An end user or OEM customer may also use its own thickness measuring system and feed it via the Ethernet connection to the air ring. Other key options for the OEM include

mapping hardware and software for the control processor and monitoring devices for the reversing nip position and nip roll speed along with a control algorithm which converts the mapped gauge profile into instructions for the air ring software. The EGC system is claimed to have the most control zones in the industry for air ring-based systems. The number of control zones ranges from 90 to 288 depending on the air ring size. A scanning actuator horizontally slides as many teeth (control zones) as needed to open or close the air flow channels (vanes) and automatically adjusts the cooling air, thus correcting thickness variation in the blown film. Just two motors activate all the movable parts in the system compared to competitive systems which use one motor per zone. Like the previous EGC air ring, one motor is used to adjust the air flow and

the second one adjusts the first motor 360 degrees. Addex Web: www.addexinc.com

MACHINERY ROUNDUP Purging ‘reclaim’ system produces quality regrind Maguire Products, Inc. claims it has streamlined the operation of its system for recycling purgings into regrind, offering potential increases in throughput of 20% and production of finer and more uniform granulate with less dusting. The group has received the CE certification required to make the system available in Europe. The modifications to the Maguire Purging Recovery System (PRS) may also benefit the granulation of polystyrene, flexible vinyl, and other polymers that might otherwise melt or degrade under the forces of size reduction, causing backup or clumping that shuts the system down. In the PRS, material undergoes two stages of size reduction. First, a rotor planer slices or planes the rock-like purging into small chips. Next, a granulator reduces the chips to regrind. The knives in the rotor planer are now 40% smaller, while their number has increased from eight to twelve. As a result, the planer produces smaller chips that are more easily and uniformly reduced by the second-stage granulator. The cutting also yields less dust than in the previous version. The cutting chamber of the secondstage granulator has been redesigned to increase the flow of air generated by a blower. The material in the granulator is thus cooled more effectively, preventing melting, and it is evacuated from the cutting chamber more rapidly. These enhancements make finer granulate possible, with minimum hole sizes in the screen of the second-stage granulator reduced from 9.52mm to 6.35mm. In a further improvement, Maguire has replaced the previous onepiece screen with a three-piece screen that is easier and less expensive to replace. Typically a purging is discharged onto the shop floor, hardens, is scraped up, and is disposed of, ultimately ending up in landfill. Over time, this adds up to a waste of material valued at thousands of dollars per year, claims Maguire. “Our PRS system is the only low-cost

equipment designed specifically for the rugged work of sizereducing heavy masses of plastic,” said B. Smith, Marketing and Sales at Maguire. “Since a 4.5kg lump of hard plastic could damage the rotor of a conventional granulator, the only other alternative for reclaiming purgings is to purchase a heavyduty granulator for $100,000 to $200,000.” The Purging Recovery System draws on the concept of the carpenter’s plane. It consists of a table that is split into two levels and a purging containment chamber that, upon startup

surface levels, is actually a rotor with staggered knives that turns at 1750 rpm With each pass of the containment chamber, the rotor planes away thin (13mm) slices from the bottom of the purging and propels these chips into the hopper of a compact granulator beneath the table. As material is planed away from the purging, a pneumatically-driven hold-down plate in the containment chamber keeps the purging in contact with the knives.

of the system, moves back and forth over the table. The planer, mounted at the point of disjunction between the two

Maguire Products Inc. Tel: +1 610 459 4300 Email: info@maguire.com Web: www.maguire.com

15 new sizes available from mould suppliers

Meusburger customers now benefit from an even larger range of mould sizes. With a total of 15 new sizes up to 996 1196, the company has extended its product range so customers can now choose from 113 different mould sizes. The extension is for both F - plates (with guide holes) and P - plates (without guide holes). For the new 66mm guiding diameter, the matching E - Accessories are also available. Meusburger Tel: +43 55 74 67 060 Web: www.meusburger.com MAY 2013 • WWW.EPPM.COM • 7

MACHINERY ROUNDUP Equipment supplier shows its flexibility UK-based material handling equipment supplier Genesis Process Solutions has recently delivered additional mobile bins to a North West compounder to use as a dynamic refill The mobile bins arriving at a system for its compounding site in North West Brabender loss-inEngland weight feeders, taking their total on site to eight. Genesis Process Solutions says the concept of a mobile bin is far from new, but in using the Krause Flexible Transport System (FTS) it gives the customer the option of using very poor flowing materials in mobile bins where a conveying system would normally be chosen. As the FTS units are filled in a controlled, dust–free manner, transported to the line via forklift truck, pushed into position on a mezzanine floor and then connected to the agitation system, they are a completely sealed unit. Once in position, the operator simply opens the manual slide valve on the FTS unit and the system then interacts with the Brabender feeder giving the signal to refill – thus opening a pneumatic valve and starting the agitation system. Genesis Process Solutions says the FTS can be supplied in many shapes and sizes to suit the customer requirements, as can the inlets and outlets, as everything is bespoke. “The ones supplied on this particular project were using a coated material, but for less dusty products, a breathable fabric would be used,” explained Genesis Sales Manager Phil Cameron. “The beauty of using the FTS is that the side walls and cone change shape with the product discharge and therefore dramatically reduces bridging and rat holing typically found in rigid hoppers,” he continued. Genesis Process Solutions, the UK & Ireland agents for Krause, also developed an agitation system to go underneath the bins using ‘pushers’ to agitate the flexible cone and ensure good mass flow. The company says various products are currently being used on–site such as calcium carbonate and fibreglass strands. “We have effectively used our knowledge and experience from our larger flexible silos and downsized to suit mobile bins. The pusher agitation system effectively mimics the Flexwall feeder in its operation and therefore gives us a great mass flow from the hoppers,” Cameron concluded. Genesis Process Solutions Web: www.genesisps.co.uk

Hot runner specialist adopts new CAE analysis Mold-Masters, a global name in hot runner technology has selected Moldex3D software from CoreTech System Co., Ltd., an injection moulding CAE simulation specialist, to be the global CAE analysis standard for design verification and optimisation of hot runner systems. Mold-Masters has reportedly invested in “a comprehensive product management project to set global CAD/CAM/CAE standards for the organisation to accommodate the growing demands in hot runner business”, according to a statement from SimpaTec, a re-seller of Moldex3D. Responsible for the project is the Global Engineering team which leads engineering offices in Germany, Canada, China and India. After evaluation and benchmarking, Mold-Masters decided to globally adopt Moldex3D to build the CAE analysis standard for the design verification and optimisation of the hot runner system. Cristoph Hinse, Managing Director of SimpaTec, stated: “We as re-seller appreciate Mold-Masters’ decision as a very important step for the plastics injection moulding industry. With Moldex3D the user is able to analyse and revise hot runner systems in order to observe quality aspects of the final product, e.g. filling pattern, weld lines, high gloss or painting free. But also economic aspects like reducing cycle times, clamping force or injection pressure or saving resin, are assessable too. We are looking forward to a fruitful and successful cooperation.” “In our 50 years in business, it has never been the plan for Mold-Masters to take the easy path in product development. We make the best, not the easiest” said Hans Hagelstein, President of MoldMasters Global Engineering. “At Mold-Masters, we are continually looking to have the best-in-class engineering analysis software to help us to deliver the ultimate in melt delivery and control systems. We selected Moldex3D

Mold-Masters is a provider of hot runner technology.

(a)

(b)

Shown is the original design (a). The evaluation with Moldex3D results in a more uniform temperature along hot runner nozzle in the revised design (b). because of its unique technologies. The tool not only offers more realistic mould filling simulation results for building the organisation standard for hot runner design analysis, but also provides more advanced 3D features to help us on the deep investigation of new product development.” “We are very excited to working with Mold-Masters which is the world leading supplier of hot runner technology” said Dr. Venny Yang, President of the CoreTech System. “Hot runner system plays more and more an important role in achieving an effective injection moulding. Moldex3D not only offers the advanced coupled flow and thermal analysis for hot runner systems, but also develops the private cloud solution for helping customers to build their own high performance computing platform. I firmly believe that Moldex3D unique capabilities will provide greater value to MoldMasters for strengthening the company competitiveness.” SimpaTec GmbH Tel: +49 241 9367 1500 Email: c.hinse@simpatec.com Web: www.simpatec.com

New dosing unit with brushless DC motor launched New Omap, an Italian supplier of materials handling equipment covering loading, storing and mixing, drying, dosing, conveying and granulating has developed a new range of dosing units. These new units are said to incorporate a brushless DC motor with torque control based on the Hall Effect (the production of a potential difference across an electrical conductor when a magnetic field is applied in a direction perpendicular to that of the flow of current). New Omap says in effect this means a much smaller physical unit but with superior self-regulating control characteristics. The new controller will also incorporate test and self-optimisation features. The company states another major advantage is that this new unit will more than cover the existing DOSA1 and DOSA2 throughput range (0.2 – 30 kg/hr of additive). Massimo Rubbis, Export Sales Director of New Omap, supplier to UK distributor Intelicare, commented: “The new brushless DC motor dosers offer significant benefits over the existing well proven and successful DOSA range. For instance, the combination of DC motor with one set of standard screws provide step-less dosing adjustment covering a wide throughput range. Customers will benefit from the avoidance of changing feed screws plus a higher 8 • WWW.EPPM.COM • MAY 2013

The new dosing unit from New Omap accuracy of dosing resulting in a more consistent and repeatable end product.” Intellicare Web: www.intelicare.co.uk

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MACHINERY ROUNDUP Granulators designed for plastic bottle processing New NCF Series super-tangential granulators from auxilliary equipment supplier Conair are claimed to have footprint dimensions at least 30% smaller than many other granulators with similar capabilities. The group says the cutting chamber configuration is ideal for handling lightweight bulky parts such as plastic bottles, but also produces clean, uniform granulate from runners and small parts. Different hopper designs and rotor/knife choices are available which are said to maximise performance with a wide variety of scrap types. Conair states four different models feature 203mm diameter rotors, in widths of 240, 360, 480 and 600mm, and deliver standard maximum throughputs ranging from 68 to 205kg. A five-horsepower motor powers the smallest unit and the three larger sizes have 7.5 horsepower motors with options to 15 horsepower.

Standard rotor speed for the NCF 810 is said to be 260 rpm and standard speed on the larger models is 400 rpm, although Conair says 260-, 400- or 840rpm can be specified on any of the granulators to increase capacity, improve regrind quality and/or minimise energy consumption. A tilt-back hopper and drop-down screen cradle are said to provide easy access to the cutting chamber for maintenance and cleaning. Conair says these features contribute to increased productivity and reduced downtime. An optional sound attenuation package is also claimed to make the NCF Series quieter than other small granulators. Conair states the super-tangential chamber design ensures that the rotor grips bulky scrap on the downward stroke, drawing it into the knives and preventing it from bouncing on the rotor. Standard tangential and straight-drop in-

Conair states its new NCF Series super-tangential granulators have footprint dimensions at least 30% smaller than many other granulators with similar capabilities feed configurations are also available. The company says the rotor itself can be open with three rows of double-angled knives for a clean scissors cut with minimum heat generation. For tougher materials, a solid rotor can be equipped with three rows of up to five cassette knives in a staggered array. Cassette knives allow for quick and easy knife changes and minimise downtime for service and maintenance. The knives require no adjusting to maintain a consistent knife gap for improved quality, according to Conair. Conair www.conairgroup.com

PVC compounder boosts capabilities with equipment investment Premier Tech Chronos has recently supplied specialist PVC compounder Dugdale plc with its eighth ChronoWeigh E55 bagging weigher, for the company’s Sowerby Bridge compounding facility in West Yorkshire, UK. During the last five years Dugdale has invested several million pounds in its new compounding plant, which has been designed to help develop and manufacture high performance lead-free PVC compounds. It is also enabling the

group to expand its range of cellular grades, anti-microbial compounds, sealing and intumescent products as well as PVC alloys for elevated temperature applications. The latest system to be installed by Premier Tech Chronos is a repeat of the previously supplied equipment, but operating at twice the throughput. A new–gravity fed Chrono-Weigh E55 weigher, with stainless steel contact parts has been supplied on a bespoke designed double level support

framework; feedbin, valve bag filling spout, and FIBC filling spout. This has been installed in an existing building that is adjacent to several previously supplied Premier Tech Chronos bagging systems. Premier Tech Chronos engineers installed and commissioned the new bagging system and integrated it with the material conveying feed system. To provide Dugdale with optimum levels of flexibility for its packing operation, the new system has a

‘push-pull’ discharge chute configuration, which allows precision individual weighments to be made into valve bags, or multi-tip precision weighments to be made into IBCs. Control of the bagging process is achieved using a SpeedAC NXT high accuracy weighing controller. Premier Tech Chronos Limited Tel: +44 115 9351351 Email: info-eu@ptchronos.com Web: www.premiertechchronos.com

Plasma group opens surface treatment and testing facility Henniker, a specialist in plasma surface treatment technology, has recently opened the doors to its new purposedesigned plasma surface treatment and testing facility in Warrington, UK. Following rapid expansion and an increasing demand for plasma treatments from the automotive and aerospace sectors, the new facility will allow Henniker to provide routine surface treatments, process development, and both pre- and posttreatment surface testing to its clients. Plasma treatment is a surface preparation technique. Plasma removes organic contamination from surfaces

with no harmful waste or by-products and renders many surfaces hydrophilic, which in turn improves adhesion characteristics. Plasma treatment installations are currently used to improve product manufacturing and finishing in areas as diverse as automotive component painting and sub-sea power connector assemblies. In its new facility, Henniker has combined plasma treatment equipment with comprehensive surface testing facilities, including surface contamination detection and identification apparatus and also surface energy testing to ISO DIN standards,

New mould temperature control connectors eliminate spillage Stäubli, a specialist in connection technology, has added a new multiconnector to its range of products for the plastics market. Named MCI 209, the new design is a flat faced multicoupling capable of connecting up to 10 separate mould cooling circuits. The flat faced design is said to eliminate any spillage on connection or disconnection, improving safety by preventing the risk of leaking high temperature or water glycol fluids, making floors slippery, as well as minimising the consumption of heat transfer fluids. Stäubli says the design also ensures no ingress of contaminants into the circuits that could affect the performance of the cooling fluid and increase the maintenance 10 • WWW.EPPM.COM • MAY 2013

required on the system. Ensuring safe and effective connections is of prime importance and the MCI 209 range is said to incorporate a fool–proof keying system that prevents connection errors and eliminates any risk of cross connection; the robust locking system ensures circuit integrity. Stäubli says all circuit connections are made by one action, reducing the time to change moulds. The optional proximity switch ensures safe working practices are maintained by providing direct indication that the plates are securely together. A parking plate provides the additional benefit of protecting the machine side plate during a tool change and improving safety by

retaining loose hoses. Stäubli states MCI 209 is suitable for both new and existing injection moulding machines and moulds, as well as other applications where fluid circuits need to be connected and disconnected without any spillage, for example in the medical and pharmaceutical markets. CAD files of the new connector are available on request. Stäubli UK Ltd. Tel: +44 1952 671918 Email: connectors.uk@staubli.com Web: www.staubli.com/en/connectors

using a variety of test methods such as surface test fluids and contact angle measurement techniques. Henniker says that the facilities are run by trained staff with many years of practical experience in plasma and surface testing techniques and are offered to new and existing clients to assist with free proof-of-concept trials, application support and process development services. Henniker Scientific Tel: +44 1925 830 771 Email: info@henniker-scientific.com Web: www.henniker-scientific.com

