EPPM 15.6

September 2013

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editorial editor david gray david.g@rapidnews.com

in this issue MACHINERY

pages 6 –13

REGULARS: Latest news

SHOWCASE: AUTOMATION & ROBOTICS SPOTLIGHT: FILM & SHEET EXTRUSION

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K 2013: THE PREVIEW

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Volume 15 Issue 6 © September 2013.

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

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John Ellis, Segment Manager Polycarbonate, Bayer MaterialScience

Clive Maier, Owner and Director, Econology Ltd.

Nigel Brown, Founding MD, Frontier Aerospace

Dr Martin Kay, Chief Consultant, Pira International

Vicki Sayer, Regulatory Manager, Colormatrix

Charmaine Bowers, Operations Manager, Polymer Training & Innovation Centre

Pipe Extrusion Recycling Micro Manufacturing 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

One of our biggest battles is to overcome this negative image of plastic being perpetuated by the popular media in recent years. However, don’t be fooled into thinking the national press are the only ones to blame; neither is this a new trend.

I managed to find an article dating back to 1953 (the same year Dow introduced the household version of its now famous Saran wrap) in the British Journal of Industrial Medicine, in which one D. Kenwin Harris paints a detailed and often gruesome picture of the many potential side-effects of exposure to plastics. Admittedly, many of his scenarios take place during the manufacture of plastics and chemicals, which to this day can be a toxic and dangerous business.

However, speaking on the consumer front, Harris concludes ominously: “The importance of a full investigation of plastic materials likely to be used for certain purposes is stressed.” Fair enough.

Since the commercialisation of polymer chemistry, there The post-war western have been concerns about the impact on human health. world was characterised by a new era in manufacturing, one which looked to economise with cheaper, disposable materials. With plastic entering the home on a greater scale, naturally there was a need to investigate the potential for long-term side-effects, especially on children.

But surely we have now reached the long-term? Shouldn’t we know about the side-effects by now?

Health concerns are not the only historical factor here. The aesthetics of plastic often derive an association with the word ‘artificial’. It is sometimes a bit cliché to quote Oscar Wilde (he talked a lot) but here goes: when asked why he thought American society was so violent during the 19th Century, he quipped, “because you have such ugly wallpaper”.

Wilde’s idea was that we fail to function properly when we detract from natural elements with artificial aesthetics. As a lover of wildlife and nature I tend to agree, but I don’t apply the same theory to plastic.

Working in the industry, I see the skill and engineering that goes into plastic product design and manufacture. It is no less a craft than woodwork or metalwork. Given the level of skill and engineering that goes in at design and manufacture, I find it hard to view these applications as ‘artificial’. In fact, when I hear it used to describe something made from plastic, I find the term ‘artificial’ quite rude!

Perhaps, as fossil fuels deplete and biomaterials come more and more into play, the incoporation of the natural into the so-called ‘artificial’ (the pernickety among us would argue that fossil fuels are themselves a natural product) the image problem may eventually fade from memory.

Plastics for the Environment

Plastic’s ‘image problem’ goes back a long way

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 at K 2013: Interactive displays highlight solutions to cross-industry challenges With 3000+ exhibitors vying for the attention of the expected 220,000 visitors, the K Show remains the industry’s largest trade show. For show attendees, the attraction of the K Show is the focus of many exhibitors on introducing genuinely new technologies.

That will be the case at PolyOne (Hall 8A, Stand J13), where interactive displays will help attendees to better visualise how each new technology impacts on an enduse market or application. The interactive displays will draw attention to advanced polymer solutions that can help manufacturers overcome challenges with differentiated technologies such as: • Anti-counterfeiting – customised masterbatches and materials • Design differentiation – colour and design services that set products apart from the competition • Vibration dampening – TPEs that absorb vibration • Energy savings – materials that can minimize secondary processes • Demand for sustainable alternatives – biosolutions for durable products and flexible materials, efficient solutions for LED lighting • Metal replacement – lighter weight polymer alternatives that add design freedom • Ballistic protection – clear and opaque sheet that can trap projectiles and save lives.

PolyOne welcomes visitors to its stand, in Hall 8a, Stand J13, to get hands on with industry-leading technology.

Presents: Metal replacement, global design and eco-conscious solutions PolyOne associates will be engaging with customers at the PolyOne stand and at venues across the Messe Düsseldorf fairgrounds.

Plastics processors, industrial designers and other interested in learning more about how plastics can replace metals are invited to join the Specialty Engineered Materials team from PolyOne at one of their four Lunch & Learn sessions during the K show. The main topic at each session will be metal replacement, with each individual seminar focusing on a different aspect of this subject area.

The presentations are technical in nature and include specific examples of metal-to-plastic transitions, the challenges entailed in these, and how they were overcome. The presentations will be in English; however, PolyOne associates in attendance will field questions in French, German, and Spanish.

Lunch will be served at each session, of course, allowing time for informal conversation as well.

All four Lunch & Learn events will be from 11:30-13:00 in Room 17, CCD Süd at Messe Düsseldorf. Attend as many as you like, but please RSVP quickly as seating is limited: Thursday, Oct. 17: Polymer solutions to replace metal in heat management applications Friday, Oct. 18: Polymer solutions to replace metal in applications requiring stiffness and strength Monday, Oct. 21: Polymer solutions that can mimic the density, appearance and feel of metal Tuesday, Oct. 22: Polymer solutions to address electro-static discharge

e spoke with Holger Kronimus, Vice President Europe and General Manager, Specialty Engineered Materials, Europe at PolyOne, to hear his thoughts on the upcoming K show.

W

need for more energy-efficient solutions. We will be highlighting technologies at our K show stand that pertain to biopolymers, bioplasticizers and to energy savings.

EPPM: What do you expect will be key technology trends at K 2013?

HK: Many of the trends are actually an ongoing evolution of changes that began years ago. Two that are of great interest to our customers are metal replacement, and the ability to avoid painting plastic parts through the use of in-mold coloration (IMC) with masterbatches.

We continue to see enormous potential for specialized polymer solutions in these and other areas, and are fortunate to have many years of experience in helping customers overcome challenges associated with both of these trends.

Eco-consciousness is another ongoing trend, and it includes not only the use of biopolymers but also the

EPPM: Will you be seeking any particular products or developments at K 2013?

HK: My focus at the K show, and at any trade show, is on meetings with customers. Fortunately they often have had a chance to walk the floor before we meet, and share with me what technologies have impressed them.

And of course the engineers of PolyOne will make time to look at the new machinery, additives, services and more on display at the show. It is an opportunity that comes only every three years, and we take full advantage of it.

EPPM: Any last thoughts regarding the K show?

HK: My colleagues and I look forward to welcoming

Readers should RSVP with name, company name, the dates they wish to attend, and the number of attendees to Anne Hippert: anne.hippert@polyone.com.

Biopolymer successes highlighted at two conferences Marcel Dartée, Global Marketing Director Sustainable Solutions & Biomaterials at PolyOne, has been invited to present at two conferences held during the K show. On October 18, he will present during the Bioplastics Business Breakfast on the topic “Formulation proficiency helps biopolymers meet the demands of durable applications.”

Dartée will discuss reSound biopolymer formulations from PolyOne. These high performance bioplastic solutions contain a minimum of 30% bio-based content, and help manufacturers achieve durability and heat resistance while also improving a product’s ecoefficiency.

On October 21, Dartée will be joined by an executive from Xindao, an international designer and manufacturer of promotional gifts, during the Design Chain @ K conference to discuss how the two companies successfully cooperated on crosscontinent design of the XD Sunshine Solar Chargers, now available commercially. In addition, this joint presentation will explain why Xindao chose reSound biopolymer solutions, and how they were incorporated in the solar charger housings to replace a petroleum-based plastic.

Information on both conferences can be found at: www.bioplasticsmagazine.com www.designchainatk.com

attendees to our stand, which will highlight some of our leading technologies and make clear PolyOne offers advanced polymer solutions that add value to nearly every application and market in which plastics are used.

This also will be the first K show at which we can welcome our colleagues from ColorMatrix and from Holger Kronimus, Vice Designed Structures and President Europe and Solutions [formerly General Manager.

Spartech]. I encourage attendees to visit our stand, in Hall 8a, Stand J13, so we can learn more about their business and their challenges, and can discuss how we can work together to help them overcome obstacles, improve profitability and drive their success.

SEPTEMBER 2013 • WWW.EPPM.COM • 5

MACHINERY

Process automation stabilises bottle lightweighting Since the introduction of PET bottles, lightweighting has been an important tactic in reducing costs. As producers continue to reduce the material content in PET bottles, they are closing in on the lightweighting limits. Some producers are realising that the closer they get to the limit, it becomes more difficult to process the bottles. Minor changes in the process can have major effects on the material distribution and the performance of an ultra-light bottle. The more material that is removed, the smaller the overall processing window becomes. At this point, tight control over the process is imperative. Therefore the need to control the location and the thickness of the remaining material is critical.

Agr’s Process Pilot blow moulder management system is said to offer manufacturers a means to take the variability out of lightweighting and provide additional process feedback.

Where material is limited and safety margins are very tight, the Process Pilot system can provide in-process feedback to manage and maintain bottle material distribution with precision.

Agr’s Process Pilot system works in conjunction with the reheat stretch blowmoulder to manage and maintain container material distribution at a specified thickness to within ~0.01mm.

This is accomplished by continuously

monitoring every bottle for material distribution, analysing minute changes and adjusting the blowmoulder controls to maintain pre-defined distribution levels. Unlike operator adjustments, the Process Pilot system can adjust one or all of the blowmoulder controls simultaneously to achieve the best possible material distribution, says Agr. By monitoring the material distribution of the blown container, the Process Pilot is able to account for subtle changes in the process that would normally go undetected by the operator. This prevents the process from drifting out of control before the operator’s next quality sample and averts the loss of processing margin.

In the course of bottle production, variables in the production cycle can affect the processing and quality of light weight bottles. The Process Pilot system can accommodate many types of environmental changes as well as preform preparation and storage conditions that can occur.

Compensation can be made for temperature, moisture content, and minor Intrinsic Viscosity (IV) changes of the preform to maintain a consistent process, within the smallest process window.

The Process Pilot system operates in a similar way to the auto-pilot in an aircraft. The process engineer sets up

the optimised process for a given bottle.

A one-time control characterisation is performed (learn mode) to finalise the recipe and establish a baseline. Once set to the defined recipe, Process Pilot manages the blowmoulder as if on autopilot, continually adjusting control parameters to maintain precise thickness distribution as the process changes.

Since the Process Pilot system can oversee blowmoulder operation on a 24/7 basis, it provides a continuity in bottle production that is not possible with other methods.

Some of the benefits this product offers in addition to improved lightweighting capabilities include the elimination of the need for section weights, reduced scrap, improved overall bottle performance and quality, and lower incidences of downtime in the blowing operation and the filling line.

A recent expansion of the Process Pilot system included the addition of the Pilot Vision integrated vision inspection component. The Pilot Vision can be configured with up to six cameras for comprehensive inspection of preforms and blown bottles for all commonly occurring bottle defects. With the Pilot Vision component, concern over random defects, especially those associated with increased PCR content, can also be eliminated, claims Agr. The Process Pilot system, along with

other quality and process management products for plastic containers manufactured by Agr International, will be demonstrated in Munich at Drinktec 2013 and in Düsseldorf at the K Show.

Details on the Process Pilot products can be found on the Agr website by using the following link: http://bit.ly/YXMw41 Agr International Inc., develops and manufactures a full line of laboratory and on-line testing/quality control devices for containers and similar products for the plastic and packaging industry. The Agr headquarters and main manufacturing facility is located in Butler, PA, USA. Agr International Inc. Tel: +1 724 482 2163 Web: www.agrintl.com

Auto giants pick Kiefel machines for door trim Both the new BMW 3 series and the new Mercedes C-Class feature a door-interior trim manufactured with forming and laminating units supplied by Kiefel GmbH, according to a press release from the group.

As the vehicles concerned are produced in various parts of the world, the machines ordered were required to be

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adaptable to the different needs of the countries involved. “Our advanced know-how and worldwide service network ensure that we are wellequipped to deal with such a challenge”, said company CEO Thomas J. Halletz.

For BMW, Kiefel has developed seven laminating machines which are used to make the door interior trim of the new 3 Series produced in Germany, South Africa and China. Each of these machines takes 80 seconds to produce a complete set of door interior trim components for a car. BMW’s worldwide operation manufactures two-and-a-half thousand 3 Series cars every day.

“After BMW, Mercedes, in cooperation with its TIER 1 supplier JCI, is the second large car producer in the last few months to have started using our machines for the producing of interior trim components”, said Mr Halletz, with respect to the order said to be worth several million Euro.

The car manufacturer ordered a total of six laminating units, which it uses to produce the door interior trims of the new C-Class. All of the machines have been equipped with an in-mouldgraining tool developed by Kiefel. This

reportedly provides a particularly smoothly-grained surface. Mercedes will soon be producing 2,200 vehicles of the new Mercedes-Benz C-Class every day in its factories in Germany, South Africa,

China and the United States. The new CClass will be available from 2014.

KIEFEL GmbH Web: www.kiefel.com

MACHINERY ROUNDUP Chiller system cuts costs for blow moulder UK processor Northumbria Blow Mouldings (NBM) says it is on target to save over £80,000 a year on cooling costs thanks to an energy-saving cooling system from IsoCool. Involving replacement of the plant’s existing beside-the-machine chillers with centralised chilled water and adiabatic cooling systems, the project is designed to optimise efficiency through the exploitation of direct air cooling and a heat exchanger. The system has a return on investment schedule of less than two years.

NBM Ltd., a part of the DNR Ltd. group of companies, specialises in the design and manufacture of extrusion blowmoulded containers for the packaging of food, personal care, household toiletries and industrial products.

NBM Managing Director Brian Wiper asked IsoCool to review the incumbent cooling system responsible for supporting the plant’s 16 blow moulding machines. Comprised of several besidethe-machine chillers with a total cooling capacity of 705kW and installed electrical power of 275kW, the system delivered chilled water to the moulds and hydraulics at 10˚C.

the efficiency of the system as a whole.

Due to the cooler climatic conditions in the area, the system should benefit from up to 100% direct air cooling for much of the year.”

The IsoFC energy-saving device works by connecting the mould and hydraulic cooling circuits through a high efficiency packaged heat exchanger unit with intelligent software, facilitating energy transfer between the systems without them mixing. During low ambient conditions, the IsoFC uses surplus capacity from the adiabatic cooler to precool water returning from the mould circuits before it reaches the refrigeration plant. Both circuits continue to fulfill their

primary functions, but with the benefits of having the life span of the components of the chiller plant extended by the reduced utilisation.

“This solution not only maximises energy efficiency for the hydraulic cooling system, but also allows NBM to take advantage of the adiabatic cooling system during low ambient conditions to further energy savings,” explained Nigel. “Overall, we have calculated that the system will run on partial free cooling for approximately one third of the year, and up to 100% direct air cooling – i.e. with the chillers switched off completely - for over 2,000 hours every year.”

IsoCool Tel: +44 1376 328455 Email: info@isocool.ltd.uk Web: www.isocool.ltd.uk

IsoCool provided a proposal for improving the system, including the separation of the hydraulic cooling system from the chillers, with a predicted payback schedule of 23 months.

“From the outset of the project the expertise in assessing exactly what we required was excellent, involving complex mathematical equations and investigations into what we had and what was needed to move forward. The decision to go ahead was simplified by the projected energy-saving figures, added to the fact that the North East enjoys typically cooler weather throughout the year,” said Brian.

To increase the energy efficiency of the system, IsoCool replaced the existing beside the machine chillers with a centralised chiller system for the moulds (utilising two of the existing chillers which were suitable for centralisation), plus a Eurochiller AX-A water chiller, and an IsoCool pump and tank group. For the hydraulics, IsoCool installed an ADCOOLER adiabatic cooler, employing an existing pump and tank group.

IsoCool Managing Director, Nigel Hallett, explained the reasoning behind separating the two systems: “The requirement for cooling water for the hydraulic circuit is of a significantly higher temperature than the mould circuit, so it doesn’t make sense to run this on energy-intensive chillers. Our adiabatic cooler, on the other hand, automatically functions as an air blast cooler when the ambient is three degrees below the return water temperature from the moulds. By bridging the two circuits with an IsoFC heat exchanger, we are able to maximise

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MACHINERY

SHOWCASE AUTOMATION & ROBOTICS Software offers virtual robot control ABB’s new robotic machine tending software is designed for applications including die-casting, injection moulding and machining. Cycle times, post processing capabilities and potential risks for collisions can be simulated virtually by the software.

The new PC-based RobotStudio Machine Tending PowerPac and the controller-based RobotWare Machine Tending software allow for simulation, validation and optimisation to be completed in the 3D virtual world and then transferred directly to the realworld.

“As a company we put a lot of effort into creating solutions that are truly innovative and address real needs among our customers,” said ABB Product Manager, Andreas Eriksson.

“With this new software we’ve hit many of the main considerations. It’s easy, fast and flexible to program machine tending cells and our control software is usable by even less skilled workers.

These are things our customers are always looking for.”

RobotStudio Machine Tending PowerPac — an add-on for RobotStudio — provides a platform for creation and editing of machine tending robot cells in a 3D virtual environment. A library of common grippers and station types, together with built-in support for most machines and peripheral equipment, enables operators to create and simulate complete cells in the virtual world. There is also the ability to define safe home position movements in a virtual environment.

RobotWare Machine Tending is designed to be a standalone, controllerbased, programming, configuration and operation tool, but is also integrated with the RobotStudio Machine Tending PowerPac. A customisable graphical user interface allows for production monitoring and control, as well as automatic program and part selection.

Although the interface has been designed so that less skilled personnel

can control most common tasks, the software also provides unlimited access to RAPID coding tools for more advanced users.

Users of ABB Robotics' machine

tending systems also have access to ABB’s Robot Care programme, including Remote Service technologies, which provide remote access to the system for production monitoring,

diagnostics and predictive maintenance.

ABB Web: www.abb.co.uk

SEPTEMBER 2013 • WWW.EPPM.COM • 9

MACHINERY

SHOWCASE AUTOMATION & ROBOTICS Robot range specified for plastics to show at K At the K Show, Stäubli Robotics will be showcasing its automation range for the plastics processing industry. Stäubli says that many of the robots and software tools on display have been developed in close cooperation with plastic processors and machinery manufacturers.

The robots designed for the plastics sector in the group’s TX and RX series are used for unloading parts, full machining of injection moulded parts, inmould decoration, in-mould labelling and other applications.

The six-axis robots are designed for downstream tasks such as deburring, testing, cutting, gluing, assembling and packaging. The robots are also said to be highly dynamic. When loading and unloading moulding machines, tool-open times can reportedly be kept to a bare minimum. The robots can handle loads up to a maximum of 34kg.

Stäubli has also launched three additional kinematic models, namely the TX340 SH shelf robot, the ultra-fast fouraxis TP80 and the RX170 hsm machining robot. The shelf-mounted robot can handle loads of up to 165kg with a reach of 3.7 metres.

The Fast Picker TP80 with over 200 picks per minute is recommended by the group for all rapid pick-and-place

applications in the plastics industry. The RX170 hsm processing robot, however, has been designed for the rapid and straightforward machining of plastic materials. The sixth axis of this special robot has been replaced by a milling spindle and, thanks to its reach, relatively large workpieces can be precisely machined. In combination with a traversing axis, machining of plastic parts several metres long is also achievable.

With regards to programming, Stäubli Robotics uses a three-stage approach that is tailored to meet diverse requirements.

Seasoned robotics users program with VAL3. This proprietary Stäubli language is said to be easy to learn and makes programming of robots a more efficient process.

Software developers have developed the ‘VALplast’ application software so that

plant operators and system integrators can use the robot without any special knowledge. The user-friendly interface allows fast programming ‘on the basis of predefined building blocks’ according to Stäubli.

In addition, Stäubli offers machine manufacturers the option of operating the robots via the control system of the moulding machine. This is made

Linear robot range to make K debut Automation group WEMO will exhibit at K with its new linear robots in the E Design series. The group claims that the design allows for economy and efficiency. The series features three models for removal weights ranging from 4-10 kg. They are used mainly for gate removal units (pick and place) and for downstream machining processes. A WEMO 6-5 E-Design for complex automation will be displayed in operation.

Robots of the group’s X Design series have been developed for even more complex automation jobs. They are capable of performing five-axis movements and are offered in eight sizes with nominal load capacities between 5-75 kg. The X Design series is suitable for injection moulding

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machines with clamping forces ranging from 250 to 40,000 kN. For still greater complexities, five additional servo axis may be integrated optionally for peripheries and driven via the robot control.

From this series, a 16-5 X-Design with 5 servo axis will be on display in Düsseldorf.

For the removal of packaging parts, WEMO offers the S Design series which is similar in construction to the new X series.

These high-speed handling units are used for packaging parts and medical applications on two-platen and stack moulds. They have a cycle time of <2.5 seconds. An integrated IML solution with side robot type WEMO 7-5 of the S Design series will be in operation.

For thin-wall parts in the

possible by the ready-to-plug uniVal Drive software solution, a real-time interface for the integration of Scara and six-axis kinematic models under external control.

Stäubli Robotics Tel: +44 1952 671917 Email: robot.uk@staubli.com Web: www.staubli.com/en/robotics

New robot handles higher payloads

packaging industry, WEMO offers equipment for IML applications which may be used both for sideways and top removal. Depending on size of the injection moulding machine, a choice of two different removal units is available.

WEMO’s WIPS handling control (WEMO Intuitive Programming System) can be used with all three series. The process sequences are divided into predefined functions, and pictograms guide the operator through the robot program.

WEMO also supplies grippers and safety systems and standardised follow-up units such as conveyor belts.

Wittmann has developed and launched the W842 robot in response to a market demand for greater payloads and versatility around mid-sized moulding machines of up to 800 tonnes of clamping force and higher.

The chief technical difference of the new W842 is a rack and pinion drive for the vertical axis. This allows the W842 to handle 25kg of payload. The length of the horizontal axis is variable (and can be executed up to a length of about 20 meters). The robot can be fitted with numerous automation features from the group’s automation stable, such as servo rotational axes, spare I/O-modules and vacuum and gripper circuits. The features of the Wittmann R8.2 robot control include real-time functions such as TruePath, SmartRemoval, EcoMode, Find’nPick, SmartStart, and DynamicDrive as well as connection to the internet.

WEMO Automation AB Tel: +46 370 65 85 00 Email: info@wemo.se Web: www.wemo.se

Wittmann Robot Systeme GmbH Tel: +49 9128 70990 Email: info.de@wittmann-group.com Web: www.wittmann-group.com

MACHINERY SPOTLIGHT eppm

FILM & SHEET EXTRUSION

Making its debut at K 2013 under a new name, Nordson EDI Europe N.V., a supplier of flat dies, feedblocks, and related equipment for film and sheet will introduce an expanded product and service portfolio to European customers, including dies of both US and European design and increased technical, spare parts, and rework services.

Nordson EDI Europe is operating from a facility in Temse, Belgium, that until recently was operated by die builder Verbruggen. One year after acquiring Verbruggen in 2011, Nordson Corporation purchased EDI — now Nordson Extrusion Dies Industries, LLC. Since then the Verbruggen business has become part of the Nordson EDI brand. In addition to building new dies at the Temse facility, the company now commissions all European remanufacturing projects there.

“The advanced equipment and

EUROPEAN FILM EXTRUDERS TO GET US DIE OPTIONS

experienced staff at Temse enable Nordson EDI Europe to build a full range of dies for the European market, including product series originally developed by Verbruggen in Europe and by Nordson EDI in the U.S.,” said Andrei Stapinoiu, Managing Director of Nordson EDI Europe. “For customers that order die systems based on U.S. designs, local manufacture enables them to avoid the shipping costs, duties, and lead times associated with sourcing dies from the U.S.A.” Rework customers will benefit as well, according to Luc Verstraeten, Head of Customer Service and Aftermarket Support. “The extensive capabilities at Temse enable customers to have dies refurbished or even upgraded at a local service center, saving time and money,” he said.

An example of how capabilities at Temse can save time for customers involves the chrome plating operation located at the plant. “Reworking dies typically requires stripping and reapplying chrome plating,” said Mr. Verstraeten. “Our ability to do this onsite enhances quality control and reduces customers’ downtime while their dies are being refurbished.”

Shortly before being acquired by Nordson, Verbruggen had made a

multi-million dollar investment in advanced equipment at Temse. These were additions to a plant that was already extensively equipped with sophisticated production systems. The staff at Temse includes skilled technicians and an engineering team equipped with manifold flow simulation software and other design capabilities.

“Ultimately we expect to offer customers a broader selection of die

systems than has been available from either Nordson EDI or Verbruggen,” said Scott G. Smith, Director of Global Operations. “As for die rework, our Temse facility is equipped with the largest and most sophisticated remanufacturing capability thus far available in Europe.”