MACHINERY ROUNDUP Italian recycler boosts quality with colour sorting

Wittmann all-wheel drive for improved dynamics Insertion and removal times are a crucial aspect of packaging and IML applications. For achieving the respective acceleration, drive torques are needed that are very close to the edge of feasibility. At speeds beyond 6m/s, accelerations of more than 60m/s² are absolutely common when using lightweight grippers. The new Wittmann all-wheel drive has been designed to reach these accelerations. The market has veered towards systems that are able to handle higher payloads at constant dynamics, claims Wittmann. A straightforward solution might be a simple increase of the available motor performance. This can be achieved, but Wittmann says that the approach has some disadvantages: Firstly, the mass inertia of a servo drive rises typically to the second – related to its performance. The bigger the motor, the higher the share of energy that has to drive the rotor. The outcomes are often overdimensioned and expensive driving packages. Unfortunately, these are all too often seen today in use with packaging and IML applications. The bevel of a toothed drive belt can only transmit a limited torque. Increasing torque, by necessity, means a broader toothed drive belt. The group has now developed a solution for the W837 range of horizontal robots. Part of the amendment is to use two smaller drives instead of one big motor. Wittmann’s product trials and research have shown that:

Two motors, each of them with half the power, amount to more than double the dynamics of a single big motor. The mechanical power that is infed in the toothed drive belt now combines on two tooth wheels. The toothed drive belt and the basic construction of the robot remain unchanged, and the extra drive effort can be kept within a limit. The drive control and its algorithms also ensure that the loads carried by each of the two drives are exactly the same. The new W837-2drive robot model was introduced at the company’s “Competence Days” in Kottingbrunn, Austria last month. The system was shown in combination with an electric EcoPower 180/750 injection moulding machine. This new IML application demonstrated the removal of lids from a fourfold mould, with a time limit of less than 0.5 seconds for demoulding. The W837 robot differs from the standard model only through its double drive chain. This feature improves flexibility and modularity when designing and commissioning production systems, says Wittmann.

View of an IML system in operation (top) and the new all-wheel drive (bottom). Wittmann Robot Systeme GmbH Tel: +49 9128 70990 Email: info.de@wittmann-group.com Web: www.wittmann-group.com

The introduction of colour sorting technology has reportedly enabled Italian plastics processor Adige Ambiente to achieve higher value yields for the 35,000 tonnes of recycled PP/PE it processes each year. Based in the Lake Garda area, Adige Ambiente’s main business is grinding and sorting industrial plastics waste to produce a recycled product to sell to plastic product manufacturers. However, the recycled PP/PE specialist needed to employ colour separation and grouping technology in order to achieve a higher-value, colour sorted, end product. Bühler installed four SORTEX Z+ bichromatic machines to sort high capacities of mixed HDPE regrind into four colour groups. The system uses bichromatic colour sorting camera technology that is designed to sort mixed colour PP/PE into four colour separated products. Adige Ambiente owner Luigi Molinari said: “We were looking for a way to ensure the highest quality sort from mixed colour PP/PE regrind. Bühler’s expert team were able to demonstrate quality and efficiency in their SORTEX technology.” Bühler Tel: +41 71 955 1111 Web: www.buhlergroup.com

We are delighted to announce the launch of our new website, with a revised layout to make your life easier. Whether it’s a quick visit to catch up on the news, or a more detailed search for new suppliers, eppm.com will have a permanent place in your favourites list. If you don’t already receive a FREE copy of our printed or digital edition of eppm, please head to the site to register your interest and provided you make specifying or buying decisions, we would be pleased to send you a regular copy. By registering we’ll also keep you up to date with what’s going on in the European plastics industry, with our weekly news broadcast sent straight to your desktop or tablet.

w www.eppm.com ww.eppm m..com MAY 2013 • WWW.EPPM.COM • 11

MACHINERY

SHOWCASE TEMPERATURE CONTROL Temp control range to be expanded in time for K Wittmann Battenfeld unveiled the latest expansion of its Tempro series of temperature controllers at Fakuma 2012 and is set to reveal further developments at K 2013.

Wittmann claims its three newest models, the Primus C120, the Tempro Plus D and the Tempro with variotherm functioning, represent leading technological edge for temperature

control in the plastics industry. The directly cooled Tempro direct C120 temperature controller was developed in response to the industry’s demand for directly cooled

Wittmann Battenfeld is set to unveil further expansions to its range of temperature control equipment at K 2013. controllers and Wittmann claims that the unit has become popular with plastics processors over the past few years. The company now offers many variants of the Tempro direct C120 – in regards to different pumps and different heating and cooling capacities. The dimensions of the new unit are said to be the same as of the Tempro primus C90 and it therefore meets the requirements of a compact besidethe-press unit. Wittmann says it can be used at temperatures of up to a maximum of 120°C, with a standard heating output of 9 kW and a maximum delivery rate of 200 l at 2.4 bar operating pressure. It is suitable for all applications where high cooling performance and high delivery rates are both required. The development of plastics markets and the new applications that go along with it make new demands on peripheral equipment and developers at Wittmann say higher temperatures for controllers have yet again increased. The pressurised models (140–180°C) of the Tempro Plus D appliance series are, therefore, now available with an optional heating output of 16 kW per temperature control circuit. Tempro plus D appliances are equipped with a dimensioned 5.7" LCD colour screen as standard. Various buttons on the display are freely configurable so that the data required in each case can be retrieved exactly as desired by the operator. In addition, the Tempro plus D Vario is now available. Here, the cavity temperature is measured via a thermal element thus allowing for heating up and cooling the cavity to a defined temperature. Heating time and cooling time are determined for every cycle, thus increasing the stability of the process. Wittmann Battenfeld Tel: +43 1 250 390 Email: info.at@wittmann-group.com Web: www.wittmann-group.com

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MACHINERY

SHOWCASE TEMPERATURE CONTROL Italian firm modifies plastics chiller range

Water could replace hot oil, claims polymers group

Frigosystem, an Italian supplier of temperature control equipment for heating, cooling and chilling of water, oil and air, has developed a modified version of its Raca Plus Energy chiller. The series employs scroll compressors and uses new technology aluminium micro-channel condensers that are said to ensure a premium level of efficiency. This solution also allows the reduction in the volume of refrigerant gas by 40% in comparison to traditional copper/aluminium coils as well as improving the resistance against galvanic corrosion. Micro channel coils are easy to clean as they can be washed with a high-pressure sprayer without bending the fins. The product range has also been extended and now starts from 50kW up to 1,200kW cooling capacity and comes with multicircuit and multicompressor systems that may be specified with or without reservoir or pumps. Efficiency has reportedly been maintained while increasing the ambient operating temperature range from 43°C to 45°C

In many cases, hot oil is the preferred temperature control fluid for injection moulding, but Ticona, the engineering polymers business of Celanese Corporation, claims it has found that processors can use hot-water systems to achieve superior heat transfer performance suitable for hightemperature resins such as its semicrystalline polymer, Fortron polyphenylene sulfide (PPS). “We have repeatedly observed that commercially available high pressure hot water technology provides sufficient heat transfer, which ensures optimum uniform tool heating for moulding highperformance materials like Fortron PPS,” said John Farrell, Global Leader Processing Labs, Ticona. “In addition, Ticona polymer processing teams in the Americas, Europe and Asia found that water systems are a cleaner, safer and better environmental choice for efficient mould temperature control.” Ticona processing engineers validated the moulding of Fortron PPS with various hot water systems, including units from Wittmann Inc. and Single Temperature

Frigosystem states these chillers may be specified with dual water circuits providing both chilled and cooled water circuits while utilising a common return. The company says all Raca Plus Energy and Raca E chillers may further be specified with free cooling to further improve energy savings. Frigosystem Tel: +39 02 9658610 Email: info@frigosystem.it Web: www.frigosystem.it

Controls Inc. “We looked for improved heating of injection mould tooling considering the challenges using hot oil,” Farrell said. “Our teams confirmed the heat transfer of water is better than oil and can achieve the appropriate crystalline content of a higher-performance thermoplastic such as Fortron PPS.” Specifically, Ticona said its processing teams made the claim that waterpressure heaters are better at controlling temperature as water is a superior heat transfer medium to oil, which often needs to be 37.77°C hotter to achieve the same temperature as water; superior to electrically heated tools, as cartridge heaters transfer heat into the tool and part, but have only passive cooling, which can lead to poor process control and part variability; and also, that they are cleaner and safer than oil systems as water is inexpensive, can be easily disposed of and does not degrade when exposed to air. Ticona Web: www.celanese.com/ticona

High efficiency chiller delivers hot energy savings UK-based cooling specialist Cool-Therm has announced that it has installed a new Turbomiser chiller at a flexible packaging manufacturer. CoolTherm states the new, high-efficiency Turbomiser chiller, installed at Amcor Flexibles Winterbourne, operates on virtually frictionless magnetic bearings, to deliver lower power consumption and reduced carbon emissions. During the project, Cool-Therm worked closely with staff at Amcor to replace one of the existing chillers at the site after it had reached the end of its operational life. Cool-Therm has worked with Amcor Flexibles Winterbourne for more than 20 years, installing and servicing three large chillers delivering the continuous chilled water required by the plant’s plastics extrusion machines. Cool-Therm says the new Turbomiser chiller, installed alongside two existing McQuay centrifugal chillers, operates around the clock to maximise savings. Andreij Duma, Operations Director at Amcor Flexibles Winterbourne, said: “Cool-Therm anticipated a 20 to 25 percent energy saving with the introduction of Turbomiser. However, the performance over the first six months looks even better than this, and the latest figures show a saving of just under 50 percent.” Ken Strong, Managing Director of Cool-

The new Turbomiser chiller from Cool-Therm. Therm, explained: “The period of use so far covers the warm season. We would expect even better efficiency still during winter. Here, Turbomiser can operate at lower condensing temperatures where the efficiency advantages are greatest.” The optimum level for Turbomiser is considered to be 25 to 60 percent of load, where, due to its operating characteristics versus conventional chillers, energy efficiency for the delivered cooling capacity is maximised. Turbomiser is equipped with integral inverter drives, enabling very fine incremental adjustments to be made to precisely match chiller output to cooling load. Cool-Therm states it is now working to fine-tune the cooling system to deliver further energy savings to customers. Cool-Therm Tel: +44 303 030 0003 Email: enquiries@cooltherm.co.uk Web: www.cooltherm.co.uk

MAY 2013 • WWW.EPPM.COM • 13

MACHINERY SPOTLIGHT eppm

INJECTION MOULDING

BORCHE: A NEW NAME IN EUROPE’S INJECTION MOULDING SECTOR

In the first issue of 2013, EPPM profiled on its front cover a 400 tonne injection moulding machine from Borche, a rapidly emerging international supplier of injection moulding machinery. The Borche story began almost exactly 10 years ago in early 2003, in Guangzhou, China. Today, the group builds in excess of 7,000 machines a year and has plans to grow this considerably. The portfolio ranges from 60 to 6,000 tonnes, with options for toggle, hydraulic and electric locking. Since that front cover was published a few months ago, Plastic Machinery Sales UK Ltd, the UK partner of Borche, has seen continued growth and demand for the range. 32 machines are now in production in the UK and a number of quotes for machines up to 2,500 tonnes have been submitted since January. We caught up with Alec Farrell, Managing Director of PMS, to find out why uptake for the Borche brand is so strong, and what the next steps are for the two companies.

EPPM: First of all Alec, when and where did your involvement with the Borche group begin? Alec Farrell: I did my training with Peco/Windsor as an engineer. I worked with a very experienced gentleman named Richard Sayers who was a chief designer for Peco/ Windsor at that time. Richard was instrumental in many of the improvements that Peco/Windsor made, and in 50 years he has been a problem-solver for the plastics industry. Richard moved out to China in 1972 and has had significant influence on the technical specification and design of Borche, ensuring industry leading technology, exceptional quality, reliability and effectively producing a product that the market needs in Europe, at a competitive price. For too long the Central European manufacturers have had it their own way and Richard asked if we would promote Borche into the European market. As we have been used machinery dealers in the UK for the past 40 years, we have considerable experience finding buyers what they want at competitive prices. Borche adds to this service, effectively allowing us to offer our customers new fully guaranteed high quality machines at used machinery prices. This removes the uncertainties within the second hand markets allowing our customers to buy exactly

what they want specification–wise. The machines are fully guaranteed, backed up by our in-house service team and as we are experienced used machinery dealers we can offer market value trade-ins on their current plant. Add to this the industry leading power saving technology, and it is a win-win for our clients. Borche fits our business model, allowing our experienced team to give the market what it needs at a price that is right. EPPM: So what attracts UK moulders to this range? AF: The price is important as CAPEX needs controlling but this is only part of the equation. Power saving technology makes the plant cheaper to run than even a five-year-old used machine, thus reducing overheads. When you add the excellent quality, the 100% reliability and the customisation that is available plus a market value trade-in on the old plant it gives a competitive advantage at a price that is affordable. In addition we stock a range of machines that are immediately available and the lead time on new orders is only 10 to 12 weeks. EPPM: Diversity and flexibility is important too - how diverse is the portfolio?

The Borche facility in China as

it is today.

AF: The range covers 60 to 6,000 tonnes. The machines carry every conceivable option and are customisable even to the point of being able to choose your own colour to fit in with your existing plant. EPPM: Why do you think the last 12 months in particular have been so good for sales of the Borche range? AF: The UK market has seen a reduction in quality in used machinery on the market. At the same time key tier 1 automotive suppliers have seen a major increase in orders which has put a strain on existing manufacturing. A number of established moulders have needed to increase capacity quickly whilst controlling the capital cost. The technology in Borche provides exceptional quality with all the benefits of modern power saving, basically providing current industry needs. EPPM: We all know your market is hugely competitive in the UK and Europe, and the major players are innovating this year especially with K just around the corner. What is Borche doing to innovate? AF: We have mentioned power saving above which is hugely important in reducing running costs. A 320-tonne BS III machine in our showroom, under moulding conditions, using P/P in the production of four litre flower pots, currently uses less power than a three bar electric fire!

Borche machines in situ. The

14 • WWW.EPPM.COM • MAY 2013

es.

range covers 60 to 6,000 tonn

Borche has an international team who are constantly updating both the toggle and hydraulic ranges to ensure industry leading quality tied with value for money. There is a range of all electric machines being released later in the year and the 6,000-tonne capacity machine has just been ordered by a Chinese company. EPPM: Why do you think Borche selected PMS to represent them in the UK? AF: Our experience and reputation within the UK market and our transparent approach to supplying the injection moulding market. We are not simply an agency; this is a partnership. We are not sales people trying to make targets, promising the earth simply to secure a sale, we are engineers with a wealth of experience providing our customers solutions to their manufacturing challenges – this is why Borche chose us as their partner. EPPM: Finally, what does the future hold for both PMS and Borche? AF: We have sold machines ranging from 60 to 1,200 tonnes (twin shot) to date into the UK. We have quotes to major manufacturers to supply machines up to 2,500 tonne. Our conservative aim is to have circa 80 to 100 machines in the UK by the year end and as the story grows to increase the exposure of this wonderful machine to a wider audience.

Stay tuned for more updates from this growing brand.

MACHINERY SPOTLIGHT

A UK water meter manufacturer is accruing sizeable energy savings, approximately £2600 per machine, after upgrading 15 of its injection moulding machines to incorporate Sumitomo (SHI) Demag’s active Control systems. Operating globally, Elster is one of the world’s largest electricity, gas and water measurement and control providers. The company has supplied more than 200 million metering devices in the last ten years across

POWER-SAVING PUMP CONTROL SYSTEM CUTS MOULDING ENERGY BILLS

electricity, gas, water and multi-utility applications. Elster’s UK water metering business manufactures metering systems for utilities, commercial and industrial organisations including South East Water and Anglian Water. It moulds all the internal components for its water meters on hydraulic and electric injection moulding systems from Sumitomo (SHI) Demag. Some of the hydraulic machines onsite at Elster are nearly 20 years old, but are vital to Elster’s operation as they perform to tolerances that could not be matched by electric machines, as Clint Sharp, engineering manager at Elster Metering, explained: “With these components we cannot take the risk of movement and subsequent shrinkage post-recovery, so we have to maintain strict moulding pressure tolerances. In some cases floor flatness has to be within seven micron. To achieve these tolerances we need machines with very long cycle times.” However, with energy prices climbing year on year, Elster was feeling the impact of the higher energy consumption of its hydraulic machine base. “Electric machines

use servo drives, which are more energy efficient than hydraulics for injection moulding presses, plus the servo motor is only in operation at certain times of the machine cycle, whereas the pump motor on a hydraulic machine runs continuously,” explained Ian Ramsay, after sales manager with Sumitomo (SHI) Demag. To help its customers reduce energy bills for their hydraulic machines, Sumitomo (SHI) Demag has developed a retrofit package called activeControl. This optimises energy consumption during idle periods in the cycle using ‘activeEnergy Saving’ to reduce consumption by up to 80%. “The cooling phase of the cycle is when traditionally, the pump would be running but not actually doing anything,” said Ian Ramsay. “Essentially, activeControl involves installing an inverter to control the frequency of the pump motor so that during idle periods, instead of running at full power, the pump motor is ramped right down to 25Hz.” Keen to trial this solution, Elster Metering bought the activeControl package for one of its hydraulic machines. This yielded cost savings of 37%, which equates to around £2600 a year, convinced Elster to fit the

invertor kit onto the rest of its hydraulic fleet. The company now has 15 machines, ranging in capacity from 25 up to 150 tonnes, operating with active Control. “Everything we purchase has to pay back within two years,” said Clint Sharp. “This was a big project for us and it has paid for itself within two years in the energy savings we have made.” He continued: “We now specify these drives for all new equipment purchases, which has eliminated other injection mould machinery manufacturers from the running. There are some who claim to offer similar energy saving packages but we’re keen to see this particular invertor kit as we know it delivers real results.” Sumitomo Demag Tel: +44 1296 739500 Web: uk.sumitomo-shi-demag.eu

The final four machines, from a total order of 13 ELEKTRA machines ranging from 1,100 to 1,550 kN clamping force, will soon be delivered to Hirschmann Automotive. “This will bring the total number of Ferromatik Milacron machines at Hirschman to 70. All of these machines

love the energy efficiency of the ELEKTRA machines, and the excellent repeatability,” said Markus Welte, head of electrical system engineering at Hirschmann Automotive. “Other benefits are how quietly the machines run, and how little space they take up. These make for a better production environment in our facilities,” he added. The collaboration between Hirschmann Automotive and Ferromatik Milacron began in 1997 with a first all-electric ELEKTRA machine. After that, the company ordered hydraulic K-TEC machines for several years, until 2002 when Hirschmann Automotive switched over completely to all-electric injection moulding machines. Hirschmann Automotive GmbH was founded in 1959 in Austria. The company creates innovative products, Machine acceptance of the ELEKTRA 155 (left to right): including connectors and Bernd Breisacher (Ferromatik Milacron), Philipp Lang, sensors for premium Markus Welte, Wolfgang Märk, Manuel Loretz (all from German automobile Hirschmann Automotive), Thomas Striegel und Ralf Cezanne manufacturers. Today (both from Ferromatik Milacron) Hirschmann Automotive are being used to produce connectors operates more manufacturing facilities for the auto industry,” said Ralf in the Czech Republic, Romania, Cezanne, Director of Sales and Morocco, and China, with around Marketing at Ferromatik Milacron. 3,000 employees worldwide. The machines have been customised for the specific requirements of Ferromatik Milacron GmbH Hirschmann Automotive and include Tel: +49 7644 78 302 numerous options, such as magnetic Email: marketing@ferromatik.com platen for fast mould changes. “We Web: www.ferromatik.com

AUTOMOTIVE GROUP TAKES DELIVERY OF 70th FERROMATIK MACHINE

MAY 2013 • WWW.EPPM.COM • 15

MACHINERY SPOTLIGHT eppm

INJECTION MOULDING

Meech International is a specialist in static NOTHING control technology. The group serves, among WORSE THAN A others, the injection moulding sector with static STATIC MOULDER: control equipment and pinning equipment for A LOOK AT STATIC in-mould labelling. EPPM caught up with TECHNOLOGY Stewart Gordon-Smith, Export Sales Engineer, IN IM Meech International, to find out how important static technologies could be for moulders. EPPM: What do people need to know about static control in moulding processes? Stewart GordonSmith: Aside from the more obvious threat of electrostatic shocks, people should be aware of Stewart Gordonhow static can Smith, Export Sales cause product Engineer, Meech handling issues International. during the part ejection phase as well as having an effect on contamination control. The attraction of dust and dirt is likely to impinge on the overall quality of a product, meaning that contamination would noticeably affect products being supplied to the automotive, medical, pharmaceutical, and electronics industries amongst others. Admittedly, an electrostatic shock is unlikely to inflict much harm to the

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operator, although it might cause a secondary incident that could prove to be more serious or difficult to contain. On the other hand, small plastic parts could fail to eject from the mould tool due to electrostatic attraction, which will result in damage to the aluminium surface, resulting in increased engineering cost and down time. There is also an increased demand by the market for in mould labelling, which demands a certain degree of technical knowledge to ensure the correct placement and retention of the label in the mould and the correct label specification. Meech work closely with robotic engineering companies and speciality label manufacturers at the design stage of a project to maximise production potential. EPPM: Why do you think that some processors don't take it into consideration?

SGS: Because static electricity is something that cannot be seen, most machine operators fail to comprehend its potential. The occurrences will take place at different times of the day and time of the year, as static is a phenomenon heavily contingent on changing weather conditions. In addition, with the cost of virgin material increasing, recycled material is used more frequently, (which has an added benefit of being seen to be green). But the use of recycled material increases the levels of electrostatic charges on mouldings, as the higher the percentage recycled to virgin base material used, the worse the problems can be. These differing reasons can result in reporting on loss of production and costly production of scrap which, if incorrectly analysed, will result in the actual cause of the problem being misdiagnosed. EPPM: In terms of savings, what are the benefits of exploring the technology? SGS: Controlling static by investing in the correct equipment will increase profitability, by reducing scrap and increasing the ability to use recycled material. The other key benefit is that, by minimising the number of operator shocks, H&S risks are also significantly diminished.

The 994 Hydra, Meech’s miniaturised in-mould labelling pinning system. EPPM: Finally, what is the sales and installation process like? Can demos be performed on-site? SGS: Meech offers worldwide technical support providing customers agents and distributors with application and product advice on their static control, web cleaning, air technology, JetStream and IonRinse systems. All of our technical sales engineers are fully qualified to provide onsite support analysis of problems and positioning recommendations are vital. With the modern Meech ionising bars being powered by a 24 volt supply, installation is becoming simpler too. Meech International Tel: +44 1993 706700 Email: sales@meech.com Web: www.meech.com

MATERIALS

PC sheet provides light-weight, custom-coloured roofing SABIC’s Innovative Plastics business has announced the first application of its Lexan Thermoclear polycarbonate (PC) multi-wall sheet in a sports stadium. The new Arena do Grêmio, a multi-use, 60,000-seat stadium in Porto Alegre, is where the custom-coloured 10mm material is used for the roofing. SABIC’s Lexan Thermoclear sheet was chosen for its light weight, toughness and impact resistance vs. glass. This tough roofing material proved itself even before the stadium was completed when the partially installed roof was undamaged during a violent windstorm. “SABIC’s Lexan Thermoclear sheet – compared to the coloured, laminated glass that was originally considered – is technologically and aesthetically superior,” said Marcos Benicio, Contract Leader, of OAS, the general contractor and installer for this project. “The durable, light-weight material was not only more cost effective, it was so much easier to transport and install than heavy, breakable glass. As an added benefit, we were able to obtain the material locally from SABIC’s facility in Campinas, which also provided technical support and colour-matching services.” “SABIC materials and technical expertise have helped architects and contractors design and build some of

the world’s most iconic stadiums,” said Jack Govers, General Manager, Specialty Film & Sheet, Innovative Plastics. “Over many years, we’ve continually improved and enhanced our sheet products to meet changing environmental requirements and aesthetic and performance expectations. Today marks a significant achievement with the addition of another aweinspiring arena – the first in Brazil – that is benefitting from the design freedom, energy efficiency and high performance of Lexan Thermoclear sheet.” Lexan Thermoclear sheet was supplied in a custom blue tone matching the Grêmio team brand. The light colour and highly reflective surface of the sheet help minimise the effects of heat and reduce the need for cooling systems. These attributes, together with the light weight of the panels (2.2 k/m2), make a contribution to the reduced environmental impact of

Arena do Grêmio, which is expected to receive Leadership in Energy and Environmental Design (LEED) certification from the U.S. Green Building Council. Lexan Thermoclear sheet reportedly delivers impact performance over a wide temperature range, from -40˚C to 120˚C, and also after prolonged outdoor exposure. It can withstand harsh weather conditions as well as temperature swings without breaking or buckling. It features a proprietary surface treatment on one side offering

excellent resistance against degradation from ultraviolet (UV) radiation. The material carries a 15 year limited written warranty against discolouration, loss of light transmission and loss of impact strength due to weathering. The SABIC team in Brazil provided wind load simulation, mechanical resistance calculation for the aluminum profiles and flame resistance regulatory reports. SABIC Web: www.sabic-ip.com

Transparent plastic limo built for Michel Gondry movie

PET sheet optimised for form-fill-seal jobs

Altuglas International, a subsidiary of the Arkema Group is a partner of the film Mood Indigo, directed by Michel Gondry. This is the film adaptation of the eponymous book of the french author Boris Vian published in 1947. Gondry is said to have combined futuristic and surreal ideas, one of which was the “Limovian”, a fully transparent limousine. Altuglas International provided nanostructured Altuglas ShieldUp produced in St Avold (57) for the car. A design team from Peugeot spent more than six months assembling the limousine, reportedly grafting pieces and accessories from a Peugeot 404. The transparent parts were made from Altuglas ShieldUp. This acrylic (polymethylmethacrylate) combines two components — PMMA and an elastomer, structured at nanoscale —

Form-fill-seal (FSS) is a fairly simple and highly efficient process. The packaging material is formed into a package, then filled with the food product, then sealed. There are typically two types of FFS process: vertical and horizontal. Vertical is typically used for flexible plastic packaging. During this production process a plastic film is fed vertically through a machine. The horizontal process, as its name suggests, involves having rigid sheet fed into a machine horizontally to form a rigid plastic package. “Manufacturers deploying FSS for the packaging of yogurt have been able to maintain the necessary high production rates, reduce their processing steps, and decrease their need for manual labour,” stated William J. Barenberg, Jr., COO of Octal, a manufacturer of PET sheet. “The FSS process also minimises the risk of food contamination due to reduced contact with equipment and plant personnel. All of these benefits combined have aided manufacturers to yield an overall cost savings compared to other yoghurt packaging options.”

which provides transparency along with mechanical and chemical resistance, according to the group. The product is the result of ten years of research and won last year’s Potier prize for innovation. Material for the parts was heated to 180°C for fifteen minutes to be softened. Some was then forced under vacuum pressure and some was blown with compressed air (8 bar) to form the different elements. Altuglas International Tel: +33 1 78 66 23 00 Web: www.altuglas.com

Yoghurt packaging systems are some of the most demanding in the world. Consistency and machinability for uptime and productivity is a key performance indicator. Octal’s DPET direct-to-sheet manufacturing system is designed to provide the kind of consistency it takes to realise the absolute maximum from form, fill, and seal lines. With a typical gauge variation of +/- 2 to 3 microns, Octal claims DPET enables FFS operations to run at highly consistent rates day after day. Sealing quality is also reportedly optimized with DPET’s highly planer surface topography. Additionally, DPET cuts easier than traditional PET sheets, meaning more uniform cutting, and knives that last longer between sharpening and replacement. DPET also delivers a smooth and glossy surface that is said to be perfect for detailed printing designs and process printing or label application, yielding packs with enhanced shelf presence. Octal Web: www.octal.com

MAY 2013 • WWW.EPPM.COM • 17

MATERIALS ROUNDUP Additives offer PVC protection indoors and outdoors In June, Sanitized AG, a producer of antimicrobial hygiene function and material protection for plastics will be launching two new advanced additives designed for the protection of plasticised PVC. In addition to antimicrobial properties, the two products will offer applicationspecific benefits including longer lifecycles, improved weatherability and thermal stability, as well as higher resistance to UV and yellowing, claims the group. Sanitized PL 12-32 is a formulation with water resistance and UV stability making it suitable for outdoor applications such as awnings and

tents. The second product, Sanitized PL 12-33 features thermal stability with the ability to retain product transparency. This product is aimed at indoor applications such as flooring and furnishings. Plastisols, coatings or foams employed in many flexible PVC products are very sensitive to attacks from microbes. Especially in outdoor applications, the extra-cellular enzymes in such microbes can break down plasticisers – and other additives that are susceptible to them. Some PVC products may become stiff and brittle, and cracks may begin to form and they subsequently decompose over time, suggests Sanitized. The

group says that applying the new additives will help boost stability. Sanitized PL 12-32 and Sanitized PL 12-33 have been designed to protect against the unwanted effects of microbes like bacteria, mold fungi, mildew, yeasts and algae, which can cause material destruction, unsightly stains, cross contamination, odour development and biofilm formation. The formulations are said to reduce initial discolouration and yellowing in use. Both

Medical Plastics Manufacturing Injection Moulding Medical Materials Extrusion & Thermoforming Automation & Robotics Process Control Prototyping Cleanroom Regulation Design

Sanitized PL 12-32 is a formulation with water resistance and UV stability making it suitable for outdoor applications such as awnings and tents. products have been individually tailored to provide a choice for different applications. Maria Toscan, Product Manager, Polymers at Sanitized AG said: “No single substance is perfect for all applications, as each has its benefits and limitations. By combining benefits and reducing limitations, we are able to offer our customers a clear choice of application-specific solutions that fully meet their needs and provide a guaranteed highest antimicrobial efficacy.” Sanitized AG Tel: +41 34 427 16 24 Email: sibylle.haenni@sanitized.com Web: www.sanitized.com

Bioplastics supplier achieves GKV certification

T ER S I G RE .. .