Nordson EDI Email: sales@nordsonedi.com Web: www.nordsonedi.com

SEPTEMBER 2013 • WWW.EPPM.COM • 11

MACHINERY SPOTLIGHT eppm

FILM & SHEET EXTRUSION

The Breyer OptiFlex line allows producers of PC, PMMA, and PET film to retain flexibility in their process, according to Breyer

itself.

The automotive market offers good opportunities for the application of inmould decoration technology, particularly for illuminated controls.

The systems cater for thickness ranges from 50-1000 µm.

The automotive market offers good opportunities for the application of inmould decoration technology. Breyer says that this market places high demands on the optical quality of the film used. It suggests that some

extrusion systems and their integrated calender machines may run into problems when processing thicknesses of less than 500 microns.

The bending of the calender rolls and thus the thickness tolerances do not allow for a thinner production in closed roll gap mode.

When pressing the film between the calender rolls too much, tensions can be stored inside the film which can result in shrinkage.

Flat applications naturally require an especially flat film. On the Breyer calender with its third calender roll, the position of the third roll in relation to the center roll can be adjusted exactly to where top and lower side cooling is balanced and the film becomes flat.

The Breyer gap control system includes an automatic film thickness setting. The operation mode allows a precise and automatic adjustment of

the gap, simply by changing the extrusion speed (pressure control mode). The operator changes the speed value on the touch screen in accordance with the new product thickness, and within a matter of seconds the product is set to the desired thickness.

With an FSR system (flexible shell roll) low pressure can be applied to the film. Thanks to a quick-exchange device on the first and center calender roll, the machine can be quickly adapted for different types of film.

In combination with the Breyer

DavisStandard, a specialist in converting and extrusion systems, will demonstrate its recentlylaunched dsX technology at K 2013. The range includes the dsX flex-pack extrusion coating line.

The group will also unveil the new dsX stretch line for cast film. Davis-Standard is offering a scheduled shuttle service to the company’s Erkrath facility where the new dsX flex-pack extrusion coating

line and dsX stretch cast film line will also be on display.

The new dsX flex-pack extrusion coating line (patent pending) is claimed to be a “pre-engineered system” which can reportedly be delivered in as little as six months and is available in two layouts to accommodate plant space requirements. The dsX flex-pack has been designed with new and developing applications in mind, including: salted snack and noodle bags, toothpaste tubes, sachet packs, personal care products, condiment packs and stand-up pouches. The computer technology which ships as standard on the dsX flex-pack

continually adjusts the product profile and allows for remote access of the line for troubleshooting and updating over a secure internet connection.

The group claims that the dsX stretch pre-stretch cast film extrusion line is “the first inline pre-stretch system enabling customers to run thinner films at higher speeds.” The dsX stretch system is two meters wide and has both five and seven-layer options. The

the winding quality of very thin films (down to 6 µm).

The group’s Polycast lines for CPP film, have been fine tuned thanks to a new turret winder up to 1200 mm in diameter.

The Bubble Guard Board line allows processors to incorporate in-line lamination of several materials for a diversification of applications. The line can produce alveolar sheets from 250g/m2 up to 4000g/m2.

Thanks to continuous R&D work, Colines has recently obtained new results in all sectors of hygienic film technology, from breathable to embossed, with cast as well as blown film extrusion. The Diaperblown line, for example, is reported to be the first 5layer blown line in the world with in-line embossing able to produce over 500 kg/h of film with “extraordinary mechanical properties”, claims the group.

This application has enabled an Italian film extruder to improve its position in the competitive market of hygienic

film, which is rapidly expanding, especially in developing countries.

Finally, combining 40 years of experience in air bubble technology, having introduced the lines with high output (over 3000 mm of web width), PP air bubble and 10-layer technology

OPTICAL FILM RUNS MADE MORE ADJUSTABLE

NEW CAST STRETCH LINE TO BE RELEASED AT K

FILM LINE SUPPLIER TO DISPLAY PRESENT AND FUTURE TECHNOLOGY AT K

Colines has released details of the film extrusion lines it will display at K 2013.

On show will be the new ALLrollEX line from Colines, which offers web widths ranging from 1000 mm-4500 mm. Particular emphasis during development was placed on

12 • WWW.EPPM.COM • SEPTEMBER 2013

calender system a film with extremely low retardation rates can be produced, which is essential for the optical characteristics of the film.

For applications in the optical field, calendered film at this thickness can act as an alternative to cast film, with Breyer claiming improved tolerances, high gloss on both sides and improved aesthetics.

Breyer GmbH Web: www.breyer-extr.com

line will be offered with coreless technology in the future, reducing material consumption.

Davis-Standard Web: www.davis-standard.com

with PA, Colines is now manufacturing a 14-layer (7+7) coextrusion line for the production of a barrier air-bubble film with very high resistance.

Colines Web: www.colines.it

MACHINERY SPOTLIGHT eppm

FILM & SHEET EXTRUSION

At K 2013 Windmöller & Hölscher (W&H) will not only display extrusion equipment, but also its entire range of machinery for the production and converting of flexible packaging at the show in Düsseldorf and at its simultaneous EXPO at the company's headquarters in Lengerich, just an hour and a half by car from Düsseldorf. The main attraction will be the unveiling of a new extrusion line, currently referred to by the code name “E-24”.

E-24 is the project name for the new film extrusion concept that will be introduced, along with its real name, on the floor of the show. E-24 runs at high speeds without sacrificing quality, claims the group. Downtimes are said to be brief and changeovers quick, and energy efficiency has also been incorporated in the design.

Also on show will be the Optimex 3layer blown film line, which is equipped with high performance modules, new automation technology and optimal melt paths to allow high output for profitable production.

BLOWN FILM COEXTRUSION DIE REDESIGNED FOR VERSATILITY

BRAND NEW FILM EXTRUSION LINE TO LAUNCH AT K

The Filmex cast film line will be producing stretch films for pallet load stability. These films are characterised by a strong holding force, as well as high puncture and tear resistance.

The line is rounded off with the new Filmatic PS stretch film winder, which is suitable for hard-to-wind films.

An additional highlight is the Aquarex blown film line with water quench cooling, which blows film downward.

The Aquarex will be running an asymmetrical barrier film. All machine components are completely integrated and production is automated. Films produced on the Aquarex are suitable for thermoforming and pouch applications.

Additional lines, including blown and

cast film, all flexo and gravure printing presses and the complete spectrum of W&H equipment from basic to the high-tech will be ready for demonstration. A shuttle bus between Düsseldorf and Lengerich is available.

W&H subsidiary, BSW (Bag Solutions Worldwide) will run demonstrations on the advanTex 2250 circular loom at its booth in Hall 17 of the K. An EXPO will also take place at the BSW plant in Prostejov, Czech Republic, where it will be showing its entire portfolio of machinery for the production and converting of PP woven fabrics for the flexible packaging industry.

Windmöller & Hölscher Web: www.wuh-lengerich.de

Plastic film and sheet extrusion systems supplier Macro Engineering & Technology Inc. has redesigned its CenterPack coextrusion die for blown film systems to improve processing versatility and minimise residence time.

The redesign has improved the die’s layer ratio range by more than 25% (from 3:1 to 4:1) while reducing residence and purging time by 40-50%, claims Macro. The upgrades reportedly mean that the die is now capable of processing both blown and cast film grade resins without any interlayer clarity issues.

Available to process film structures up to nine layers and in die diameters up to 2m, the die is suitable for processing Nylon 6, EVOH, PP, PETG, plastomers, LLDP for laminating and thermoforming applications. It features a stackable design using a center-fed system for minimum residence time.

Macro Engineering & Technology Inc. Web: www.macroeng.com

SEPTEMBER 2013 • WWW.EPPM.COM • 13

MATERIALS

Chinese PEEK hits Europe through new network European distributor Dreyplas has taken over responsibility for sales into the European market of PEEK (polyether ether ketone) from Chinese group Jilin Zhong Yan High Performance Plastic Co.Ltd. (Zhong Yan). The latest additions to the Dreyplas portfolio stem from a production line operated by the Chinese raw material manufacturer with a capacity of 1,000 metric tons a year.

The range covers PEEK powder and granules with high, medium and low viscosity as well as glass and carbon fibre-reinforced PEEK materials in standard grades for direct processing and compounding. The material from Zhong Yan is said to be noted for its relatively light inherent colour and consistently high quality. On completion

of the current start-up phase in Europe, Dreyplas will be able to supply its customers quickly and flexibly from the company’s European central warehouse.

The new PEEK grades supplement the distributor's present portfolio, which consists predominantly of raw materials from Asian suppliers for compounding.

They include additives to improve the tribological properties such as special PTFE micro powders as well as application-specific carbon fibre sizes, flame retardants and high-performance plastics such as LCP. The Zhong Yan PEEK materials are reported to have high temperature resistance and offer similar corrosion resistance to nickel-steel. Without flame retardants, they can achieve very high

flame retardance ratings with good selfextinguishing properties. Because of their high purity, outgassing is low, minimising the impact on the environment. Their dielectric properties are said to remain largely constant over a wide frequency and temperature range. Thanks to their high hydrolysis resistance, the mechanical properties are retained even after long-term exposure to moisture under high pressures and temperatures. Typical fields of application include components used in the aerospace industry as a substitute for aluminium and other metals, automotive parts for the engine compartment, insulating components in the electrical and electronics segment, and corrosion-resistant parts for

chemical apparatus and systems in the food industry.

Dreyplas Tel: +49 2159 815 310 Email: info@dreyplas.com Web: www.dreyplas.com

French group launches thermoforming PP grade French materials supplier Polychim has launched a new homopolymer polypropylene for packaging applications.

The new product is said to offer high quality and faster thoroughput to converters.

Polychim’s homopolymer PP grade HA31XTF attempts to overcome the performance trade-offs associated with conventional nucleated PP homopolymers in thermoforming applications.

The grade uses Milliken’s Hyperform HPN-600ei, which stimulates an improvement in the aesthetics of final parts, achieving superior transparency and reduced yellowing for thermoformed

goods compared to traditional nucleated homopolymers.

As a result, Polychim claims HA31XTF outperforms its previous conventional nucleated homopolymer for thermoforming through better haze and less yellowing.

The Hyperform HPN-600ei nucleator also claims to provide the possibility for thermoformers to improve productivity by up to 10% and reduce costs.

The grade is aimed at clear PP and opaque thermoformed applications such as food packaging.

“Through listening to our customers it became clear that there was a definite gap in the PP homopolymer market for a

solution offering both better production cycle times and enhanced end-product quality,” said Bo Oxfeldt, Vice President at Beaulieu International Group and responsible for the European and North American PP business.

“As a result of Polychim’s close collaboration with Milliken, we have been able to address this balance and develop an improved homopolymer PP that offers the upgrade in performance the market has been looking for.”

needed to find a supplier that could provide us with type of consistency and reliability we require. PolyOne delivered on both counts.”

PolyOne GLS Thermoplastic Elastomers Tel: + 49 7225 6802 216 Web: www.glstpes.com

Milliken Tel: +32 9 265 1100 Email: eurochem@milliken.com Web: www.millikenchemical.com

Application: “OXO Tot” toddler feeding dishes PolyOne GLS Thermoplastic Elastomers has collaborated with kitchenware manufacturer OXO to develop the OXO Tot line – a set of durable, feeding dishes that allow toddlers to feed themselves. The new line was designed to “help OXO further differentiate its brand in the competitive kitchenware market” according to PolyOne GLS. OXO chose PolyOne GLS Dynaflex TPE for several components in the new offering. “In a collaborative effort with OXO, PolyOne custom formulated a Dynaflex TPE to meet the specific demands of this application,” said Charles Page, Global Marketing Director, PolyOne GLS Thermoplastic Elastomers. “Our TPE formulation expertise enabled us to provide OXO with a tough, durable, attractive, foodsafe solution that would stand up to the kind of abuse only a toddler can dish out.”

The OXO Tot feeding line, which OXO markets as free of BPA and phthalates, has received numerous accolades for its 14 • WWW.EPPM.COM • SEPTEMBER 2013

design, including a 2012 Bronze IDEA (International Design Excellence Award) in the Kitchen category. The custom Dynaflex TPE was used on several components of OXO’s new Tot dishes, including a removable lid that is used to store leftovers, a grippy non-slip base and a separable plate, ring and lid to allow for easy dishwasher cleaning.

In addition to offering a translucent base material that eases colour matching for OXO’s vibrant colour scheme, the material meets both U.S. FDA177.1210 and EU10/2011 standards for food-safe applications. The material’s high tensile strength – 7.6MPa – reportedly exceeds OXO’s bite/tear criteria for infant care applications.

“At OXO, quality and safety are of the utmost importance. All materials are of the highest quality and all products are thoroughly tested to uphold and surpass the strictest safety standards,” said Alex Lee, President of OXO. “In addition to finding a food-safe, easily colorable TPE for this application, we

MATERIALS ROUNDUP Application: two-component pump dispensers

Semi-finished grades given medical device approval

Goldwell supplies hair care products and hair colourations as well as service to hairdressers. The group’s latest packaging makes use of Kraiburg’s Thermolast K compounds, in a pump dispenser, which has been designed to ensure that hairdressers are able to apply hair dyes evenly by means of pressure on the membranes of the pump. “Due to the chemical composition of the hair colourations as well as the high mechanical stress during the application, we needed a material for the membrane inside the application system, which is of such a high quality that it is able to withstand these high demands. At the same time, the materials have to meet European regulations concerning food contact, which also apply to our hair care products”, said Sebastian Kraus, Manager Packaging Development at the company Kao Germany, which is owner of the Goldwell brand. The TPE used in Thermolast K is free of PAHs, phthalates and allergens, and is RoHS- and REACH-compliant.

The pump dispensers are produced in a 2-component injection moulding process. Kraiburg claims that compared to assembling the part after processing, this saves valuable time as well as production costs.

“We have already collaborated successfully with Kraiburg TPE in previous projects several times. That is why it did not take us long to choose the Thermolast K product series as a suitable TPE for our application system”, said Sebastian Kraus from Kao Germany. Together with Kao and the mould maker, Kraiburg TPE adjusted the production process to the injection moulding unit in order to achieve a good adhesion to the hard component PP. In German-speaking regions, Goldwell is

Following the introduction of a quality management system for medical products in accordance with EN ISO 13485:2012 for medical devices, German group Röchling Sustaplast KG has been certified by TÜV Rheinland, the German technical inspection agent.

The company from the Rhine-Lahn region manufactures semifinished plastic products that are used in devices for medical technology, among other applications. They are employed in surgery, dental technology, diagnostic radiology and treatment systems. For the manufacture of these products Röchling Sustaplast has introduced a quality management system compliant with EN ISO 13485:2012, tailored its operational processes to meet the requirements of the standard and obtained the appropriate certification from TÜV Rheinland.

For operational processes, the certification lays down standards that are intended to ensure that products are suitable for use in the industry. In implementing it, Röchling Sustaplast confirms the physiological safety of the semi-finished products and traceability back to the raw material batch. “We meet

a well-known brand in hair care and coloration products exclusively for hairdressing professionals. Founded in 1948, the company is part of the Salon Business sector of the Kao Corporation, Tokyo, which offers skin and hair care products on the global market. At the headquarters in Darmstadt, there is a research and development center, the production with the most modern high performance machines as well as a logistics center. Goldwell globally operates more than 40 communication centers for the training and further training of hairdressers.

the high standards expected of the manufacture of medical products. The focus is on patient safety. All our processes are geared to that”, said Eugen Schmidt, who heads up the Medical Technology unit. The certificate is valid for five years. TÜV-Rheinland verifies compliance with the specifications for the QM system in annual audits.

The group offers a range of materials for the medical sector through the product ranges of Röchling Sustaplast KG and Röchling Engineering Plastics KG, Dallas (NC) USA, and the injection moulding products of Röchling Oertl Kunststofftechnik, Brensbach, and Röchling Advent Tool & Mold, Rochester (NY) USA. Ludger Bartels, COO of the Röchling Group, Mannheim said: “By establishing a quality management system in accordance with EN ISO 13485 we have taken a significant step forward on the way to strengthening our position as the leading supplier of plastic products for medical technoloogy. We will continue down this path consistently.”

Röchling Engineering Plastics KG Tel: +49 5934 7010 Email: info@roechling-plastics.com Web: www.roechling.com

Kraiburg TPE GmbH & Co. KG Tel: +49 8638 98100 Email: info@kraiburg-tpe.com Web: www.kraiburg-tpe.com

EP grades take the heat Polyscope, a producer of styrene maleic anhydride (SMA) copolymers, has added a third group to its product portfolio by manufacturing terpolymers consisting of styrene, maleic anhydride and Nphenylmaleimide. These new products are commercialised and branded as XIRAN IZ grades.

Two new grades, XIRAN IZ1018M and XIRAN IZ0721M are designed to increase the high heat performance of many engineering plastics. They were reportedly developed in response to the increasing trend towards styrenic engineering plastics with high temperature resistance and low volatile residuals. The new XIRAN IZ grades have been designed to be exposed to higher processing temperatures while retaining miscibility in styrenic polymers like ABS. XIRAN IZ1018M and XIRAN IZ0721M have a different ratio of styrene, maleic anhydride and N-phenylmaleimide.

In order to produce these products Polyscope says it has upgraded its continuous polymerization process in Geleen, The Netherlands. This has

enabled the group to engineer a terpolymer with high thermal stability and adhesion properties brought about by the presence of the maleic anhydride groups, resulting in a balance between thermal improvement, mechanical properties and cost performance.

Compared to similar materials in the market, the XIRAN IZ grades are claimed to deliver a high degree of efficiency, both by increasing engineering plastics high heat performance and by having very low volatile residual levels. This is especially relevant for styrenics like ABS. Polyscope Tel: +31 683 638 041 Email: ptackx@polyscope.eu Web: www.polyscope.eu SEPTEMBER 2013 • WWW.EPPM.COM • 15

MATERIALS ROUNDUP WRC rally car uses composite panels A European Rallycross Championship car made by Citroën is using Carbon-Kevlar composite body panels.

The Citroën DS3 is driven by former World Champion Petter Solberg and features 11 composite parts designed and manufactured by Galway Carbon.

Each panel was vacuum infused using Scott Bader’s Crestapol 1250LV urethane acrylate type acrylic resin reinforced with carbon fibre and Kevlar fabrics. The bonnet also has a foam core in an attempt to save weight.

Parts originally made from steel such as the nearside door, bonnet and boot were instead made from the composite components, which is said to reduce the

parts’ weight by between 82 and 89 percent.

Overall, Galway Carbon says the car’s original weight has been reduced by over 56kg.

Sean Hession of Galway Carbon said: “There are several reasons why we chose Crestapol 1250LV. The resin’s mechanical performance is exceptional, combining the strength and durability needed to reliably cope with harsh rally car racing conditions.

From the processing side, it is extremely good for vacuum infusion, with very rapid cycle times at room temperature, which is way ahead of any comparative epoxies, and the surface finish is excellent.”

Scott Bader Tel: +44 1933 663100 Email: enquiries@scottbader.com Web: www.scottbader.com

Packaging colours to fall from the cloud An agreement has been struck between a major consumer brand owner and a colour science and technology company.

Procter & Gamble, owner of brands including Gillette, Tide and Pampers has implemented PantoneLIVE from X-Rite and Pantone, a cloud-based colour service with the aim of improving operational efficiency in packaging execution.

According to Pantone, colour is critically tied to brand equity and therefore maintaining colour consistency on product packaging is essential for brand recognition.

“PantoneLIVE is an efficient, effective and seamless technology that saves time and money, and helps ensure design intent makes it to shelf, whether we are creating a new Charmin package design, proofing an Olay label, mixing ink for Tide packaging or assessing the quality of Gillette packaging on press,” said Phil Duncan, global design officer at P&G. “PantoneLIVE is an excellent solution for simplifying how we access digital colour palettes for design, proofing and print. When fully implemented, the productivity benefits will be significant – both internally for P&G and for our suppliers.”

To facilitate colour standardisation across all materials in the production process, P&G now has the ability to upload proprietary colour palettes onto PantoneLIVE’s secure, cloudbased portal, which suppliers can instantly access from around the world. This centralised colour communication process aims to minimise colour revisions and reduce approval times, creating go-to-market efficiencies and, ultimately, lower development costs.

“With supply chains located around the world, it is extremely difficult for large corporations to maintain universal colour consistency,” explained Dr. Sonia Megert, vice president of the Pantone Digital Business unit at X-Rite/Pantone.

“ThePantoneLIVE system is ideal for an innovative, global corporation like P&G because it provides a centralised online repository for managing, controlling and accessing official brand colour criteria.”

Pantone Web: www.pantone.com

16 • WWW.EPPM.COM • SEPTEMBER 2013

MATERIALS

SHOWCASE SPECIALISED ADDITIVES New flame retardant launched FRX Polymers, Inc. has developed an inherently flame retardant polymer, a polyphosphonate, which has phosphorus in the backbone of the polymer. The material, called Nofia, are polycondensation polymers that are made by the reaction between a phosphonate containing monomer and dihydroxy compounds. A broad range of dihydroxy compounds can be used, making it possible to modify the properties of the polymers.

The Nofia polyphosphonate family includes homopolymers, copolymers and oligomers that can be used in a broad range of thermoplastic and thermoset resins. Nofia materials are non-migrating flame retardants. This is an advantage over traditional small molecule flame retardant additives that can migrate out of the host polymer.

Upon migrating, small molecule FR additives can also lose their efficacy.

The homopolymer and the copolymers can be used as blending compounds.

Nofia homopolymers and copolymers have high melt flow and high melt strength. When added or blended in the host polymer they often help with processability, retention of properties

and improved surface appearance.

In some applications, e.g. film, sheet and thin wall section injection mouldings, the copolymers can also be used as a standalone material. The copolymer is transparent and has a UL 94 rating of V-0 down to 0.2mm.

The oligomers, which vary in molecular weight and functionality, can be added to thermoplastic resins or be used as reactive intermediates in thermoset applications.

Nofia polymers have reportedly been successful in a number of resins and application areas. The thermoplastic resins include: PBT, PET, PTT, PETG, PLA, PC, PC blends, TPU and other engineering thermoplastic elastomers.

The oligomers show good compatibility with UPET, phenolic, epoxy and PU resins.

The applications and markets where Nofia can be used include: • Fibre applications for commercial textiles • Monofilaments for industrial and transportation applications • Biocompounds and engineering compounds for consumer electronics and other durable applications • Film and sheet for thermoforming applications in mass transportation and building and construction • Films for electronics packaging applications • Profiles for Building and Construction applications • Laminates for Electronics applications

• Prepregs and laminates for use in a wide range of applications in transportation, construction and aviation.

• In some polymers systems, e.g.

TPU, Nofia can achieve Class A in ASTM E-84 while maintaining transparency. Nofia polymers also show good heat release performance.

FRX Polymers is currently building a production scale plant in Antwerp, Belgium which will come on stream in the fourth quarter of 2013. FRX Polymers has a large pilot plant in Switzerland from which material is currently supplied to a variety of commercial applications. The headquarters and R&D are in Chelmsford, Massachusetts, USA. FRX Polymers will be exhibiting at the K show in Hall 5, Stand C06-1.

Nofia and FRX Polymers are registered trademarks of FRX Polymers, Inc. FRX Polymers, Inc. Tel: +1 978 244 9500 Email: info@frxpolymers.com Web: www.frxpolymers.com

Chemical group to bring specific new flame retardants to K Chemtura Corporation will present new additives within its line of flame retardants and organometallic specialties for plastics at K 2013 in Düsseldorf, Germany.

Great Lakes Solutions, a Chemtura business and specialist in flame retardant products and solutions will present its new polymeric flame retardant products: Emerald Innovation 1000 and Emerald Innovation 3000.

The Emerald Innovation series are said to have been designed to minimise the impact on the environment and human health.

Emerald Innovation 1000 flame retardant is said to have potential as a replacement for decabromodiphenyl oxide and decabromodiphenyl ethane, and is used in a variety of applications such as consumer electronics, automotive, textile back coating and

construction materials. It is designed to replace commonly used flame retardants in polyolefin and styrenic resin systems. Chemtura states that minimal adjustments are needed when replacing existing products in flame-retardant applications. It reportedly maintains comparable fire safety performance at similar load levels to other high-efficiency brominated flame retardants.

Emerald Innovation 3000 flame retardant offers producers of expanded polystyrene and extruded polystyrene (EPS & XPS) a replacement for hexabromocyclododecane (HBCD).

In addition to the flame retardants, Chemtura’s Organometallic Specialties business will discuss its

co-catalyst and activator systems. The group will launch its new AXION MAO activator technology at K 2013. AXION MAO is intended for use in the catalyst systems of advanced elastomer production. Customers will reportedly be able to work with Chemtura to tailor the activator for their specific catalysis needs.

Chemtura Web: www.chemtura.com

SEPTEMBER 2013 • WWW.EPPM.COM • 17

MATERIALS

SHOWCASE SPECIALISED ADDITIVES PP clarifying agent offers savings all-round Milliken’s Millad NX 8000 clarifying agent for polypropylene (PP) can save material, save energy, save time and save money, all while achieving high quality end products, claims the group.