. W O N

25-26 September 2013 NEC, BIRMINGHAM, UK

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Recently, FKuR Kunststoff GmbH was certified as one of the first bioplastic producers according to the GKV Code of Conduct. Since its inception, FKuR claims it has attached great importance to social responsibility, not only by developing sustainable products, but also by adhering to the highest moral and ethical principles in dealing with all internal and external partners. “We see the commitment to the GKV Code of Conduct as an important step to reaffirm and spread our corporate philosophy,” said Dr. Edmund Dolfen, Managing Director FKuR, of the adherence to the Code of Conduct. Designed as a self-commitment, the GKV Code of Conduct is a voluntary agreement through which its member companies want to ensure strict compliance with global requirements for ethical and moral behaviour, as well as maintain conduct compliant to antitrust laws and competence (Compliance). Also, the promotion of fair and sustainable standards in dealing with suppliers and customers along with its own corporate members is part of this commitment. The certified companies commit to environmental sustainability, to ensuring occupational health and safety at work, as well as compliance with international standards such as the UN Human Rights Charter, among others. FKuR Tel: +49 2154 9251 0 Email: info@fkur.com Web: www.fkur.com

MATERIALS ROUNDUP CO2 could be useful as a blowing agent for polyurethanes The Institute of Plastics Processing (IKV) in Industry and the Skilled Crafts at RWTH Aachen University is developing a new foaming technology for the production of foamed polyurethane mouldings. The new technology enables the use of CO2 as the blowing agent. It is regarded as the most promising and environmentally friendly alternative to chemical foaming with water, which results in hard segments and embrittlement in the polyurethane part. Until now, however, the use of large amounts of CO2 as the blowing agent led to a lack of control of the foaming process. Initial tests already show that the new

CO2 foaming process results in much lower densities than have been possible until now. To achieve controlled expansion of the reaction mix, a gas counterpressure is generated in the foaming mould. This cavity pressure, which is above the vapour pressure of the dissolved CO2, prevents early foaming-up. With a specific reduction of the cavity pressure, the timing and speed of the expansion process can be controlled. This prevents early expansion and collapse of the foam. For this process, the IKV scientists cooperated with PME fluidtec GmbH, Ettenheim, in the development of a sealed-off mould with valve technology

and a corresponding process control. Furthermore, the high-pressure HS500 metering machine from Hennecke GmbH, Sankt Augustin, was adapted to the new process technology. IKV has successfully started up the technology. Preliminary trials have already yielded flexible foam parts with a density of around 90 kg/m3. The process thus opens the door to expanding the range of individually adjustable mechanical properties of the PU foam. The material foamed with CO2 can be made more flexible than one that is foamed chemically. In addition, it significantly reduces the amount of isocyanate that was needed for the

conventional chemical foaming reaction, and thus helps to reduce costs. The Institute of Plastics Processing Tel: +49 241 80 93806 Email: zentrale@ikv.rwth-aachen.de Web: www.ikv-aachen.de

TPE group offers solutions for automotive mats

The Hexpol TPE group has developed several grades of thermoplastic elastomers (TPEs) specifically engineered to address the requirements for automotive mats. The range, known as Dryflex AM, combines the performance of rubbers with the processability of plastics and includes grades based on SBS and SEBS which are available in hardnesses from 50 to 75 Shore A. High flow grades are available which have been designed for complex mouldings with a large surface area such as trunk liners. Other applications for Dryflex AM materials include floor mats, coin mats, fascia mats and trim. For automotive floor mats the material needs to have high scratch and abrasion resistance. It is also critical that the material is non-slip, even when wet. The material structure of Dryflex AM compounds produces the high coefficient of friction, helping to create a non-slip surface. Dryflex AM materials are low odour and fogging. They require no vulcanisation and are 100% recyclable during production. This means less energy is used and production is faster and more cost-efficient, according to the group. Sven-M. Druwen, European Sales Coordinator for Hexpol TPE commented, “Our teams work hand-in-hand with our automotive customers to develop solutions that address new and emerging demands. With governments’ worldwide enacting fuel efficiency and carbon emissions laws, one of the ways car manufacturers are looking to address these regulations is lightweighting. By reducing the weight of each component they can look to reduce the weight of the whole vehicle. That is one of the reasons we have developed our TPEs for automotive mats, they have a lower specific gravity compared to several alternative materials, you can therefore not only create lighter-weight parts, but you can also produce more parts per kilogram of material.” Hexpol TPE Web: www.hexpoltpe.com MAY 2013 • WWW.EPPM.COM • 19

MATERIALS ROUNDUP TPE selected for environmentally friendly bottle design

World Cup to be covered in plastic

A reusable water bottle developed by Vapur, a designer of flexible, reusable, handheld products, features a custom cap made of thermoplastic elastomer (TPE) from Kraiburg TPE. The new ‘anti-bottle’ — designed to stand upright when full and folded or even rolled when empty — reportedly features sustainability advantages including reduced energy and transportation costs. The patented product is also BPAfree and phthalate-free, says Kraiburg. Vapur teamed with HQC Inc., a manufacturer of custom injection and insert moulded products for medical and packaging companies, to develop the product. Kraiburg TPE was brought in by distribution partner Chase Plastics to take part in the process and create a customisable technical solution for the bottle’s cap. Thermolast K compounds from Kraiburg TPE were developed to meet current market demands and are utilised in virtually all industries, states the group. One of Kraiburg TPE’s Thermolast K FD/n series compounds was

Polycarbonate sheet from Bayer MaterialScience will keep 70,000 spectators protected from the elements as part of the Estadio Nacional stadium roof at the 2014 FIFA World Cup in Brazil. Bayer claims its Makrolon solid polycarbonate sheets are sturdy, highly impactresistant, and break-proof and meet the relevant requirements for safety, weather resistance, transparency, economic feasibility and design. The Makrolon UV 2099 grade that will be used in the stadium has a UV coating on both sides that is said to remain in place after being processed by cold-bending, and even after many years of weathering. The polycarbonate sheets have a light transmission of 82 %, said to ensure optimum natural light for healthy turf growth. The final inner ring of the stadium roof will consist of 110 metric tonnes of Makrolon UV 2099, with each sheet 12mm thick and over 10 metres long. Bayer says that thanks to their relatively low weight compared to other materials,

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selected for this particular application because of its FDA compliance, surface aesthetics, and colourability. The FD/n series is available in hardness ranges from 25-85 Shore A durometer and can also be overmoulded to polypropylene. The compound is compliant with food contact regulations in the U.S. (FDA) as well as EU Regulation 10/2011. The TPE is halogen free, has a 45 Shore A durometer, and is recyclable. Thermolast K TF4BNB is also latex- and PVC-free. The Thermolast K FD/n series is targeted at food contact applications including container and lid seals and bottle grips. Kraiburg TPE GmbH & Co. KG Tel: +49 8638 98100 Email: info@kraiburg-tpe.com Web: www.kraiburg-tpe.com

Image by gmp Architekten von Gerkan, Marg und Partner / Rendering: Björn Rolle, Berlin the polycarbonate sheets do not require a costly sub-structure. Furthermore, the sheets are said to be easy to process, allowing direct handling on-site. The Estadio Nacional continues the long list of projects in recent years where Makrolon has been used in sports arenas for major international events, including the roofs of the stadiums in Shenyang and Tianjin for the Summer Olympic Games in 2008, the Arena Legia in Warsaw, and the PGE Arena Gdansk for UEFA Euro 2012. Bayer MaterialScience Web: www.materialscience.bayer.com

MATERIALS

SHOWCASE COMPOSITES Composites industry body predicts five new market trends The composites market is growing at a rate of 6% per year since 2010. With a growing demand for better environmental impact reduction and costs savings, composites are used more and more often to lighten structures, aircraft, and vehicles in general, thus improving energy efficiency. JEC Group, a major composites industry organisation, has identified five developments in the market that could grow even bigger by 2030. “Indeed, the global composites market represents 81.6 billion euros in value for 2012. This market is growing at an average of 6% per year. The composites industry is growing in volume in correlation with the increase of gross domestic product by country. And penetration continues in some sectors like aeronautics. For instance, we expect the composites market for aerospace to be four times bigger than today by 2030. Also new applications in high volume markets continue to appear for instance, i.e. electricity, electronics and consumer goods, especially in Asia. JEC Group has developed a “Knowledge & Networking” service package including three platforms in Europe, AsiaPacific, and the Americas to cover the whole composites market. They enable the group to detect main trends that contribute to the Frederique Mutel, JEC composites Group President & CEO

I can foresee five new trends that could change and boost the market, therefore contributing to making it bigger by the next five years

“

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market growth. I can foresee five new trends that could change and boost the market, therefore contributing to make it bigger by the next five years. The forecast is 12 million metric tonnes by 2017 compared to 9.2 million metric tonnes in 2012” said Mrs. Frederique Mutel, JEC Group President and CEO.

Converting processes towards mass production Over the past few years, the composites sector has developed its ability to convert processes, including for large and complex-geometry parts. Large companies have invested heavily in these new technologies, which lower the cost of composite parts (for example, thermal curing technology enables mass production in the aerospace and the automotive sectors). “Innovation is mainly directed towards manufacturing, and in particular, mass production

Materials group pushes into the Russian composite resins market Ashland Performance Materials, a commercial unit of Ashland Inc. has announced the formation of a partnership with Composite Trade, a Russian distribution company, to tap into Russia’s growing demand for composite resins. The new alliance, Ashland Rus, combines Ashland’s resin technology with Composite Trade’s network and local market knowledge. “This partnership will place both companies in an ideal position to better serve customers in the growing Russian composites market,” said Rafail Aminov, Director General of Composite Trade. Ashland’s product range including, unsaturated polyester resins, fire retardant resins and gel coats, are being marketed in the region for strength, corrosion resistance, fire retardancy and surface characteristics that are required in Russia’s growing building and construction, transportation and marine markets.

With Ashland Rus, Ashland says it is creating a local platform to make its technology more easily accessible to the market segment of direct and larger accounts. This will be in addition to the current distribution model for Composite Trade and its customers, which will remain unchanged. “Working together, we can build on our collective strengths and deliver the market-leading innovation, technical expertise and service that our customers expect,” stated Stefan Osterwind, Commercial Vice President, Ashland Performance Materials EMEA and India. The intention, claims the group, is “to create local resins and gelcoats manufacturing capability to further customise products for local markets.” Ashland Rus Tel: +7 812 332 56 06 Email: amazaev@ashland.com Web: www.ashland.com

notably in Europe” said Mrs. Mutel. “For example, of all the patents granted for composites in Europe in 2011-2012, 52% involved robotics and automated manufacturing processes.” Developing properties of thermoplastics New resins, fibres and additives have been developed in order to improve mechanical, thermal or conductivity properties. JEC says that this will have a huge impact on the automotive sector thanks to the revolutionising of thermoplastic resins. At JEC Europe, 80% of the samples on display were cars or car parts. Turning materials into smart composites Another revolution for the sector are smart composites with sensors, which enable companies to foresee the ageing process of the parts they create. They also enable the structures to repair themselves. Conquering new application sectors New sectors have started to turn to composites, for instance, the energy sector (transmission and distribution), electronics and consumer goods (cell phones, tablets) etc. Using greener materials: recycling Finding a way to recycle has become one of the priorities. Recyclates are now used to produce new composites and are also at use in other industries, such as cement work. JEC Group Web: www.jeccomposites.com

LV2013 looks at composites A conference being held in Germany in October, LV2013 Lightweight Vehicles Conference, will focus on the efforts being made by the plastic industry to move to lighter vehicles with the tightening of EU regulation. The event is organised by European Plastics News. The second day of the conference has a focus on composites and will begin with Marcus Ruhnau, Head of Material Development R&D at moulder Dr Schneider Kunststofftechnick, who will report on a breakthrough in carbon fibre. Dr George Kellie will give an analysis of the growth in nonwoven composites in automotive interiors, and will look at how they are playing a major role in lightweighting, followed by Brunetto Martorana from Fiat who will give a talk about the group’s successful integration of composite materials in vehicle structures. LV2013 Web: www.lightweightvehiclesconference.com

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MATERIALS

SHOWCASE COMPOSITES Thermoplastic resin developed that processes like thermosets At JEC 2013, Arkema launched its Altuglas Composite, which, the group claims, is the first new thermoplastic resin to allow the manufacturing of composite parts on the same equipment and processes as thermoset composites. The resulting composite parts reportedly exhibit mechanical properties similar to those of thermoset parts, but their thermoplastic nature allow thermoformability and recyclability. Arkema and its partners won a JEC Award in the “Thermoplastics” category. Altuglas is an acrylic material, developed by an R&D partnership between Arkema and PPE (P le de Plasturgie de l’Est). To optimise Altuglas Composite formulations, Arkema and PPE have partnered with specialists in the composite industry – MVC (Brazil), Chomarat (France) and 3B Fibreglass (Belgium). The product is made of methacrylic thermoplastic composites, reinforced by continuous glass, carbon or flax fibres with the same processes (RTM or Infusion) used today to produce thermoset composite parts (made with unsaturated polyester, vinyl ester or epoxy resins) with similar polymerisation cycle times. The resulting parts show properties, in terms of rigidity and mechanical strength, comparable to parts made with thermoset resins. The acrylic nature of Altuglas Composite enables more possibilities for composite/composite or composite/metal assemblies. Very high mechanical strength for such assemblies can be achieved through the use of adhesives (e.g. methacrylate-based structural adhesives) or, due to the