This additive was developed to meet the requirements of plastics processors, offering optical and physical properties balanced with productivity increases and energy efficiency for injection moulded, blow moulded and extruded polyolefin-based applications. It advances low temperature processing and sets new benchmarks in the aesthetics and performance of PP, contributes to new opportunities for inter-material replacement, enable lighter weight parts, and promotes more sustainable end-applications.

The rapid conversion of 70% of the clarified PP market to Millad NX 8000, considered to be the clarifier of choice for new transparent PP applications, indicates the high value placed on its ability to deliver productivity improvements of up to 18%, energy

18 • WWW.EPPM.COM • SEPTEMBER 2013

savings of up to 13% and 10% reductions in carbon dioxide emissions, in addition to giving a fresher, cleaner look to PP-based applications claims Milliken.

The clarifying agent makes it possible for PP parts to be made with optical properties until now only associated with more glass-like polymers such as polycarbonate, polystyrene, and acrylics. With its lower density, PP provides a solution that is less costly and with a lower carbon footprint — in short, more sustainable. Polystyrene is already being replaced by PP containing Millad NX 8000 for thermoformed food containers and cups for cold drinks, while some coffee blenders are now using new PP grades instead of polycarbonate.

Supporting the general trend towards higher-flow and faster-processing grades of PP, the solubility of Millad NX 8000 in PP is far better than previous generations of clarifying agents. This is especially important in the production of housewares and thin

walled products, where processors are constantly searching for productivity improvements.

Milliken has been focusing on helping converters to process polypropylenes clarified with Millad NX 8000 at lower temperatures to improve productivity and save energy. Milliken has also

been working closely with brand owners to achieve their sustainability targets by replacing materials like polystyrene as well as PET and PC, and it has also been working with resin producers on new developments in high MFR PP injection moulding grades.

Milliken Web: www.millikenchemical.com

APPLICATION FOCUS FOOD CONTACT

EFSA opens ‘BPA in food-contact assessment’ to public consultation

Food grade mould release suitable for silicone rubber applications Axel Plastics Research Laboratories has announced a new, water-based, semipermanent mould release that is especially suitable for moulding silicone rubber products that will come in contact with food. The use of silicone rubber for consumer goods has increased steadily in recent years as consumers have responded favorably to the soft touch of rubber in many products. Capitalising on silicone’s flexibility and heat resistance and the rubber’s ability to be easily and dramatically colored, silicone rubber products are now enjoying exponential growth in products designed for the kitchen and table. With this increase in silicone products designed for use in contact with food, has come an increased interest and scrutiny of the materials used to release these moulded silicone parts. While food grade mould releases exist, many of the conventional mould releases do not provide the easy

and clean release that high production injection moulding and overmoulding of silicone on plastic require.

XTEND W-3236FG directly addresses these requirements, claims the group, with a nonhazardous, aqueous solution of proprietary resins and reactive surface modifiers that meet the E.U. Food Directive (10/2011) and comply with food contact plastics under U.S. F.D.A. 21CFR 176.170/21 and CFR 176.180. The mould release film created by XTEND W3236FG is long lasting and resistant to transfer, making it suitable for high production, injection, transfer or overmoulding. Parts moulded with XTEND

W-3236FG will be clean and blemish free and ready for any secondary processes without cleaning.

Axel Plastics Research Laboratories (AXEL) Web: www.axelplastics.com

Food contact polyolefins updated for 2016 deadline

EFSA (the European Food Safety Authority) will launch a public consultation from July through to midSeptember on an updated and extended assessment of exposure in Europe to bisphenol A (BPA) in food contact materials. The Authority’s last exposure assessment of BPA was in 2006 and this new assessment marks a major update, encompassing both dietary and non-dietary sources (including paper, inhalation and dust).

While EFSA’s experts have made significant progress in assessing the potential human health risks of BPA, the body says that more time is needed to evaluate key health effects identified in animal studies and their possible relevance for human health.

All stakeholders and interested parties will be able to provide their comments on the draft exposure assessment through an online public consultation from mid-July to mid-September 2013.

In a second stage in early 2014, EFSA will publicly consult on the human health aspects of its risk assessment prior to finalising its scientific opinion.

In the interests of openness and transparency, EFSA says it will continue to provide regular updates on the progress of its work.

EFSA Web: www.efsa.europa.eu

Companies in the food packaging chain using polyolefins (polyethylenes and polypropylenes) can now access SABIC’s new food safety and compliance declarations. SABIC has now got all of its food contact declarations updated in line with changes to European Union regulations, ahead of the 2016 deadline.

SABIC has been required to retest all its polyolefins packaging materials to make sure they are compliant with the new testing conditions. The declarations are available on the European pages of www.sabic.com.

The new regulations involve more stringent testing on the ways migration from packaging into food is tested. As these new regulations come into force over the next three years, plastics processors and packaging companies will need to seek further assurances on compliance from their materials suppliers.

EU Plastics Regulation (EU) 10/2011 (PIM) came into force on May 1, 2011, and introduces several changes to regulations embodied in Council

Directive 82/711/EC, particularly with reference to testing conditions for migration of individual chemicals and in what can be used in the tests to simulate actual foods. There are changes to the duration of some tests, to the temperatures at which some tests are carried out, and to the simulants for aqueous and alcoholic products inside the packaging. However, the new regulation will not become compulsory until January 1, 2016. In the meantime, it sits alongside existing food contact legislation.

For PE and PP, SABIC has assessed all substances regulated with a Specific Migration Limit (SML) under the new conditions (10 days at 60˚C). Its tests reportedly showed that none of its PE or PP materials will be subject to additional restrictions for use in food contact applications.

“This is a clear demonstration of the company’s commitment to the packaging market, which accounts for close to a third of all its polymer sales in Europe. SABIC carries out regular compliance tests,” said Mark Vester, Business Director for LL/LDPE at SABIC. “By doing this, we are meeting our obligations to our customers under Responsible Care,” said Vester.

SABIC has used its Product Stewardship team to conduct the assessment, with analytical facilities for compliance testing.

“SABIC considers the provision of product safety and compliance information as an important customer service,” said Jos Hennen, Senior Global Product Steward food contact and healthcare for polyolefins at SABIC. “We support customers to ensure that our plastics are used in a safe way all along the value chain,” Hennen said.

Food contact legislation in Europe is based on the principle that all substances are forbidden unless they are explicitly allowed. As far as migration from the package to the contents is concerned, there are strict limits on specific migration (SML, relating to individual chemicals) and overall migration (OML, the sum of all specific migrations).

While there is no formal obligation for them to execute migration tests, all manufacturers of plastics raw materials have to provide a Document of Conformity (DoC) to their direct customer, providing confirmation that the material meets the relevant legal requirements. Additionally, they have to disclose the identity of monomers and additives, regulated with an SML and/or QM restriction, as well as the identity of “dual-use” additives, and they have to provide information on restrictions of use if relevant.

SABIC Europe Web: www.sabic-europe.com SEPTEMBER 2013 • WWW.EPPM.COM • 19

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

esse Düsseldorf has announced a special exhibit will form part of the K 2013 trade show, named ‘Plastics Move the World’. Specially selected product innovations will be presented in Hall 6 which illustrate the many improvements already attributed to plastic products today and their potential contribution to future challenges, for example, by protecting global resources in the future.

The exhibit will look at the direct contribution of plastic to different areas of mobility, but also aesthetic aspects, i.e. its effect on art and design, as well

M

as its potential for solving future problems such as demographic growth, increasing energy consumption and climate change.

Plastic in personal mobility (in the form of cars, trains, public transport and aircraft) will be one aspect of the exhibit.

The trade show organiser says that polymer materials also move people in sporting terms, and can also be ‘moving’ when used in the arts. In both categories the show will offer surprising examples of the potential of plastic.

Examples will feature from competitive sports, sports for the disabled and leisure sports as well as applications in theatres and museums as well as architecture.

Also on display will be innovations in energy-efficient living as well as future medical applications, water treatment and the food supply for a growing global population. This area aims to look at ways in which polymers can act as

Images copyright Messe Düsseldorf.

“Plastics Move the World” exhibit announced for K 2013

‘troubleshooters’ in high-tech applications.

In addition to presentations, the special show will also feature lectures as well as regular discussion panels with experts from science and the industry. On the second day of the trade show, the first VIP, Bertrand Piccard, a pioneer in the are of solar-powered aircraft, will discuss his project. His Solar Impulse craft is currently on its longest mission, crossing the USA from San Francisco to New York using only solar energy. In 2015, he plans

to complete a non-stop flight around the globe with a solar-powered aircraft.

The daily discussion panel will also deal with issues such as marine debris, which threatens oceans and coasts. The sessions will be conducted alternately in German and in English. The traditional “Youth Day” will take place on Sunday, 20th October. This event will feature several panel discussions between young adults and high-ranking scientists and representatives of the plastics industry.

hydraulic Allrounder 820 S with servohydraulic drive, operating with a mould from Georg Kaufmann Formenbau AG. Through the overmoulding of continuous-fibre reinforced thermoplastic inserts (organic sheets), high-strength, resilient composite parts are created, which weigh less than 300 grams at a length exceeding 500 mm. The continuous fibres – generally glass, carbon and aramide in woven and nonwoven forms – determine mechanical properties such as strength and rigidity.

The matrix material is responsible for the force transfer between the fibres in the composite, and protect the reinforcing structure from buckling and environmental influences.

In this application, a six-axis robot will pick up the organic sheets from a magazine. These will be heated and transferred to the LIPA (lightweight integrated process application) mould at the forming temperature. Here, forming

of the insert and injection moulding of the functional and reinforcement elements such as edging, end eyes and ribbed structures will take place simultaneously in a cycle time of around 40 seconds.

Also on display will be a fully-electric cube-mould application for the production of juice container closures, which will be presented with Foboha. On the electric two-component Allrounder 720 A with a clamping force of 3,200 kN, the large size 800 injection unit will be arranged horizontally. The small size 400 injection unit is arranged horizontally and on the moving mounting platen of the machine. In this application, fully electric means that both rotation of the cube and the linear sliding motion of the 12+12-cavity mould are driven electrically.

Arburg returns with lightweighting technologies and more Arburg will display more than ten exhibits on its stand in Hall 13, Stand A13 at K this year. The electric Allrounder 820 A, which completes the high-end electric Alldrive series will make its world premiere in Düsseldorf.

Both the 4,000 kN toggle-type clamping unit and the size 2100 electric injection unit have been developed for this machine. Arburg says that with these developments, the gap between 3,200 and 5,000 kN in the electric clamping unit range has been closed. The same applies to the hybrid Hidrive range, for which this new toggle size will also be available in future. With the new clamping force and injection unit sizes for electric machines, there is now greater modularity in the range.

In automation, Arburg will team up with fpt Robotik to display an Agilus six axis robotic system from Kuka with integrated Selogica user interface. The system is suspended from a linear axis arranged

20 • WWW.EPPM.COM • SEPTEMBER 2013

transversely to the machine. The combination of a six-axis robotic system with a linear axis is said to permit more dynamic movements and faster entry into the mould. The small robotic system can move on its axis and the floorspace below can be used without restriction. It is designed for load weights between 6 and 10 kg.

The automation display will be in operation on a two-component Allrounder 470 S, which will be demonstrating particle-foam composite injection moulding (PCIM). A plastic wheel rim will be injected onto a particlefoam tyre. Transfer of the pre-moulded part to the mould will be followed by overmoulding of the tyre with TPE. The six-axis robotic system will be used for all handling tasks, from insertion of the foamed tyre through to transfer of the finished parts to the packaging system, which includes printing of the bags during the process.

The group will also be presenting longfibre direct injection moulding. Glass fibres at 50 mm in length can be added directly to the liquid melt, where they are homogeneously distributed. The fibre length, fibre content and material combination can all be adjusted.

The process will be demonstrated on an ‘energy-optimised’

Arburg Web: www.arburg.com

K 2013: THE PREVIEW

EXECUTIVE Q&A: ENGEL To gain an exclusive insight into Engel’s K Show exhibit, EPPM interviews Gerd Liebig, Group Marketing Director, Engel Austria GmbH. Engel posted a record turnover for the last financial year. With K Show falling in the middle of the next one, do you predict that this upward trend will continue? Is it reflective of a boost in demand in the injection moulding sector?

As anticipated, the extremely favourable business climate for the automobile industry has weakened. We assume that it will stay at a slightly lower level in the next few months, and that - in line with this - the demand for injection moulding machines will drop below last year's level. Additionally, the development in the emerging markets, such as Russia or Turkey, will be slightly below expectations in the next few months.

All told, the market volume for injection moulding machines shrank by 10 % in 2012. The sole reason for this is the declining demand for low-tech machines in China. At the same time, though, the global demand for automated and industry-specific system solutions is increasing, and in China, too, the demand for European hi-tech continues uninterrupted. Despite the drop in total market volume worldwide, we were able to increase both our turnover and our market share in China in the last fiscal year. The trend towards integrated and automated system solutions has a pronounced influence on the average price for injection moulding machines and ultimately on the clamping force. At the same time, the demand for larger machines is increasing, with larger and larger moulds and with more cavities being used.

You have had good news and success stories in the Central and Eastern Europe regions recently. Why are we seeing such positive signs here?

Pressure to be efficient is at its greatest in central Europe. In line with this, these markets are the drivers for the development of efficient process technologies and automation solutions.

Companies in Germany, but also in Austria and in Switzerland, have the highest process integration and automation level in the world and are role models for many other regions.

Also you’ve released e-calc - an app for machine setting and parameter calculations. Are there plans to develop more apps? Should moulders be looking to give remote access to the workforce 24/7? And what does this mean for productivity?

We are just at the start of our use of the internet and mobile devices in injection moulding. The potential is enormous. e-calc is one of the first apps developed for the plastics industry, and we will now use our experience with e-calc to develop more apps for our customers.

Of course, what we're thinking here is the service and maintenance areas where we already offer efficient remote

features, for example in the form of our Engel e-service.24 service package. The biggest advantage of the smartphone is that everyone has one with them at all times. In other words, we can rely on an existing infrastructure to generate added value for our customers without any investment outlay.

Incidentally, the second Engel app will be available at the end of August. Our K app gives visitors to K 2013 an efficient approach to preparing their visit. On-site in Düsseldorf, the app guides visitors to the exhibits relevant to their requirements and industries.

You’re breaking down your display into your key markets by application.

Why is it important for Engel to exhibit this way?

Our aim is to be the world’s best at creating customer benefit. One important precondition for doing this is that we speak our customers’ language.

Only if we know and understand our customers’ requirements and industries very well, are we in a position to generate a competitive edge with our solutions. This is why our sales activities are organised in five Business Units, Automotive, Technical Moulding, Teletronics, Packaging and Medical, and this industry structure is also reflected in our trade fair booth. The fact that we are not just focusing on individual innovations, but on applications, is also driven by our customers’ requirements; our customers are not typically looking to buy machines, but solutions for concrete tasks.

The portion of system solutions is thus steadily increasing in our order books.

Our understanding of the system solution is a turnkey production system from a single source that is individually tailored to meet project requirements.

Only if all other system components, such as the injection moulding machine, automation, moulds and peripherals are perfectly in tune with each other from the outset can efficiency potentials be leveraged to the maximum.

The all-important question - what are the new machine and equipment launches at K? With a total of 25 machines on show – 12 of them at our own booth in Hall 15 – we are, at K 2013, reaching a greater innovation density than ever before at a trade fair. The new products we will be presenting are the Engel e-speed and the Engel e-motion 30 TL (figure 1) injection moulding machines.

Additionally, the Engel v-duo large-scale machine that was introduced last year and the Engel viper 120 linear robot (figure 2) are celebrating their trade fair premieres. Another highlight is our new generation CC 300 control unit (figure 3). We invite all visitors to the trade fair to try out the new control unit themselves on site and get to know it.

Figure 2.

Figure 3.

Figure 1.

What were the drivers behind each of these developments?

The new Engel e-speed 650 injection moulding machine brings together the best of both worlds: the new Engel high-speed machine, designed for use in sophisticated packaging applications, relies on the tried-and-tested technology of the company's all-electric, high-performance e-motion and e-cap series and also boasts the performance and robustness of the Engel speed series, meaning it unites outstanding injection speeds with maximum energy efficiency.

The all-electric Engel e-motion 30 TL combines maximum precision and energy efficiency with low machine weight and a compact design, thereby setting a new global standard in the manufacturing of precision optical parts and electronic components.

Specially designed for lightweight, automotive applications, we have expanded the dual-platen, Engel duo large-scale machine model range, adding a vertical variant, the Engel vduo. In many insert applications, vertical machines facilitate parts handling and fixing of semi-finished parts.

Additionally, the vertical version of the Engel duo large-scale machine is also characterised by its compact design, low height and weight, and excellent energy efficiency.

The largest model in our Engel viper linear robot generation, the Engel viper 120, is also mainly used in the automotive industry. A nominal load-

bearing capacity of 120kg makes this the largest linear robot in its competitive class; its demoulding stroke of 3000mm and range of 3550mm have opened up brand new dimensions in linear handling.

Last but not least, there is the new CC 300, which will make the use of injection moulding machines and integrated system solutions even more efficient, user-friendly and safe. "One button operation" becomes a reality with our new generation control unit.

How can visitors get the most out of their visit to Engel?

For the first time at K 2013, Engel is offering maximum service for efficient preparation of a trade fair visit in the run-up to the fair with our K microsite and app. Both online and off-line, trade fair visitors can discover exhaustive information and movies on exhibits, innovative applications, new products and technologies. For the visit to the fair, the microsite and app provide a clear-cut plan of the booth and all dates for machine demonstrations. But communication cannot take place without people. A total of 250 staff from all over the world will be travelling to Düsseldorf. Every visitor to the fair will find the right contact for their national market and their industry at K 2013.

See Engel in Hall 15, Stand C58.

Engel Web: www.engelglobal.com

SEPTEMBER 2013 • WWW.EPPM.COM • 21

K 2013: THE PREVIEW Extruder combination allows recycled profile production In response to the trend towards increasing use of recycled materials in profiles, battenfeld-cincinnati will demonstrate a newly designed extruder combination.

At K, the Construction Division of the group will showcase the conEX 63 P conical extruder mounted in a ‘piggyback’ configuration on a twinEX 78-34P. Both extruder models are equipped with energy-saving features as standard.

In some cases, the recycled materials used in window profiles make up more than 40% of the total weight and are used wherever they are not visible. battenfeld-cincinnati has now designed

the twinEX/conEX piggyback extruder combination precisely for these applications with a high proportion of regrind. The two counter-rotating twinscrew extruders combined achieve an output of about 500 kg/h. The parallel twinEX 78 can plasticize up to 290 kg/h, and the conical conEX 63 handling up to 220 kg/h.

Thanks to the coextruder’s frame design, this machine combination allows flexibility in die connection facilities, making die changes easier. The extruders share a common control cabinet for simplicity.

The die comes with a central plug, and can be connected quickly and easily,

eliminating operating errors such as incorrect wiring, claims the group.

Like all extruders from battenfeld-cincinnati, both use AC motors for increased efficiency. The Intracool screw core tempering system is also featured, boosting the energy-efficiency of the the setup. The extruders come with fully insulated barrels, reducing energy loss through heat radiation whislt boosting stability thanks to the constant temperature.

battenfeld-cincinnati Web: www.battenfeld-cincinnati.com

Moretto to display ‘selfadaptive’ control system

Moretto S.p.A. will attend the show with several new materials handling products.

One major development on display will be One Wire 6 (OW6) – a self adaptive control and management unit for conveying systems.

Moretto claims that it is not necessary to set time and other parameters on the new One Wire 6. A machine that collects the material to be processed at twenty meter distance can be connected to the stored material at one hundred meters distance, simply connecting the machine to the desired pipe, and no data or parameters need to be modified. One Wire 6 is designed to recognise the new conditions and adapt.

The OW6 server can store up to 80 clients among receivers, suction units and automatic manifolds. Wall-mounted, frame-mounted, and floor-mounted installations are all possible.

The group will also bring its Teko range of temperature controllers which are designed to control the mould temperature through water. The range is now larger with the addition of the new indirect change pressurised series. The new series has increased the working temperature but still uses water as a heat exchange medium.

In dosing technology, Moretto will display the DGM Gravix gravimetric series. The unit features a specific weighing algorithm which forms part of the Vibration Immunity System (VIS).

It features a colour interface with simple programming. The range is suitable for production from 30 to 12,000 kg/h with dosages of up to 12 materials. It allows more than 1000 hopper combinations.

Moretto S.p.A. Web: www.moretto.com SEPTEMBER 2013 • WWW.EPPM.COM • 23

ADVERTORIAL

Shaping the Products of Tomorrow… In Plastic With the plastic industry rapidly changing and technology evolving, it is essential for manufacturers to keep ahead of the competition. It is no longer down to just supplying quality products cost effectively and on time, but what other factors differentiate them from their competitors. Flambeau believes innovation, skills and knowledge are key to successful growth.

For over 65 years Flambeau has provided quality injection and blow moulding solutions for customers around the world in a variety of industries. The European headquarters is strategically located in Kent, UK, allowing ease in servicing the needs of the UK as well as Northern Europe.

Automated Large Tonnage Injection Moulding Flambeau has dedicated injection moulding facilities around the world, with over 160 machines ranging from 24 to 1700 ton clamp force. Accredited with TS 16949 and ISO 14001 approvals, Flambeau has attained high ratings against a number of its major customers’ quality standards. These are building blocks in the company’s pursuit of quality and excellence.

Mark Spain, the Technical Solutions Business Manager explained how recent investment in machinery will make a significant contribution to Flambeau’s growth in the coming years: “With the recent investment into a 1700 ton Engel Duo 11050, we have more than doubled our tonnage range. This is evidence of the future direction of our company. As a trade moulder we identified a gap in the market for larger injection mouldings, and as such this investment allows us to produce mouldings up to 6kg in weight, something not many other manufacturers can offer”. The new 1700 ton Engel is a noteworthy addition to their machinery range and gives them an enviable flexibility in using the most effective production techniques. Such as replacing existing single cavity tools with fully automated multi cavity tooling to reduce processing costs.

Technical Blow Moulding Solutions With the use of automotive plastics set to continue its growth over the next five years, the demand for technical blow moulded products is also set to increase. As a fully technical resource and specialist in blow moulding, Flambeau offers extrusion and suction blow moulding and the use of a wide variety of resins suited for any application. Producing products for market leading automotive OEMs, with over 100 machines ranging in size from 1 to 200 litres, Flambeau are innovators in manufacturing high quality plastic components and assemblies.

Packaged Retail Products What sets Flambeau apart from its competitors is the support they can offer their customers with solutions from product concept through to finished packaged product. Flambeau is a leader in supplying technical solutions to its customers, with world class engineering services and manufacturing capabilities; providing a complete “turnkey” option for even the most challenging project.

These skills have been developed over years’ of manufacturing products for their own retail brands as well as providing a contract moulding service. These established brands provide market leading products around the world including Stadium Building Products which has been supplying the construction industry with high quality innovative products for over 100 years, The Neat Nursery Co. which is recognised as one of the leading UK manufacturers of plastic moulded baby products, Flambeau Outdoors which offers a large variety of fishing and hunting products including decoys, to Duncan Toys which has been a world leader in yo-yo’s and skill toys since 1929.

24 • WWW.EPPM.COM • SEPTEMBER 2013

Expertise You Can Trust Since 1947 Flambeau has been at the forefront of plastic processing. From just one machine manufacturing just one product, the company’s humble beginnings have developed and grown to encompass a diverse range of manufactured plastic products in the industrial, Automotive and Retail markets. Their expertise gives them the ability to provide a diverse range of products and services, from tooling design for injection and blow moulded thermoplastic components to contract manufacturing of complete assemblies.

Flambeau is one of the only international plastic manufacturers that specialise in designing plastic solutions for customer requirements utilising both injection and blow moulding technologies. Their accreditation to TS 16949 and ISO 14001, demonstrate their adherence to the highest quality standards. They will support you on your project from concept right through to a finished packed product ready for retail.

This flexibility puts them above their competitors.

Flambeau gives its customers truly Global Innovative Solutions based on 65years of Expertise.

Flambeau will be exhibiting at this year’s highly prestigious K Show; promoting their manufacturing capabilities, as well their retail brands. 2013 will be the first time Flambeau has exhibited at K, and will be used as a platform to present their technical capabilities on the international stage as well as meeting new and existing customers to demonstrate how Flambeau can provide, confidence in their technical capabilities, quality products and economical processing costs. Visit them in Hall 7, Level 2/A20.

For more information contact: Flambeau Tel: +44 (0) 1843 854 002 Email: eusales@flambeau.com Web: www.flambeau.co.uk

K 2013: THE PREVIEW Brazil 2014 ETFE supplier to exhibit at K AGC Chemicals Europe, Ltd. is part of AGC group, a producer of fluorochemicals and fluoropolymer materials.