K Show 2013, Hall 8a, Stand D01

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thermoplastic nature of the matrix, through welding in the case of composite/composite assemblies. The range is available with ready-to-use Luperox peroxide initiators from Arkema’s range, allowing optimised polymerisation. In terms of application, the product can be used for aesthetic semi-structural composite parts such as shaped truck parts, bus body panels, hoods for agricultural machinery, etc., usually made of UPR-based composites. To refine the Altuglas Composite formulation for these parts, Arkema and PPE have collaborated with MVC, a company well known for its expertise in the manufacture of technical composite parts. The partners succeeded in developing the first large demonstration part produced using a room temperature RTM-light process with Altuglas Composite resin. The reinforcing glass fabric, processing equipment and polymerisation cycle time were identical to those used by MVC today for the industrial production of UPR composite parts. In early 2011, Arkema and PPE created a joint research laboratory located in Saint-Avold (France) aimed at the development of innovative chemistries and processes for the production of thermoplastic composite parts. Altuglas Composite is also suitable for high performance structural composite parts used in applications such as wind turbines, automotive parts or sports equipment, mostly based today on epoxy resins. To develop an optimised solution for glass reinforced Altuglas Composite

based structural composites, Arkema and PPE collaborated with Chomarat, a reinforcing fabrics producer, and glassfibre producer 3B-Fibreglass. The definition of optimised fibres, sizing and reinforcing fabric for Altuglas Composite matrices leads to composites that reach mechanical strengths very similar to those of classic epoxy/glass thermoset composites at similar reinforcement volume fractions. Additionally, Arkema and MVC claim they have developed a fully

thermoplastic solution which eliminates the need for a traditional gel-coat for upper layer. In this technology, the decorative layer is prepared by thermoforming a thermoplastic multilayer sheet such as ABS/PMMA in the mould prior to the reinforcing fabric laying operation. The Altuglas Composite resin matrix naturally adheres to the ABS/PMMA surface layer. Arkema Tel: +33 1 49 00 80 80 Web: www.arkema.fr

APPLICATION FOCUS ELECTRONICS

Harvesting unused energy with conductive polymers A large proportion of the energy we produce disappears unused into thin air via waste heat. Tiny thermoelectric generators can tap this potential, whereby the electricity is produced by way of temperature differences. However, so far their production has been laborious and expensive. At the same time there is a lack of suitable materials. The Fraunhofer Institute has been researching a new manufacturing process with which these generators can be cost-effectively produced in the form of largearea flexible components from electrically conductive polymers via 3D Printing. The following is from the report provided by the Institute. We are all familiar with them – the gigantic white clouds of steam billowing from power station cooling towers. As impressive as this spectacle may be, in reality it represents a waste of energy as large power stations only rarely manage to convert more than 40 percent of the produced energy into electrical power. The rest is released unused, mainly via the cooling towers, into the atmosphere. Researchers have been working on utilizing the potential lying dormant in the over 150 m high concrete giants. The magic formula for this is known as thermoelectrics. This area of physics is concerned with generating electricity from temperature differences, and it is precisely in cooling towers where there can be very large differences between the hot steam and cooler concrete skin under some circumstances. The scientists’ vision is described by Dr. Aljoscha Roch of the Fraunhofer Institute for Material and Beam Technology IWS in Dresden: “Thermoelectric generators (TEG) currently have an efficiency of around eight percent. That sounds very small. But if we succeed in producing TEG cost-effectively, on a large scale and from flexible materials we can install them extensively on the insides of the concave cooling tower wall. In this way, through the enormous amount of energy produced in the huge plants – around

Intertronics’ electrically conductive polyurethane adhesive

1500 liters of water evaporate per minute – we could generate large quantities of electricity.” Together with his colleagues at the IWS, Roch has now taken a big step closer to this goal. The scientists have succeeded in producing TEG by means of a printing process. The miniaturized generators are not only be produced cost-effectively, on large surfaces and in a flexibly manageable manner, but the materials used are also environmentally-friendly. “TEG are today largely produced by hand from toxic components which contain lead for example. We are now using modern 3D printing technology and harmless polymers (plastics) that are electrically conductive,” explained Roch. The new printing technology functions in a similar way to an inkjet printer. The difference is that instead of a thin jet of ink, a thermoelectrically active polymer paste emerges from the cartridge and produces the around 20 to 30 micrometer thick thermoelectric layers. “The generators have to be of a certain thickness in order to build up electrical voltage from temperature difference. Currently available 3D printing processes could be very suitable for achieving the required depth,” says Roch. The IWS researchers are demonstrating the printed TEG for the

first time in a cooling tower model at the Hannover trade fair. But how is the electricity then “harvested” from these polymer generators which are only a few micrometers in size? The hot steam activates the electrons in the generator, the negatively charged particles migrate to the cooler side and an electrical voltage is produced. Even small temperature differences such as one degree are sufficient for this effect. This has been known to physics for almost 200 years, but due to the lack of efficient manufacturing methods and suitable materials it has not been extensively utilised. The manually produced, brick-like TEG are used in space travel and in the form of tests in the automotive industry. Mounted on the exhaust pipe they supply current for the vehicle’s onboard electronics, for example. To date 600 W, the power output of around 6 light bulbs have already been demonstrated. When multiplied by the many millions of vehicles on Germany’s roads alone, several thousand million kilowatt hours could be saved by TEG. Cars and cooling towers are, however, only two examples out of many. “In principle waste heat is produced through the operation of every technical installation. With TEG fitted on industrial

A demonstration of a printed TEG wriggling flexibly around a sample component.

production lines, in sewerage systems, at large computer centers or on any type of exhaust air system very large and hitherto unused sources of energy could be developed,” concluded Roch. Fraunhofer Institute Tel: +49 89 1205 1399 Web: www.fraunhofer.de

Electrically conductive PU adhesive launched Adhesives specialist Intertronics has introduced Polytec PU 1000, an electrically conductive polyurethane adhesive which it says addresses applications in die attach, bonding of components in hybrid circuit applications and surface mount technology (SMT); areas where silver-filled electrically conductive adhesives have been used for many decades. Oxfordshire-based Intertronics says usually such adhesives are epoxy-based, twocomponent or premixed and frozen singlecomponent systems, but its Polytec PU 1000 polyurethane solution provides an alternative with advantages including flexibility and room temperature cure. Polytec PU 1000 is a single-component, silver filled, paste adhesive which can reportedly be cured quickly at room temperature and is flexible and elastic, which Intertronics says

makes it ideal for bonding of flex-circuits, temperature-sensitive substrates or substrates with highly dissimilar coefficients of thermal expansion. It has found applications in smart cards and RFID circuitry, where cure can be effected in seconds. Intertronics says it is considered suitable for the electrical interconnection of active and passive components, particularly if convenient processing or high flexibility of the adhesive is desirable. This PU-dispersion is suggested for electrically conductive bonding and coating applications on absorbing substrates like fabric, paper, leather, cork and non-absorbing substrates like glass, ceramics, PMMA, metals and most plastics. Intertronics Web: www.intertronics.co.uk

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APPLICATION FOCUS Polyamide launched for LED applications DSM has introduced Stanyl ForTii LED LX, an LED (light emitting diode)-specific grade of Stanyl ForTii high temperature polyamide with halogen-free flame retardant grades as a material for LED packages. Over the past years, sales of LED packages have increased by over 50% per year and performance also improved in double digit percentages. This growth was driven mainly by the switch to LEDs for LCD (liquid crystal display) backlighting and by developments in the lighting industry. LED manufacturers are looking for materials that deliver high reliability, enabling smooth high volume production and excellent light output. High-flow Stanyl ForTii LED LX is a mineral-filled grade featuring UV resistance. Stanyl ForTii LED LX is said to display reliability over time and, more specifically, high initial reflectivity, as well as excellent mechanical strength. Its flow properties reportedly make it suitable for use in high cavity tools. This enhanced reflectivity of Stanyl ForTii has an immediate effect on the LED package light output and enables LED suppliers to improve their key specifications. The product features a specific polymer structure. LED lifetime is extended through its adhesion to silicones and epoxy encapsulates as well as the metallic lead frame, avoiding chip degradation due to moisture or air diffusion.

Approximately 20% of the world’s electricity consumption is used for lighting applications. This provides a significant opportunity to cut both emissions and electricity costs. Today’s LEDs consume about 70-80% less energy than conventional lamps. At the same time, they increase service life and design flexibility. Since LED solutions are rapidly becoming more affordable, LED lighting is being adopted increasingly in many applications around the world. Over the past few years engineering plastics have become the incumbent solution for LED. LEDs with high power densities make thermal management the key focus area in LED lighting design. Without appropriate thermal management, they will gradually lose brightness, change their colour spectrum over time and present higher failure rates. DSM’s Stanyl TC features mechanical performance and thermal management, while increasing design flexibility, according to the group. Designers may be able to reduce the overall weight of lamps, while increasing electrical safety and productivity in manufacturing. Total system costs can be reduced by up to 30-40% compared with cast aluminium. In life cycle analyses, CO2 emissions for a typical heatsink in Stanyl TC are up to 85% lower than an equivalent die cast aluminium heatsink.

Stijn Meijers, Global Segment Manager for Lighting said: “DSM is strongly committed to the lighting industry. This is demonstrated by our growing portfolio of material solutions for lighting, developed for a wide range of highperformance applications such as highly reflective grades for LED packages or thermally conductive grades to enable improved thermal management. By

using our industry-specific material portfolio, our customers are able to gain a number of significant benefits including greater efficiency, weight saving, higher flexibility in manufacturing, and a smaller carbon footprint.” DSM Web: www.dsm.com

Flexible printed electronics to make interactive toys

Two super-reflective grades for LED lighting launched

Two companies and two technological centres have created a Spanish consortium to develop the scale-up of flexible electroluminescent (EL) devices for application in the toy sector through an in-depth and detailed study. Named FLEXeTOY, the project aims to see these devices become drivers of the toy sector, according to the groups, by creating prototypes of toys that integrate devices printed on flexible materials and achieving electronic functionalities that have never been seen before in objects and products for children. Financed by Spain’s Ministry of Economy and Competitiveness, the project totals €981,687 and will be completed in August 2015. As a result, prototype toys will be obtained so that SMEs in the toy sector can manufacture value-added products, in mass production and at low cost, to increase their competitiveness at international level. The teams claim that the insertion of flexible electronic devices in toys and children’s articles will make products more attractive and dynamic, enhancing their interaction with users and increasing the child’s attachment to the product. For example, these devices could require an action on the child’s part (by lighting up, depending on the drawing), allow the child to imitate adult

Ticona, the engineering polymers business of Celanese Corporation, has introduced two newgeneration Thermx polycyclohexylenedimethylene terephthalate (PCT) resins, said to deliver outstanding initial reflectance and reflectance stability required in lightemitting diode (LED) packages found in display backlight and general lighting. “Developers at Ticona have developed two high performance super-white grades of Thermx PCT, meeting the challenging requirements of LED reflectors, especially for high brightness, medium-power LEDs,” said Ruth Castillo, Thermx PCT and Vectra/Zenite LCP Global Business Director — Ticona. “Thermx PCT provides superior colour and reflectance stability under heat and light compared to commonly used high temperature polyamides.” Thermx LED 0201 and Thermx LED 0201S are fibre filled, super-white PCT compounds. According to Ticona, they are able to withstand the demanding LED requirements for reflector resins with regard to heat and light stability — high initial reflectance, high reflectance stability under heat and light, excellent silicone adhesion, processability and mechanical properties. They are also said to benefit from excellent reflow capability and low moisture absorption. Ticona says this LED product family features the optical and mechanical properties as well as the process requirements for specific applications. “These super-white Thermx PCT LED grades provide customers with much

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roles (switch on the cooker, turn on the lights of a toy house) among many others. In economic terms, the manufacturers can introduce high-tech devices into their articles, thus improving their competitiveness and sustainability in the medium term. The prototypes that will be developed will reduce electric and electronic waste while complying with RoHS directives and with European standards EN62115 for electrical products and EN71 concerning toy safety. The graphic arts and electronic industries involved in the project will benefit from the developments of the project on flexible substrates, opening up new sectors of application, compared to conventional electronics. According to TIE (European Toy Industry Association), the toy market generated a production value of €5.5 billion in 2011, from 5000 companies that generate 220,000 jobs. Spain is ranked in second place, behind Germany, and is noted for having a high export capacity. The capacity for expansion both in the Spanish and the European market of the results of this project can be clearly seen, claim the groups. AIJU Web: www.aiju.info

Multi-LED application by Philips. Source: Philips. better reflectance stability than PA9T and PA6T nylons at high temperature,” Castillo said. “Now, they can mould reflectors with excellent surface characteristics that maintain UV and colour stability, providing superior longterm performance.” Ticona produces engineering resins that are used in many fields, including automotive, appliance, medical, and information and communications technology, as well as consumer and industrial segments. The group provides products for applications requiring predictable mechanical performance, consistent chemical and thermal properties, dimensional stability and a tolerance for heat and moisture. In general, the group claims, they must be strong, stiff, stable and cost-effective. Ticona Web: www.ticona.com

APPLICATION FOCUS Conductive compound meets stringent safety requirements for mining pump

Engineering plastics chosen for high-density connector application

All-Flo, a manufacturer of air-operated diaphragm (AOD) pumps, has developed a specialised version of the company’s 25mm polypropylene AOD pump. The brief was to create an entire pump with conductive, but non-metallic, materials. All-Flo selected RTP Company to provide the material. Many end-users demand non-metallic materials that better resist corrosion from harsh chemicals or reduce weight for portability. “Plastic materials provide benefits our customers need that we simply could not otherwise obtain,” said Paul McGarry, All-Flo's Sales and Marketing Manager. All-Flo’s 25mm pumps are used in mining operations because of their non-metallic construction. “Miners have to carry equipment down in tight elevators or often walk it from hole to hole; they tell us they really appreciate the weight difference our pumps deliver,” said McGarry. “Using RTP Company’s glass fibre reinforced polypropylene compounds enables us to achieve the considerable weight savings, while providing a stronger degree of resistance to atmospheric corrosion.” “While many of All-Flo's pumps can meet ATEX Directive requirements for being safe to operate in potentially explosive environments, safety standards can vary from country to country and some companies have their own safety standards that are stricter than regulations require,” explained McGarry, referring to the recent customer challenge to construct a specialised version of the 25mm AOD pump using conductive, non-metallic materials. “We didn't have to go far to find a

When Samtec Inc., a worldwide manufacturer of electronic interconnects, was designing and developing its SEAM/SEAF Series of high speed, high density connectors, it approached Ticona, the engineering polymers business of Celanese Corporation, and its family of liquid crystal polymers to resolve a processing and assembly challenge. “Our SEARAY high density, open pin field grid arrays presented an interesting material challenge — we needed a proven halogen free high performance polymer that could withstand technology for improved solder joint reliability and ensure compatibility with lead-free reflow processes and environmental initiatives,” said Doug McCartin, HUB Engineering Manager at Samtec Inc. Samtec, which had sampled several competitive materials with little success, worked with Ticona to identify two solutions from a family of halogen-free, high-performance polymers — Zenite 6130LX for the SEAM Series, which is the mate to the SEAF Series that is injection moulded with Vectra E135i. The SEAM/SEAF Series with high pin count from Samtec provides telecommunication, data communication, high-end computer, industrial and medical customers with the flexibility in their design and routing process that helps them meet their specific electrical performance requirements. For example, to isolate a signal for a high speed application, some use many circuits for grounds, while others combine multiple

solution,” said McGarry. “Our engineers always say that if you need specialised materials, RTP Company is the one to talk to.” Working in partnership with AllFlo and its injection moulder, Royal Plastics of Mentor, OH, a number of materials were trialled and a variation of the RTP 100 Series glass fibre reinforced polypropylene compound was chosen after passing evaluation testing. The addition of a carbon powder provided the conductive properties to meet the customer requirements. “Not only did RTP Company provide a conductive material that had the properties and met the requirements, it had the same processability and worked with our existing moulds,” said McGarry. “For our moulder, Royal Plastics, it's really just a matter of switching out materials for us to produce a specialised version of our 25mm polypropylene pump.” RTP Company Tel: +1 507 454 6900 Email: rtp@rtpcompany.com Web: www.rtpcompany.com

close proximity circuits for power. “In addition to having the world’s largest LCP product line, Ticona supports customers in their product development efforts with initial part design, computer modeling and simulation, prototyping, tooling consultation, testing and part validation,” said Ruth Castillo, Vectra and Zenite LCP Global Business Director — Ticona. “In this case, we were able to identify two LCPs that met Samtec’s performance criteria for weldline strength and excellent processability, including lead free solderability.” Zenite 6130LX, a 30% glass-reinforced, lubricated LCP resin reportedly offers a combination of toughness, stiffness, dimensional stability and creep resistance — even at very high temperatures. Inherently flame resistant without the need for halogenated flame retardant additives, the Zenite and Vectra product line includes grades that are suitable for application with thinner walls, higher temperature resistance, higher production rates, lower overall part costs and recyclability. As highly crystalline, thermotropic (melt-orienting) thermoplastics, they can withstand SMT soldering temperatures, including those needed with lead-free solder. “As a global solution provider with more than 50 years of material, component design and processing expertise, Ticona was able to help Samtec resolve their material challenges,” Castillo said. Ticona Web: www.ticona.com

TPE developed for skin contact electronics In the highly competitive environment of electronic entertainment devices (i.e. cell phones, tablets and audio players to name a few), manufacturers need to find solutions meeting end users’ requirements (durability and aesthetics) while setting their product apart from competition. Some might use vivid colours, original design or even an attractive price to differentiate their offer. When it comes to the material selection, designers struggle to find an ideal solution which could avoid any compromise on performance, design or cost. As an example, TPSiV shows great potential for part differentiation and offers good performance in terms of durability and soft touch, but as with any siliconbased system, it can be a high cost solution. COPEC is a new TPE from Kraiburg, which is said to offer a “velvety” and “silky” feeling, whilst repelling dirt. According to Kraiburg, there are none of the “sticky” properties associated with some TPEs. COPEC compounds also feature a resistance to skin oils and many detergents, and are, the group claims, suited to products which are touched very frequently. Reported benefits of COPEC for electronic entertainment devices include: • Improved haptics for better ergonomics (soft, silky feel and not sticky)

• Long term aesthetics (dirt repellent material/surface) • High UV and chemical resistance (including sebum and more) • Excellent mechanical performance (scratch, mar, tear, tensile strength) • Customised vivid colours • Cost savings opportunities vs. traditional silicon-based solutions (i.e. TPSiV) • Easy 2-shot over-moulding • Good adhesion to ETPs (ABS, PC, PC/PBT, etc.) The product is said to offer designers the possibility to obtain improved haptics resulting in a silky, non-stick or smooth finish, plus improved UV and chemical resistance (to a wide range of oil and aggressive media). Significantly higher overmoulding bond strength to ABS, PC and PC blend substrates COPEC offers high quality and differentiated parts. Polar alloys of TPE offer a “silky” feel, useful to designers aiming to offer good ergonomic features. COPEC can be used for multicomponent injection moulding with various thermoplastic materials used in electronic applications such as ABS, PC, PC/PBT, etc. Kraiburg TPE Tel: +49 8638 98100 Email: info@kraiburg-tpe.com Web: www.kraiburg-tpe.com

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2013: THE PREVIEW 16-23 October 2013, Düsseldorf, Germany

Welcome to the first of our K Show previews. Over the coming issues, EPPM will provide a comprehensive guide to your show. Each preview will open with a message from Messe Düsseldorf regarding a key market for the plastic sector. This month, the trade fair organiser analyses the trend towards reshoring of manufacturing back from China to the US. he migration of manufacturing from North America to China began 20 years ago when companies expected to reduce production costs 30 to 40% through cheap labour and other incentives. The savings never matched expectations. Now that labour costs, tariffs and related production expenses in China are rising, manufacturing is moving again – this time to North America in a trend called reshoring. Reshoring, identified in 2012, is the transfer of manufacturing from China back to the U.S. and Canada. It is happening because China is becoming too expensive in labour and other costs to sustain the margins North American companies want. Costs between the U.S. and China are “heading toward equilibrium,” says David Sievers, Principal, Strategy and Operations Practice at The Hackett Group, a global consulting firm in Miami, Florida. When expenses are counted, Sievers says it costs a U.S. manufacturer ¢84 on the dollar to make and ship products back to North America from China. At this level, “it’s a toss-up” as to whether any economic benefit is realised from manufacturing in China. A key driver is labour. Wages in China are rising at an annual rate of 15 to 18%. There are rising costs in other areas. Tax

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incentives are expiring, energy is expensive and shipping costs are increasing. Sievers refers to all such expenses as “total landed cost” (TLC). Others include: capital investments; production costs; handling and inventory; transit, tariffs and other taxes; receiving and distribution in North America; product inspections; correcting quality problems; and labour. The 16% differential between TLC and U.S. production expenses, Sievers says, happened this year. He expects it will result in many companies reshoring to North America. Hackett Group hasn’t looked at plastics opportunities, says Michel Janssen, chief research officer, but “it’s reasonable to expect that plastics will benefit from primary manufacturers bringing work back.” Another analyst, Boston Consulting Group of Boston, Massachusetts, identifies seven manufacturing sectors as near a “tipping point” when it comes to reshoring. One is plastics and rubber products. But others include areas of high plastics use – transportation, appliances, electrical equipment, computers and electronics. Some say the impact of reshoring on jobs in North America will be considerable. Harry Moser, who founded the Reshoring Initiative in

(Images copyright Messe Duesseldorf). Kildeer, Illinois, believes reshoring has generated 50,000 U.S. manufacturing jobs across all industries in the past three years, and could result in 500,000 new manufacturing jobs by 2015. Moser developed cost-analysis software called “Total Cost of Ownership” (TCO), which is free to registered users at his website (www.reshorenow.org). This lets decision makers evaluate the real price of manufacturing in China by comparing cost factors. He believes that if companies analyze offshore manufacturing with TCO, they will see savings based on product price evaporate. One aspect of operations in North America that is influencing reshoring is the growing productivity of workers and efforts by companies to reduce costs. In March 2013, The Hackett Group released a study that states U.S. manufacturers in all sectors are targeting “an aggressive 1.5% reduction in cost of goods (COG) sold for 2013 … to drive margin growth.” A major factor behind this is gains in internal manufacturing productivity, which could account for 50% of cost reductions. Hackett Group reports that outsourcing was “aggressively used” through 2011 by companies to reduce manufacturing costs. In 2011, the average COG reduction by companies was 0.3%. The shift away from outsourcing as a cost-cutting strategy

and toward internal productivity began in 2012, when companies increased total cost-reduction efforts to 1.5% that year. If they are successful in reducing total COG by 1.5% in 2013, companies will have cut these costs tenfold since 2011. Greater productivity, cost reductions and reshoring are also expected to increase export activity and add 2.5 million to 5 million U.S. jobs by the end of the decade, says Boston Consulting Group. In a study last year, the company stated that cost reductions and comparatively low prices for electricity and natural gas, could by 2015 give the U.S. an “export cost advantage of 5 to 25%” over Germany, Italy, France and the U.K., as well as Japan. This would result in the U.S. taking an export share of 2 to 4% from the European countries and 3 to 7% from Japan by the end of the decade. This could increase U.S. export revenue from these countries by $90 billion (€69 billion), and globally by $130 billion (€99 billion). For almost 20 years China was touted as the future of manufacturing – Goliath on an unstoppable global juggernaut. Reshoring shows that a commitment to productivity and cost cutting, product quality and customer service is a better model for sustainable growth than a strategy based almost entirely on price. Messe Düsseldorf

K 2013: THE PREVIEW Molecor looks ahead to K 2013

Drive control upgrade seeks to cut costs

Molecor Tecnologia is a Spanish company founded in 2006 and considers itself a pioneer in air-based molecular orientation technology applied to pipelines for the transport of water. Today, the company’s interests are divided into two lines of business. Molecor Canalizaciones manufactures and commercialises PVC-O pipes and Molecor TECH is able to manufacture PVC-O pipes up to DN 800mm and 25 bar (365 psi). The first PVC-O pipe manufactured with Molecor-patented technology was the DN200mm. It was produced just in time to be shown at K-2007, which was also Molecor’s first K-Show. In 2008 the range increased to DN400mm, which was until then the ‘unofficial’ limit for PVC-O pipes. Molecor says it was able to break this limit for the first time in 2010 by manufacturing tubes of larger diameters such as the DN450 and DN500 mm. The latter came to be known as “the biggest PVC-O pipe in the world” and that is how Molecor chose to present the product at K-2010. A conference was also held with a very positive response from the public. Between K-2010 and K-2013, Molecor has gone a long way to increase the range of PVC-O pipes now produced. In

Honeywell has upgraded Experion PMD, boosting the range and functionality of its comprehensive automation solution for controlling processes, machinery and drives through a single system. The new release of Experion’s integrated Process, Machinery and Drive control, (PMD) reportedly widens the scope of the solution further, and aims to integrate several other products like Alarm Management, Integrated Historian, OneWireless and Digital Video Manager solutions for the first time. The release, named Release 800, also adds a new field controller, Field Controller Express (FCE), with over 60 percent more controller point capacity, integrated Profibus and TotalPlant Alcont UPLINE/IOLINE highway interface, native peer-to-peer connectivity with Experion MX and the Experion PKS controller family through parameter connection and a single point of data entry. “With Experion PMD the result is better quality, more efficient production, and reduced maintenance and project lead times,” said Brad Garnett, Business Director of Pulp, Paper & Continuous Web Solutions at Honeywell Process Solutions. He added: “The updates in Release 800 make it a truly all-encompassing automation solution for pulp and paper manufacturers, as well as others in the chemicals, metals, pharmaceuticals and food and beverage industries.” PMD controllers can be used on all control levels for implementing

2010 the range went from DN90mm to DN500mm in PN16 (232 psi) and PN25 bar. Today, PVC-O pipes are manufactured up to DN630mm PN25, and the technology is now apparently ready to reach up to DN 800mm. Molecor expanded in 2011 and an additional factory was opened on the outskirts of Madrid, with the aim of further improving and advancing in R&D. This year the company is again moving to a larger facility in order increase its manufacturing capacity and therefore offer an improved service to its clients. At K-2013, Molecor will present one of its latest technological developments, the ISS+. ISS+, patent pending, is designed to manufacture PVC-O pipes with the Integrated Seal System, where the gasket is placed automatically inside the socket. Molecor Tecnología Web: www.molecor.com

advanced controls, fast machine controls and process controls. A single, consistent set of engineering tools across these levels should, according to Honeywell, mean lower capital costs and enable cost effective execution of production line and plant-wide control. The company claims benefits will include reduced database maintenance, easier training, increased access to diagnostic information, single alarm and event logging, and faster control responses. The new release is fully scalable and also continues to support migration from Honeywell’s TotalPlant Alcont (TPA) systems. Customers migrating to Experion PMD are able to reuse many existing TotalPlant Alcont assets to minimise costs, commissioning and start-up times. Existing TotalPlant Alcont application solutions are converted to Experion using existing cabinets, I/O and wiring so the costs of implementation can be minimised while aiming to significantly extend the life of assets. Honeywell Web: www.honeywell.com

Latest machines offer wide range of testing AMETEK Test & Calibration Instruments has introduced the latest additions to its Lloyd Instrument line of advanced materials testing systems. The Lloyd Instruments LS5 and LS2.5 are both single-column machines featuring the latest linear guide technology, preloaded ball screws and advanced software compensation systems. The new features look to ensure the highest level of precision displacement measurement. The LS5 is a 5kN/1124 lbf machine and the LS2.5 is a 2.5kN/562 lbf device. Both are available with an extensive range of grips, fixtures, extensometers and software options and feature a large work area with 150 mm throat depth for larger specimens and a wide range of work tables for increased flexibility. Both machines are said to be equally suited for a wide range of materials testing applications in quality control, academic, and research and development environments. Among the industry applications for the LS5 are plastics, packaging, medical devices, automotive, electronics, textiles, rubber and pharmaceuticals. The LS2.5 system is especially suited for plastic,

rubber and other high-elongation materials due to its wide crosshead travel, which can reach 1400mm. Both can be used for tensile and compression testing, friction, tearing, peeling, insertion/extraction, creep/relaxation and many other measurements in manufacturing, product development and research. Each instrument reportedly offers a wide speed range for high precision accuracy and improved productivity. The LS5 has a crosshead speed range of 0.01 to 1016 mm/min, while the LS2.5 features a crosshead speed range of 0.01 to 2032 mm/min. The two machines have a load accuracy of +/- 0.5 down to 1% of load cell value, which provides high dynamic range and thereby reduces the number of load cells required to cover the force range. The machines use plug‘n’play YLC Series load cells that feature anti-rotation collars to avoid load train twist and facilitate easy axial alignment. Eight interchangeable YLC load cells are available with different load ratings and resolutions. At the heart of the LS5 and LS2.5 materials testing system is testing software named NEXTGENPlus that allows users to control and monitor all aspects of the system from a single front end for data analysis. It also features a library of test methods, SPC functionality and visual analysis. Ametek Web: www.ametek.com Lloyd Instruments Web: www.lloyd-instruments.co.uk MAY 2013 • WWW.EPPM.COM • 27

K 2013: THE PREVIEW New foam grade said to offer less waste Zotefoams plc. has released its new product PackaZote – a new foam grade which is reportedly competitively priced. The company claims its new grade’s properties will make it an economical choice for the packaging market. Paul van Rheenen, Sales & Marketing Director said: “We are excited to reveal our new packaging grade PackaZote.” “This is a new direction for us as a company, but we are aware that for us

to maintain our reputation as world leaders in cross-linked block foam, we need to listen to the market.” Zotefoams’ venture into the economic packaging foam market has lead to great interest and an apparently very competitive foam product, with benefits believed to outshine the competition. PackaZote was developed to fill a gap in the market with a product that can fulfil its application need while offering the converter properties including isotropic

New film winder claims to serve every customer

Austrian technology group ANDRITZ has developed a new film winder in modular design that the company claims can adapt to different individual customer requirements. The ANDRITZ Biax winder – completely designed and manufactured in Austria – offers new drive technology on the winding core and reportedly meets the highest requirements in terms of ergonomic design. Safety devices and wide access doors allow safe and easy maintenance and the special contact roll set-up ensures

high winding quality, even at high speeds. The moving winder is currently unique for this film width on the market for production of biaxially stretched plastic films and offers constant roll configuration and vibration-free movement. The product can be viewed at the ANDRITZ manufacturing location in Graz, Austria. ANDRITZ Web: www.andritz.com

behaviour, purity, lighter density and less lamination. The product is available as a 200mm x 1200mm x 53mm slab, which in application terms means less wastage and better application methods. Zotefoams makes its products using a high-pressure nitrogen gas solution process, which is said to produce pure, chemically inert foam without blowing agent residues and with a uniform cell structure and regular cell walls.