The group’s products are used in the automotive, construction and aerospace industries, with applications including wire coating for automotive, aeroplanes and space rockets, fuel hose, non-stick coatings for cookware, film for solar panels and the exterior façade of stadia such as the Allianz Arena in Munich and the Itaipava Pernambuco Arena in Recife, Brazil.

The Itaipava Pernambuco Arena is one of the venues for the 2014 FIFA World Cup and has 25,000 square metres of AGC’s 0.25mm-thick Fluon ETFE FILM. The film’s lightweight and flexible qualities have contributed to the stadium’s rounded, creatively designed appearance. It also allows a

considerable amount of light to pass through it, enabling nighttime illumination effects. The film is said to be highly durable, long lasting and exceptionally resistant to soiling.

To secure the supply of chlorodifluoromethane, a key raw material used to produce fluoropolymers, AGC Chemicals Europe has entered into a multimillion pound joint venture with Mexichem UK Limited.

The new company will be called ‘Fenix Fluor’ and is based at Mexichem’s Rocksavage site in Runcorn, UK. The Minister for Business and Enterprise, Michael Fallon MP, attended the official opening ceremony of Fenix Fluor earlier this year and said: “I am delighted to cut the ribbon on Fenix Fluor. The chemicals industry is of critical importance to the UK, and the

Screw and barrel group to debut as a K exhibitor formation of Fenix Fluor strengthens the supply chain in this country, building on our competitiveness across the world.”

In the summer of 2013 AGC Chemicals announced a further 100% expansion in the production capacity of its Fluon LMETFE AH Series to keep up with dramatic growth in market demand.

AGC’s Fluon LM-ETFE AH Series has been engineered to provide enhanced adhesion when melt bonding ETFE to PA. It can be used in co-extrusion applications where ETFE barrier properties, non-stick and exceptional adhesion to polyamides are needed, for example in fuel hose and laminated hose. The grades in the Fluon LM-ETFE AH Series form the ETFE construction in the SUNBESTA Fuel Hose System, a coextruded system incorporating PA12 from UBE Industries Ltd. If antistatic protection is required, the grade AH3000L from this product range is ideal.

In July 2013 AGC Chemicals announced the launch of the new SUNBESTA ZV fuel hose system, a 3 layer system with substantially improved emission barrier performance, thanks to the addition of an extra layer of Nylon 9T from Kururay Co., Ltd. This new fuel hose system offers a solution to next generation requirements, meeting global emission regulation trends.

AGC Chemicals Europe, Ltd. Web: www.agcce.com

Burgsmüller GmbH, a subsidiary of the KraussMaffei group, will have its own stand at K 2013 in Düsseldorf for the first time. The specialist in screw and barrel elements will exhibit its range of products, from standard components for twin-screw extruders and injection moulding machines through to individual solutions with high-end wear resistance.

In addition to producing screws, barrels and components, Burgsmüller claims to be considered the inventor of the internal and external whirling process.

“Our specialties are firstly our production expertise which enables us to economically manufacture wear parts for twin-screw extruders and injection moulding machines within an extremely short space of time and secondly our process expertise which allows us to answer every individual question by providing an ideal solution,” said Jens Biel, Managing Director of Burgsmüller GmbH. Burgsmüller GmbH Tel: +49 5563 7050 Email: info@burgsmueller.de Web: www.burgsmueller.de

SEPTEMBER 2013 • WWW.EPPM.COM • 25

K 2013: THE PREVIEW Masterbatch maker comes boosted with new lines UK masterbatch supplier Colloids will bring a host of new products to the K Show under its newly re-structured brand.

The first development is the PACE series which includes masterbatches based on solvent black (nigrosine) and/or carbon black as well as formulations offering improvements in frictional properties or heat stabilisation The E-TEC range of antistatic, dissipative and conductive compounds for applications where varying degrees of permanent electrical conductivity are required is also new.

In addition the group will promote an enhanced range of special effects for film, to further augment its seasonal colour palettes.

Lead-free film – with a doubling of the grades available — covering the extremes of opacity and both light and colour fastness, all approved for EU food contact applications will be on display on the stand.

Finally, the all new Sustain line will feature at K. Sustain is a bio-based line for environmental sustainability (typically corn starch or cane sugar) and is available in either universal or polymerspecific (polyamide, polyethylene and polyesters including PLA) masterbatches. The Sustain range is fully recyclable and Colloids claims it will not impact on the quality if mixed with fossil derived polymers of the same type, unlike biodegradable polymers.

Technical and commercial staff from

Colloids will be on hand at the show to discuss the developents, as well as the benefits of significant recent investments in plant, including €1m for a complete new twin screw extrusion line featuring high torque and high volume extrusion, with multiple loss-in weight feeders in addition to an underwater strand pelletizing technology (particularly suited to high temperature crystalline polymers) for more uniform geometry. Another recent change has been a major restructuring that has seen both production facilities in the UK brought together under the Colloids brand, as well as investment in the following departments: R&D, Quality, Black and Colour Development and Regulatory Affairs.

Russell Livesey, Managing Director of Colloids said: “Every day Colloids works hard making the most economically viable masterbatch – with all the right attributes – readily available in the right quantities at the right place and time: as my team and I look forward to explaining further at K in Düsseldorf.” Colloids will exhibit in Hall 8A, Stand D01.

Colloids Ltd Tel: +44 151 546 9222 Web: www.colloids.co.uk

Calcium carbonate group turns to packaging for K Calcium carbonate specialist Omya will display its full portfolio for the plastics sector at K 2013. In particular the group plans to focus on the packaging market for the exhibition.

The group will present its expanded portfolio of the Omyacarb and Omyafilm ranges for new applications, including film extrusion, caps and closures, sheet extrusion and extrusion coating.

In recent years, Omya has acquired distribution companies to boost its reach, including Lipscomb and Durr Marketing/Azalea in the Americas and United Chemicals in the Asia Pacific area.

The group places emphasis on the evinronment, stating that its calcium carbonate, when added to plastic, reduces the overall negative impact upon the plastic application, which has led to a development in environmentally friendly applications.

Other new products include ‘Direct Addition’ technology and more products under the Hydrocarb range for vinyl extrusion in the construction market.

Omya Web: www.omya.com

26 • WWW.EPPM.COM • SEPTEMBER 2013

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K 2013: THE PREVIEW Mould base and hot runner technologies on display

K to host latest in in-line extrusion measurement

HASCO will be presenting an array of products from its Mould Base and Hot Runner Divisions at K 2013 in Düsseldorf, Germany in hall 1, stand A23.

The Mould Base Division is focusing this year on two main areas: “Guiding and Locating” and “Temperature Control”.

A large number of new components will be introduced, as well as product improvements such as refined mounting tolerances for location elements. In addition to this, new connection couplings and temperature control hoses will be on display.

Other functional components with DLC coatings will demonstrate the potential for new applications by providing longer service life. A new thermal insulating sheet ensures an optimum heat balance in the injection mould.

The Hot Runner Division is focusing on needle valve technology. It is displaying a hydraulically operated Z2380/… cylinder for the displacement of needle valve assemblies, making the system easier to maintain. The cylinder can be dismantled without exposing the hydraulic drive, thus protecting the system and the environment from hydraulic oil contamination. HASCO implements the pneumatic drive for the

Swiss measurement technology specialist Zumbach will use K to demonstrate its solutions for in-line measurement and quality control in the extrusion arena.

Zumbach’s ultrasonic WALLMASTER and WALLSTARTER systems offer application-specific solutions for wall thickness measurement and control.

Outside and inside diameter can also be controlled, when an ODAC laser measuring gauge is connected.

WALLMASTER is available with conventional or touch screen, and can be connected to UMAC and several ODAC diameter gauges as well as fault detectors. It also features controls, statistics, SPC, and processor communication.

WALLSTARTER is an economic processor solution for UMAC ultrasonic eccentricity and wall thickness measurement, making it suitable for single layer plastic tubes and hoses.

Also on display will be UMAC CI, a high performance ultrasonic measuring system, working on a completely digital basis, which allows flexible and specific configuration of the measuring task.

UMAC RZ and Z scanners feature a completely new design (patent pending).

The transducers can be synchronously adjusted to the best possible measuring position within seconds, claims Zumbach, and the scanner covers an outside diameter up to 180mm. This system is suited to fully non-contact, inline wall thickness measurement of cable jackets, tube and hose.

needle valve assemblies with the Z2371/… cylinder.

Entire actuating plates for needle shutoff systems are now moved on an allelectric basis, employing a new drive and control technology. This electric activation is particularly suitable for highcavity systems in the packaging industry and medical technology. Individually configurable travel paths and speeds help to improve product quality and process reliability during the injection moulding process. The drive programme is rounded off by a range of modular needle valves for individual pneumatic and hydraulic controls in different housing variants. In the control technology field, both a product optimisation and a central control unit will be on display.

HASCO Web: www.hasco.com

Meet the Team AGC Chemicals Europe, Stand 7AC10

Proud suppliers of: for the Itaipava Pernambuco Arena for the 2014 World Cup

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UMAC R scanners now feature up to eight measuring points and bigger diameters (up to 450mm), and will also be exhibited.

For its MSD diameter gauges, Zumbach has also launched a new series of measuring heads for on-line diameter and ovality measurement and control. The MSD models said to be efficient both in terms of price and performance, specifically for applications in the plastics and cable industries.

Dual and triple axis ODAC diameter and ovality gauges are a new range of laserbased gauges for high precision measurement of tubes and hoses. A selection of standard and new models with special laser beam geometry, fault detection function and high scan rate will be on show.

Complete profile cross sections including withdrawn dimensions, radii etc. can be measured and displayed with the group’s PROFILEMASTER systems by applying light sectioning technology (laser and CCDs).

Representing the complete line of PROFILEMASTER systems will be the compact PMM 80 and 140D models.

Surface faults can be detected,

K 2013: THE PREVIEW Dual load cells ensure precise weighing

depending on the kind of fault, via image processing or photometrical with a new 3-axis fault detector KW 33TRIO. SIMAC 63, also on display, is a modern surface inspection system that uses image processing. The design was based on achieving the best price/performance ratio for practically all tubes, hoses and other quality products made of plastic, rubber and other materials, according to Zumbach.

Finally, the group will display noncontact precision speed and length measurement with the laser surface velocimeters of the LSV series. Models with zero speed and direction detection are also available.

ZUMBACH Electronic AG Web: www.zumbach.com

The latest addition to Koch Technik’s patented Graviko gravimetric dosing range will form a key part of the German group’s stand at K 2013. Werner Koch Maschinentechnik GmbH, more commonly known as Koch-Technik, is a provider of peripheral systems for plastic processing.

Graviko, a gravimetric dosing and mixing system, provides the user with a range of products for dosing material for injection moulding, extrusion and blow moulding.

Depending on the Graviko device type, material throughput of 3kg to 2000kg an hour is possible in the plastic processing system. The recently unveiled GK 65 is the latest addition to the series of gravimetric dosing products and provides a throughput of up to 70kg of plastic an hour. Alongside the main component, the basic version weighs up to three volumetrically added material components in its internal, vibration-free weighing container. This is the first Graviko product to have two synchronous precision load cells to yet further improve the continuity and precision of the weighing process. Every filling is weighed one hundred times in succession. The dual weighing unit registers the values and transfers them to the Koch control unit. This in turn compensates for fluctuations until the dosing recipe is reached accurately.

Once all values match, the dosed batch is emptied into the mixer below. Here a horizontal agitator homogenises the mixture before it is processed in the subsequent shaping process.

The Mcm-g Touch control unit from KochTechnik is used to calculate and control the dosage values as stated in the recipe.

This device is designed to operate with all gravimetric dosing systems according to the group. All dosing parameters are set and monitored on the touchscreen's graphic interface. Once the recipe has been entered, dosing takes place starting with the first cycle without the need for calibration. The system has options for saving programs and recipes, a ground material program, FTP server and control for the hopper loader and blower. All interfaces for networking and inclusion in the production-monitoring visualisation software are provided as options.

Because the Graviko devices are structured using Koch-Technik's modular

system, the user can move, swivel away or fold up all device components for rapid material changes – quickly and without the need for tools. The gravimetric devices are used directly on the processing machine or as accompanying dosing and mixing stations.

The gravimetric dosing function of the patented Graviko is said to result in the highly accurate dosing of various material components and reportedly offers longterm stability. Koch-Technik will exhibit in Hall 10, Stand A21.

Koch Technik Tel: +49 7231 8009 0 Email: info@koch-technik.de Web: www.koch-technik.com

Come and see us at Hall 11, Stand B30 Visit our stand to discuss the latest in polymer testing systems.