Zotefoams Web: www.zotefoams.com

Automation systems to go on show

At K 2013, KEBA plans to demonstrate both new and further developed products based around the KePlast control solution for injection moulding machines. The KePlast system is scalable in control, operator panel and input/output. It can also be applied to low-cost and high-end applications. Several types of injection moulding machines – whether they are hydraulic, all-electric or hybrid – can reportedly be controlled quickly and precisely. Furthermore, KEBA will present

KeMotion IMM Handling, a precise robot control for fast take-out handlings without vibrations. Those who visit the KEBA stand will see various products that aim to increase productivity and energy efficiency and also aim to improve the ease of use in injection moulding processes. KEBA and its products can be found at stand 12-B22. KEBA Web: www.keba.com

German producer releases new cleaning agent WEICON has unveiled a new product in its cleaning range – WEICON Citrus Cleaner. WEICON Citrus Cleaner has been developed for the cleaning of machinery and equipment, precision engineering and precision mechanisms in industry and trade. The new product removes stains left by oils, greases and lubricants, resins and tar, rubber residues and abrasion. It also cleans pencil marks and ink from pens and markers. Furthermore, it can remove the residues of adhesive tapes and labels, silicone sealant and polyurethane foam. The cleaning effect is a result of a combination of active pH neutral

substances. The spray can be used on a variety of different surfaces such as metal, plastic, glass, ceramic and painted or coated surfaces. WEICON Citrus Cleaner can be applied in several different environments like industry and trade, public institutions, transport, construction or even at home. The cleaner is said to be easy to use and WEICON advise that for safety reasons, users should test the product on a hidden area beforehand to ensure there are no adverse affects on the surface. Weicon Web: www.weicon.com

New update looks to improve ease of use Compuplast have announced a new version of their Virtual Extrusion Laboratory – version 6.7. The company claims the new version offers significant improvements, which aim to increase capability of the programs and the comfort for the user. A full 3D Solution for some mixing elements in the extruder module has also been incorporated. Chill roll and multi-layer modules have been converted to the new environment, reportedly giving the programs many new features. The spiral die and flat spiral die modules have a capability of full 3D

solution with a possibility to see results in in full 3D mode due to a new 3D visualisation option. The cooling module contains new variable shrinkage indicating the product’s potential tendency to be damaged or bend. For K-2013, the profile die program has been especially converted into the new environment. This aims to reduce the necessary number of clicks and make the program easier to operate overall. Compuplast Web: www.compuplast.com

New Dynamic Testing Machine series announced Metravib has introduced a brand new series of Dynamic Testing Machines, designed to offer a wide range of dynamic tests in one single machine. The tests include glass transition, frequency dependence up to 1kHz, Payne & Mullins effect, high frequency testing, fatigue testing 28 • WWW.EPPM.COM • MAY 2013

under various controlled waveforms and rubber heat build up testing (flexometer). The tests can be carried out through a large choice of specimen holders that aim to give practical and efficient testing of most solid materials such as elastomers, polymers,

composites, metals and ceramics and bio-sourced materials. The design of the new series, named DMA+, consists of a floor standing mechanical test frame, controlled by a computer station equipped with dedicated software. Each DMA+ model includes a

thermal chamber designed to operate at temperatures ranging from -150°C to 500°C, temperatures associated with various cooling solutions. Metravib Web: www.acoemgroup.com

K 2013: THE PREVIEW Exclusive: Messe Düsseldorf blogs for EPPM

Thermoforming company to present two new machines

As we draw ever-nearer to K, and the momentum starts to build, EPPM's new website (www.eppm.com) will play host to some exclusive blogs from Messe Düsseldorf, the organiser of the show. In this first blog in the series, the trade fair specialist introduces visitors and exhibitors to the highlights of the newly revamped www.k-online.de the online portal to the show.

WM Wrapping Machinery are to present their vacuum/pressure forming machine mod FC 780 EIM2 Speedmaster (780x570mm) at K-2013. The machine has in-mould cutting and additional press for steel rule cutting in line and robot stacking. Another machine mod, the FT500 will be also on show. This thermoformer, for in-mould forming and trimming (570x375mm), has a lower tilting platen and a robot stacker with twisting plate. These two machines can be found at stand 3/16A.

“Clever scientists have now discovered a new area of application for down feathers. Apart from their use in padding or thermal insulation, down is also an ideal biopolymer material. This is not science fiction but the introduction to the latest "Topic of the Month” presented on www.k-online.de, the internet site of the K 2013 trade show. Every month, this site features exciting topics from the world of science and plastics, such as “Nylon toothbrush now 75 years old“, “Nylon in feature films”, “Plastic design” or “Plastic reduces greenhouse effect” – to name but a few. On a more practical note: on www.konline.de useful information such as the complete list of exhibitors, news from the industry, a personalised tour of the trade show or a ticket to the trade show for printing at home are only one click away. While this sounds perfectly commonplace today, at K 95, this technology sounded very pie-in-the-sky and hard to imagine. In the past 18 years, K-Online has made a quantum leap. Gone are the times when our internet site contained very basic information and little more than a copy of the printed visitor leaflet. K-Online has become a medium in its own right. The content is compiled and prepared for different target groups such as exhibitors, visitors or journalists.

Different features focus on information, organisation and communication. The platform offers shopping functions (e.g. visitor tickets and technical services for exhibitors) and with its vast database it is the portal for the industry with topical information from all different segments. A new Innovation Compass, to be launched in mid-September, will provide information on exhibitor innovations. With its wide array of information, KOnline has become the Wikipedia of the international plastics and rubber industry. At present, K-Online has about 50,000 pages full of topics in a clearly structured design to give users quick access to the required information. In addition to German and English, the content is also available in the nine most important languages spoken at the K trade show, French, Italian, Spanish, Portuguese, Dutch, Russian, Chinese, Japanese and Arabic. Naturally, K 2013 is also available for mobile devices (m.konline.de) and as a K App for iOS und Android. By the way, the next Topic of the Month “Aerogels: lightweight among high-tech materials” deals with nanostructured aerogels.

WM Wrapping Machinery Web: www.wm-thermoforming.com

“Trendgineering” – the motto for major machinery group “Trendgineering” is the trade fair motto under which KraussMaffei, KraussMaffei Berstorff and Netstal will be presenting their products, as well as their technologies for global market trends, at K 2013 in Düsseldorf, Germany from October 16-23, 2013. Solutions for market trends, including light-construction projects in the automotive industry, but also the increasing demand for plastic products in the medical, construction and logistics sectors, as well as for thinner packagings in the food industry, will be presented. “Our trade fair presentation will be under the motto “Trendgineering”. With

premium-quality solutions, at K 2013 we will consolidate our position as the innovative technology leader in the industry - to the benefit and advantage of our customers,” said Jan Siebert, CEO of the KraussMaffei Group. KraussMaffei Group Web: www.kraussmaffeigroup.com

To read the blog post in full, along with posts from other contributors, head to www.eppm.com/blog

Masterbatch developed for laser inscription Specialist plastics processor Grafe from Germany provides masterbatch for laser marking. Laser-marked plastics are resistant to chemicals and abrasion, and inscriptions therefore remain clearer over longer periods of time, claims the group. Using its own Foba laser marker to conduct preliminary tests, Grafe says it can determine the best settings. “Laser marking is an efficient process in the design of plastic products and has become a real alternative to conventional printing methods over the past years,” said Danny Ludwig, Head of Development at GRAFE. “It is quick and economical, and it produces a longlasting, very clean, precise and welldefined marking without having to pretreat the parts.” Laser marking is suitable for three types

of marking — light, dark and coloured marking. The end-result is determined by the process and by the polymer and the admixtures used, such as pigments and other additives. These additives are necessary in the laser marking process to guarantee the required standards of contrast, definition and speed. Ludwig continued: “Depending on the desired application we develop the ideal recipe for the masterbatches, which can then be tested in-house for writeability using our own laser marker. In this way our customer receives a fully tested plastic product and all the necessary parameters for marking the part later.” Grafe-Gruppe Web: www.grafe.com

New CO2 cleaner to allow continuous production Swiss company ASCO Carbon Dioxide Ltd has released a new cleaning product for the maintenance of moulds and tools. ASCOJET, manufactured specifically for the plastic injection moulding sector, has been produced to serve as a reportedly powerful but gentle cleaning method for moulds.

The cleaner, composed of 100% carbon dioxide, appears to have several benefits that come with its use. It can be applied directly to the moulds without them having to cool down or be removed. On top of this, the cleaning material claims it has advantages over sand and granular cleaning as its properties ensure there is no residue left over after the moulds are cleaned. ASCO Web: www.ascoco2.com MAY 2013 • WWW.EPPM.COM • 29

INDUSTRY NEWS & EVENTS

Global chemical group forecasts restructuring and job cuts BASF has announced amendments to the structure of its Performance Products segment. The segment bundles BASF’s businesses with chemicals used in many end-user products. The group says that “increasing standardisation and the entry of new competitors have changed the business environment significantly.” This is said to have particularly impacted BASF’s plastic additives operations. The objectives of the new structure include streamlining processes, investing in new technologies and adjusting the group’s portfolio and organisational setup. The planned measures will lead to a reduction of about 500 positions worldwide by the end of 2015. “The expansion of our specialty business in the Performance Products segment made us more robust to economic fluctuations. However, the growth and profitability of the standard products do not yet meet our requirements. We have therefore identified numerous measures which we are implementing step by step. Further measures are being analysed,” said Michael Heinz, member of the Board of Executive Directors of BASF SE and responsible for the Performance Products segment.

BASF says it aims to improve the efficiency and profitability of the Plastic Additives and Pigments & Resins business units in Europe, which are mainly located in the Basel area. In the Pigments & Resins business unit, European product and quality management and product safety will be pooled in Ludwigshafen. Global product management lead will be bundled in Hong Kong. In the Plastic Additives business, a more market-oriented approach will be introduced. The new strategy will lead to a decrease in the need for product-related research in plastic additives and pigments in the Research Center Basel, claims BASF. Specifically, the Research Center Basel will be scaled down. There will also be less need for administrative services provided by the Business Center Switzerland for the BASF Group companies in Switzerland. This will lead to a job reduction in the Basel-based Business Center Switzerland. The Paper Chemicals division, headquartered in Basel, is not affected by the current measures. The restructuring will lead to a reduction of a total of up to 350 positions in the Basel area by the end of 2015. This

In the Pigments & Resins business unit, European product and quality management and product safety will be pooled in Ludwigshafen. Image copyright BASF. includes the pooling of tasks at other sites. BASF has said that it aims to implement the job reductions related to the restructuring measures in the Basel area in a socially responsible manner, and states it will attempt to find job

opportunities in other BASF Group companies for as many employees as possible. BASF Web: www.basf.com

“Packaging recycling begins with design” claims industry body

New common brand for Sumitomo Bakelite plastics business

Plastic packaging design threatens new EU recycling targets. That’s the claim made by EuPR (Plastics Recyclers Europe). The statement goes on to say that “packaging recycling does not begin with collection but design.” The group blames the idea that modern packaging designs today are focused mainly on maximising performance. Careless design may lead to problems with fully emptying packets, as well as material combinations which are incompatible with recycling, according to EuPR. Plastics Recyclers Europe believes that the introduction of an EU classification system will assist designers in evaluating their creations, in addition to helping them choose the best options to improve their recyclability classification. RecyClass is the concept proposed as a solution, and is intended to build on existing Design for Recycling Guidelines. It will offer a platform to determine the recyclability class of plastic package

Sumitomo Bakelite Co., Ltd. Group has unveiled a new identity for its High Performance Plastics Business Unit to customers around the world. From April 8, 2013 the companies forming the business unit will present themselves to the market as one entity: SBHPP. The creation of SBHPP highlights the worldwide integrated sales and marketing network, and global manufacturing capabilities offered by the manufacturer of phenolic resins, moulding compounds and circuitry materials. Customers of SBHPP will benefit from globally available resources and expertise of the global leader in engineering thermoset resins and moulding compounds, according to the group. SBHPP is represented by 20 companies spanning Asia, China, Japan, Europe and North America. This includes a new company base in New Delhi, India, to further strengthen its support for customers in emerging markets. SBE India Pvt. Ltd. will include warehousing, marketing and a sales organisation to serve customers’ needs in the region for plastics and associated materials.

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designs, based on a scale from A to G (seven classes comparable to EU energy efficiency classes). “Many months ago we started working on this project. At this stage a first draft of our model is being tested in several technical institutes in different European Countries,” said Paolo Glerean who heads PRE’s packaging design task force. “Our goal is to present the RecyClass tool during a special event at Interpack in Duesseldorf in May 2014.” EuPR Web: www.plasticsrecyclers.eu

Mr. Noboru Yamawaki, SBHPP Business Unit Leader, commented: “With ‘SBHPP’ we are unifying the way we present ourselves to the market. Our new identity clearly identifies us as one business unit, part of a large and established worldwide group our customers can rely on, and committed to exceeding our customers’ expectations in material performance, customer service, technical expertise, and product quality.” From April 8, customers can access information on all products and services via one website: www.sbhpp.com. SBHPP Tel: +81 3 5462 4111 Email: info@sbhpp.com Web: www.sbhpp.com

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INDUSTRY NEWS & EVENTS ROUNDUP New lightweighting education and research forum starts work The Aachen Center for Integrative Lightweight Production (AZL) of RWTH Aachen University has named its founding partners in a kick-off meeting on February 6th 2013. Representatives of the 33 founding companies came together to start the cooperation in Aachen. In the framework of the Excellence Initiative by the German Government, new clusters will be established on the campus of the University of RWTH in Aachen in the next 10 years: 19 new institutions will be set up on 800,000m2. As one of the first institutions on the new Campus, the Aachen Center for Integrative Lightweight Production (AZL) will be set up. The AZL, founded by Prof. Dr. Christian Brecher and Prof. Dr. Christian Hopmann, is part of the faculty of mechanical engineering, with 62 professorships and more than 10,000 students. The aim of AZL is to develop the automated production of load- and cost-optimised lightweight components, suitable for mass production and versatile process chains in composite and multi-material design. All the necessary expertise along the entire value chain is said to be within walking distance on the campus assembled around the AZL, where over 700 scientists are working on production technologies, lightweight materials and applications. The expertise covers the production from carbon- and glass fibres, textile preforming, high-volume capable plastics processing, automation, machining and testing to applications ranging from oil, water, gas, infrastructure, buildings to and automotive engineering. Dr. Michael Emonts, CEO of AZL, explained the unique research environment: “AZL is set up within the new cluster “Integrative Production Technology”, which additionally offers approximately 25,000 m2 laboratory space for 800 scientists, at the Campus Melaten in Aachen. Within the Campus, companies have the possibility to open own branches or complete development laboratories. The advantage of the direct contact to the staff and the

Planned buildings for the Integrative Production Technology Cluster at RWTH Aachen University Campus. equipment of the excellent research institutes – and especially the close contact to highly qualified students as potential staff after graduation – is already used by major companies from different industrial sectors.” One of the first projects with the founding partners of AZL is a strategic market and technology study over 12 months, focussing essentially on the evaluation of the technical feasibility for mass production of new applications for lightweight materials to establish the institute’s activities. This study identifies applications, components, distribution channels, number of pieces, economic potential, requirements for materials and process chains in five major market segments. Dr. Kai Fischer, Divisional Director Composite Production Technology of AZL, explained: “The unique aspect of this study is that new markets for composites are being identified which are not yet accessible for these materials. The study therefore provides an ideal basis for the development of new strategic business areas for the participating companies all along the value chain.” “We are delighted to announce today at the JEC Show in Paris 33 founding partners for the launch of the AZL, covering the whole value chain. Most of them are revealed below, some of them

will stay anonymous”, announced Dr. Kai Fischer. “From materials suppliers over moulder, manufacturing suppliers, tier 1 and tier 2 to OEMs, we are proud and happy to have with us AFPT, Ashland, DSM, DuPont, EMS Chemie GmbH, EM-Systeme, FA Kümpers, Future Fibres, Gurit, Henkel AG & Co. KgaA, Johnson Controls GmbH, Kegelmann Technik, Lamilux, LANXESS, Laserline GmbH, Lürssen Werft, Mahr Metering, Opel, Röchling, SABIC, Siemens, Tencate, ThyssenKrupp AG, Ticona, Toyota Motor Europe.” Dr. Fischer continued: “The cooperation of this fantastic network is the foundation of the AZL and its future projects.” In summer 2014, the AZL will open its doors with the result of the study. But already since 2012, AZL is working in industrial projects and public research projects. Additionally the targeted projects resulting from the market- and technology study will be developed and implemented. Michael Effing, CEO of AMAC, who supports the AZL, commented: “Many of the current mainly thermoset-driven applications still have significant labour costs and we see them step by step moving to Middle East and Asia. The composite technology is of imminent importance for Western Europe and North America, like for lightweight automotive applications or others. We

need to ensure that this technology can stay in Europe and that is why we build on the promising value of the integrated manufacturing of composite systems at the AZL. This is how we want to support the future of composites in the Western world.” Together with the opening of the AZL, the Composite Academy will be launched. Dr. Michael Emonts explained: “The AZL’s Composite Academy will offer various disciplines for extraoccupational training, education, seminars or in-depth qualification of experts on all levels, like technicians, lab workers, engineers, and managers. Participants will be able to pass specific education in the field of composite technologies and extra-occupational education.” Dr. Emonts continued: “With the background of the current shortage of experts and the need for restructuring industrial companies in the future with the introduction of new materials, this Composite Academy will provide essential services, which complete the unique one-stop-shop offer of the AZL. We expect the Composite Academy to take off in 2015”. Aachen Center for Integrative Lightweight Production (AZL) Web: www.azl.rwth-aachen.d

Engel expands again in Germany Engel has further expanded in Germany. The international supplier of injection moulding technology inaugurated its new sales and service facility in Wurmberg near Stuttgart on 19th April with customers and partners present. The group has invested €5 million in its new location. “Germany is our most important market, this is where we generate around a quarter of our global sales”, said Dr. Peter Neumann, CEO of ENGEL Holding during the inauguration ceremony, which was attended by 130 guests. “In the last few years we have continuously increased our market share in Germany. Our investment in South Germany sees us do justice to this growth.” Joining Nuremberg, Hagen and Hanover, Engel Deutschland GmbH Technologieforum Stuttgart, located in Wurmberg, is the fourth subsidiary in Germany. 22 staff for sales and application technology, training, service and energy consulting are employed at the site. 32 • WWW.EPPM.COM • MAY 2013

“Our objective is to establish ourselves as an information and communication hub for our customers in South West Germany,” said Claus Wilde, Head of the new site. At 700 square metres the technical centre is the largest of any Engel subsidiary. It offers space for seven automated production cells which are available to customers for

demonstrations, tests and training. The exhibits change to match the programme of seminars and workshops. “We can present new applications to clients and guests every time they visit” said Wilde. Energy efficiency and lightweight design are two current focus topics. Many global firms in automotive supplies have their head offices in

Baden-Württemberg, as do leading research institutes such as the Fraunhofer Institute in Pfinztal, with whom Engel has cooperated on fibre composite technologies. The Wurmberg location also offers a direct link to the A8 motorway. “We have substantially shortened the route to Engel for our customers in the Southwest,” said Claus Wilde. “Customer proximity is becoming increasingly important as a success factor. Many plastics processing firms are moving away from small standard machines in favour of larger, complex and technologically sophisticated system solutions. That means plastics processing companies and systems suppliers are having to work together more closely all the time.” Engel Tel: +43 50 620 0 Email: sales@engel.at Web: www.engel.at

INDUSTRY NEWS & EVENTS ROUNDUP Acquisition expands recycling range Pallmann Group has made an acquisition of technology from Swiss company BP Recycling Systems GmbH. Pallmann Group is making the acquisition via Pallmann Industries Inc., a group company based in the USA. The value of the transaction has not been disclosed. The acquisition of BP Recycling Systems’ technology will extend Pallmann’s range of machines to include a full line of equipment for making briquettes and pellets from municipal and industrial solid waste, biomass, plastics, textiles, glass, non-ferrous metals, and wood. Briquetting and pelletising are technologies downstream of preshredding and sorting of waste into

homogenous waste streams, and are key for preparing the waste going into recycling and fuel. The acquisition also enables Pallmann to expand into new sectors, such as recycling of industrial waste and preparation of refuse-derived fuel (RDF) for combustion or gasification. “This type of technology is a perfect match with our existing competencies in shredding all kinds of solid waste,” said Rolf Gren, President of Pallmann Industries. “It offers a good basis to expand our offering to our existing customers as well as to new ones.” “Handling solid waste is becoming more important as there is a growing need to find alternatives for landfills and reuse all available resources on a global scale,”

European vinyl recycling on track for 2020 target

he continued. “The remaining waste can also be used as a source for energy at power plants.” Pallmann Industries Web: www.pallmann.eu

Materials handling system designed for packaging group UK ancillaries distributor TH Plastics has agreed a contract to deliver a Moretto material handling system for packaging group Kobusch. The group was selected to provide the system for one of Kobusch’s sites in the UK. Specialising in co-extrusion and thermoforming for rigid packaging for the food industry, Kobusch required a system with a blender that could handle up to two tonnes of regrind flake per hour. TH Plastics worked with Moretto to develop a system which included the DGM1000, a flake loader designed to

work with difficult to flow regrind flake, a Eureka Drying System for the virgin PET and a supervisory system to monitor all the equipment. Crawford Fleming, Project Manager at Kobusch said: “We selected TH Plastics as they were able to offer us a fit-forpurpose and cost-effective solution that was tailored to meet our specific requirements. “The systems work seamlessly together and we’ve been able to achieve optimum levels of over three tons of flake material per hour, which we’re extremely pleased with.”

TH Plastics Tel: +44 1457 855514 Email: info@thplastics.co.uk Web: www.thplastics.co.uk

Joint venture aims to shoot to top of list Europe's largest PVC producer has signed an agreement to create a 50-50 joint venture with an international chemical group. A letter of intent was signed by Brusselsbased Solvay and petrochemical manufacturer INEOS in a move that looks to create a company in the top three worldwide. The agreement means the combined business will strive to generate net sales of EUR 4.3 billion and have over 5,600 employees spanning nine countries. Jean-Pierre Clamadieu, CEO of Solvay said: “This proposed partnership is an ambitious and value-creating industrial project.” “We want to create a world-class player that will benefit from the high-quality assets of both companies,” he added. Jim Ratcliffe, Chairman of INEOS said: “This agreement will result in the

creation of a truly competitive and sustainable business.” He continued: “The newly combined business, which will be of world scale, will be able to better respond to rapidly changing markets and competition.” As a consequence of the joint venture, both firms believe there will be a drop in logistics and transport costs, as well as a sharing of best practices and a combination of marketing and sales forces. Solvay’s contribution to the new business will be its vinyl activities and its Chlor Chemicals business, which are spread across seven European sites, five of which support sustainable production of PVC. Kerling, Europe’s biggest PVC producer and a subsidiary of INEOS, will contribute to the new business. This adds 10 sites across seven countries.

The letter of intent (LOI) is subject to negotiations between employee representatives and the two companies will run separately until completion of such procedures. INEOS Web: www.ineos.com Solvay Web: www.evonik.com

Recycling and security to mix under new license A leading developer of plastic waste recycling has agreed a deal with a security consultancy specialist. Environmental Recycling Technologies (ERT) has granted a licence to Falanx Protection Ltd for its Powder Impression Moulding (PIM) process. ERT has developed its PIM process, which converts mixed waste plastics into commercial products. The licence allows for the manufacture and sale of products made using the PIM process for anti-ballistic and anti-blast uses within the Middle East and North Africa, or MENA. Roger Baynham, Managing Director of

ERT, said; “The anti-ballistic and anti-blast products made using PIM opens up an exciting market for the application of our technology.” “We are thrilled to be working with the team at Falanx and are confident that they can successfully commercialise our PIM technology within the MENA region,” he added. Under the terms of the agreement, Falanx will pay ERT a licence fee of $100,000 in addition to annual royalties based on sales of products made using the PIM process. John Blamire, Chief Executive of Falanx Group plc stated: “We are very pleased to be working with ERT. Their technology

allows us to offer a product that gives improved blast resistance to buildings and the perceived threat of terrorism has resulted in an increase in enquiries for this type of product.” Falanx, a wholly owned subsidiary of Falanx Group plc, is a security and risk management consultancy working with clients worldwide. The group also offers training to companies and governments in security and close protection. Environmental Recycling Technologies plc Web: www.ertplc.com

VinylPlus, the European PVC industry sustainable development programme, recycled 362,076 tonnes of PVC last year. The target is to be recycling 800,000 tonnes per year by 2020. A more comprehensive and wider scope for what constitutes ‘recycled PVC’ has been adopted to include post-consumer and limited types of post-industrial PVC, as well as some of the regulated waste streams in the EU. New methods of recycling difficult-to-treat PVC waste are currently under evaluation and efforts have reportedly been made to address the ‘legacy additives’ issue related to the presence of restricted chemicals in recycled PVC. The 2012 results were presented at the Vinyl Sustainability Forum 2013 in Istanbul. VinylPlus Chairman Filipe Constant said the industry “is effectively moving from a model of resource consumption that follows a ‘take-makeuse-throw away’ linear pattern into a truly circular economy model which puts endof-life materials back into the production stream extending the added-value of PVC’s inherent durability and versatility.” A number of VinylPlus taskforces are studying ways to incorporate renewable energy and raw materials, the sustainable use of additives and the environmental footprint of PVC production. A VinylPlus product label concept for PVC products has been developed in collaboration with The Natural Step – an NGO providing input and guidance for the development of the VinylPlus programme – and the UK expert certification body BRE. “It is quite impressive to see such a dynamic value-chain working together to make the entire industry and its products more sustainable,” said Reha Gür, VicePresident, Turkish Plastics Manufacturers Association, PAGDER. “As most of Europe and the world are experiencing difficult economic times, this is even more admirable. We are honoured to host the Vinyl Sustainability Forum in Istanbul and hope the work of VinylPlus can help inspire our country’s PVC companies – large and small — to move a step closer to the principles and goals behind this programme.” An important focus of the VinylPlus programme is the promotion of ‘sustainability awareness’. In that regard, a number of communication projects were supported last year to reinforce the Voluntary Commitment messages along the value chain. VinylPlus also engaged in external debates including Rio+20, the United Nations Conference on Sustainable Development. Speaking at the Forum in Istanbul, Ambassador Tomas Anker Christensen, Senior Advisor at the United Nations Office for Partnerships said: “Partnerships are a key enabler for achieving progress on agreed development goals, including sustainable development. VinylPlus has demonstrated success and we are keen to see how the European industry challenges itself to be more ambitious and concrete in addressing identified challenges. Industry has a critical role to play in accelerating change, greening the economy and driving sustainable progress around the world.” VinylPlus Web: www.vinylplus.eu MAY 2013 • WWW.EPPM.COM • 33

ADVERTISERS’ INDEX

EPPM CLASSIFIEDS MATERIALS

Company

Page

Abbey Masterbatch

20, 34

ACS/Cumberland

Air Control Industries

Albis

Arburg

Bausano

Birmingham Granulators

Boussey Control Europe

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DB Automation

DME

Engel

EPPM Website

Equipnet

HB-Therm

Herbold

Koch-Technik

Krauss Maffei

RE-PROCESSING EQUIPMENT Cont’d

Granulators – Shredders – Pulverisers New and second hand systems bought and sold Spares for all machines

BLACK MASTERBATCH Compounding Pipe Film

Moulding Recycling Conduit

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Mediplas

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Plastic Machinery UK

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PMH GmbH

Process Control

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Renmar

13, 34

Tappex

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TransXL

Vinyl GB

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34 • WWW.EPPM.COM • MAY 2013

Contact: Dick Monkhouse Tel: 01928 734724 Email: sales@herbold.cu.uk

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MAY 2013 • WWW.EPPM.COM • 35