SEPTEMBER 2013 • WWW.EPPM.COM • 29

30 • WWW.EPPM.COM • SEPTEMBER 2013

K 2013: THE PREVIEW Additives group to launch WPC solution at K

Croda Polymer Additives states it has established itself as a world leader in slip, anti-block, anti-fog, anti-static and UV protection agents. The group, which is celebrating 45 years in business this year will demonstrate its slip additives, sold under the Crodamide brand, which are claimed to offer great performance.

The range is said to offer the largest selection of amides in different physical forms on the market today, which supports the many different processing conditions manufacturers are currently using.

New two-platen machine to be unveiled in Hall 13 Borch Machinery Co. Ltd of China will show its latest two platen machine BU900 at its 117 square meter K Show stand.

The latest version of two platen machine, named the BU series, has been developed using European technology. It was researched and designed by Borch together with a European technology team, and, claims the group, aims to meet domestic and international requirements. With its servo system and compact structure, the machine is said to combine space and energy efficiency with machine stability. The BU machine is suitable for large-size applications such as garbage bins, household appliances,

automotive parts, and pallets etcetera.

Borch says it is also suitable for more complex parts using more precise methods, such as low-pressure moulding, foam injection moulding, and venting-type moulding.

Borch was established at the beginning of 2003 in Guangzhou. The factory now covers an area of 180,000m2. Borch specialises in the design and manufacture of high-precision injection moulding machines, and offers fully

automatic machines up to the 6000 tonne capacity level. An ISO900, CE accredited manufacturer, Borch is represented by its distributors in over 30 countries. The group will exhibit in hall 13, stand C47.

Borch Web: www.borch-machinery.com

“Croda’s expertise in plastics technology, built on our many years of experience, has allowed us to emerge as market leaders,” said Jill Ullathorne, Technical Marketing Manager – Polymer Additives. “We are so excited to be celebrating 45 years of Crodamides this year, as this celebration acknowledges our long-standing commitment to innovation in this market area, while recognising how this foundation will support our future growth into new and exciting areas within plastics.”

Croda has announced a new line of specialty additives for wood plastic composites (WPC). The Incroflo range will help to support customers developing materials for the wood plastic composites area, which is a fast growing plastics industry in Europe. To create these materials, plastic and wood need to be processed together quickly and efficiently. Incroflo specialty additives act as lubricants to allow increased throughput of WPC during processing by increasing flow rate and dispersion. This allows for lower processing temperatures and pressures during manufacture. In addition, the Incroflo range: • acts as a barrier between the WPC and the extruder to reduce wear, especially on screws • optimises mechanical performance as measured by MOR, MOE and Charpy impact resistance • improves surface finish • reduces water absorption, which can lead to warping.

Croda will have technical experts on hand to discuss projects with its customers, as well as offer samples and literature of the Incroflo and Crodamide ranges in addition to the other products in its wide range of specialty additives.

Croda Polymer Additives Web: www.croda.com/pa SEPTEMBER 2013 • WWW.EPPM.COM • 31

K 2013: THE PREVIEW Sample preparation equipment to go on display Ray-Ran Test Equipment Ltd has been a specialist in the design and manufacture of polymer testing equipment since 1977. Part of its product range deals with instruments to prepare samples from either the raw material, sheet or pipe The group supplies CNC profile cutting machines which are suitable for producing tensile test samples from underground thick wall pipes or sheet material generally up to 100mm thick.

Cutting speeds, in the region of 2,800 to 28,000 rpm, give the desired surface finish and ensure that the temperature at the cutting surface does not affect the material characteristics.

Cutting presses are also available from the group as pneumatic or hand operated which when used with the RayRan test sample cutters will cut thinner samples up to 8mm thick from materials such as foil, film, plastic sheet, paint or foam.

The group also supplies small injection moulding apparatus which can take raw materials such as pellets or flakes, and mould dumbbells, impact bars or colour plaques using a combination of heat to melt the polymer, and a pneumatic ram to inject the molten polymer into the mould under high pressure.

The samples produced from the above machines can then be used on a range of test equipment to test the physical charachteristics of the material, which in turn forms part of a complete test facility for a range of plastic materials.

Ray-Ran will exhibit in hall 11, stand B30.

Ray-Ran Web: www.ray-ran.com

Netstal to unveil two new ELION models at K 2013 Netstal is expanding the ELION product range with two new models. At K 2013 the machinery group will be launching the ELION 4200 with hybrid drive concept and the all-electric version of the ELION 2200. The two machines will be aimed at complex packaging applications, closures, medical technology and high-precision technical parts.

The group will be demonstrating the manufacture of a 29/25 water cap on the new ELION 4200. The HDPE moulded part will be produced in a total cycle time of two seconds using a 96-cavity mould.

A 1ml syringe cylinder made from Basell polypropylene will be produced on the new, all-electric ELION 2200. The cycle time will be around 9.6 seconds, with a product weight of 1.54g. Manufacturing of the medical part will take place using a 48-cavity mould “At K 2013, Netstal will be presenting two new models of the successfully established ELION series, consequently underpinning its position as a market leader for fast and precise machines,” said Dr Hans Ulrich Golz, CEO of Netstal and president of the injection moulding technology segment of the KraussMaffei Group.

The new 4200 clamping force size is based on a hybrid drive concept. Eco Powerunit drive takes advantage of the energy-saving potential of hybrid technology, claimed the group. The ELION hybrid is said to reduce energy consumption by up to 50%. “Thanks to its innovative dual-valve technology, the high-performance injection unit, which is also used in our EVOS series, is able to reach injection speeds of up to 2,000mm/s at extreme levels of acceleration. This level of injection performance minimises material use and reduces cycle times. Ultimately, this offers the benefit of lower production costs," explained Dr Golz.

Netstal Web: www.netstal.com 32 • WWW.EPPM.COM • SEPTEMBER 2013

K 2013: THE PREVIEW Complete ancillaries range to run in Hall 10 Wittmann has announced a host of new products for K 2013, in the form of robots and automation systems, mould temperature controllers, granulators, material drying, conveying, and blending. All new products will be on display on stand A04 in Hall 10.

In addition, Wittmann Battenfeld will exhibit injection moulding machinery and complete production cells in Hall 16, stand D22.

Wittmann has developed and launched the W842 robot in response to a market demand for greater payloads and versatility around mid-sized moulding machines of up to 800 tonnes of clamping force and higher. Further information on the W842 can be found in our automation and robotics spotlight.

In drying technology, the group will display the Drymax Aton2, a new development for the Wittmann segmented wheel dryer.

The thermal energy refeed via the group’s ‘3-Save Process’ uses only what’s needed from the

regeneration energy in order to dry the molecular sieve in the wheel’s segments. If, in addition, a limiting value for the dew point is set, the Aton2 automatically optimises the drying process through ‘EcoMode’.

At K the group will present a complete drying battery consisting of a Drymax central dryer and Silmax drying hoppers with an overall volume capacity of 900 litres. The hoppers are equipped with SmartFlow technology, which is described as ‘breath-responsive activated air control flaps.’ The battery’s hoppers – also ‘breath-responsive’ – are provided with dry air from a Drymax E300-FC central dryer.

There will also be products running in the conveyor portfolio. Wittmann’s Feedmax single loaders as well as the Feedmax B central material loaders will be on show.

The latches on the Feedmax loader can be opened easily without a tool, allowing for quick cleaning. The central section and material inlets are made of stainless steel, as well as the material outlet. The material inlets have a wall thickness of 5mm, making the unit capable of withstanding polymers such as glass fibre reinforced PA. The central section can be removed and replaced with a glass alternative if desired for visual monitoring.

Wittmann will also present Gravimax blender models from the series 1 and 3 ranges. All plastic-contact components in these units are made from stainless steel.

They also come equipped with two weighing cells and a bowl mixer. The group says that the bowl mixer was designed to avoid electrostatic charging of masterbatch.

The touch-screen control is reported to feature selfexplanatory imagery and the option to enter each ingredient value in percentages for easy start-up. Up to 120 different recipes – and their respective components – can be stored using arbitrary names. Wittmann’s Gravimax blenders use Real Time Live Scale (RTLS) technology for batch-to-batch consistency.

Additionally, there are new models of the group’s Tempro directly cooled temperature controllers in the basic C120 series, now with smaller dimensions.

Wittmann now offers many variants of the C120 – from different pumps through to different heating and cooling capacities. Using the largest version of the series, users can heat moulds weighing up to 10 tonnes.

The smaller Tempro basic C120 unit measures 230 x 690 x 630 mm and can achieve a delivery rate of up to 200l/min. It comes with a heating capacity of either 12 or 18kW at a pump capacity of 0.75 or 1.5 kW. Options include serial interface, external sensor, alarm contact, internal bypass for relieving the pumps, and also manual mould purging.

The most powerful model in the line is available with either 18 or 24kW of heating capacity, and can also be adapted to heating capacity of 46kW. The respective pump capacities range from 200 to 280l/min.

Finally, Wittmann’s new MC 33 granulator will be making its K 2013 debut. The new machine can be operated beside-thepress or in a central role, and has been designed to handle demanding materials for injection and blow moulding processes, including in-line recycling of sprues/runners, PET preforms during mould start-up, among others.

The granulator operates at 7.5kW and features high throughput capacities of 100–150kg/hr.

The infeed hopper is a double-walled steel construction, designed to reduce noise levels. For cutting, Wittmann has used hardened cutting tools made from high quality steel alloys. The MC 33 collection bin has been designed with a 360° swivelling outlet, and allows for vacuum connection from any direction.

Wittmann Group Web: www.wittmann-group.com

Haitian to launch smaller ‘Jupiter’ range The Jupiter II series injection moulding machines from Haitian have been available on the market since the beginning of the year in the 12,000 to 66,000 kN range.

At K 2013, the Chinese firm will premiere the 5,500 kN Jupiter, with other lower clamping forces coming online in 2014.

“We have overhauled the machine from the ground up, the design now has a clean and tidy appearance, the technical weaknesses were addressed, and new clamping force classes have been added. Of all of the series the Jupiter II has definitely taken the biggest step in terms of development,” said Mr. Fu Nanhong, Chief Engineer of Haitian International Ltd. The new Jupiter is said to be more stable, with rapid, friction free movements. There is a choice of six injection sizes for each clamping unit.

“We exhibited the new Jupiter at Chinaplas for the first time and we got a lot of positive feedback from all sides,” said Professor Helmar Franz, CSO and member of the executive board at Haitian International. “It is the best equipped for international challenges”. As per the group’s tradition, the new machine was first introduced in China. The company claims that the first few months saw orders and shipments of over 100 units. There are now orders now coming from Europe ahead of what Haitian calls the ‘official marketing launch’ .

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The Jupiter II series portfolio will be expanded from 2014. The group cites a “desire for greater efficiency and more application possibilities” as the instigator for the new clamping forces of 5,500, 7,500, 9,500 kN. “It was well worth the effort,” said Professor Franz. “The Jupiter II should also be highly interesting outside of the automotive industry”.

Haitian Tel: + 86 574 86177005 Email: haitian@mail.haitian.com Web: www.haitian.com

K 2013: THE PREVIEW Laser group to focus on microfluidics LPKF will be presenting its new PrecisionWeld laser system designed for microfluidic applications. The system can reportedly create weld seams with a thickness of 100 µm and has positioning repeatability of 10 µm.

This is accomplished by separating the housing from the processing compartment.

This design has been used in practice, as it was based on the company’s ProtoLaser systems which have been used in the PCB prototyping sector for many years.

It uses a scanner system to guide the laser beam and a positioning table.

This expands the effective working

area to 320 x 320mm. In addition, an integrated camera system allows for the detection of specially applied fiducial marks, or it can use the geometric elements of the device itself. This allows compensation for tolerances in the device or its fixture.

With the LPKF PrecisionWeld, parts can be joined using classic transmission laser welding as well as the new clear-joining technology.

In transmission laser welding, the two parts to be joined have different absorption properties, e.g. a laserabsorbing basal unit has a clear cover plate. The laser beam passes through the upper laser-transparent layer but

is absorbed when it hits the lower part, so that the energy in the light is converted to heat and melts the plastic. A moderate joining pressure is applied which promotes thermal conduction into the upper part, producing a reliable and precise weld seam.

Because it has a laser wavelength of 1,940 nm, the LPKF PrecisionWeld is also capable of joining two transparent components. This the clear-joining technology: at this wavelength, most technical polymers absorb enough of the light to melt at high energy densities. The laser beam is focused precisely on the welding horizon to apply the energy where it is required to create a weld – without needing any special additives.

Other features of the PrecisionWeld include a setting which identifies the surface of the component and automatically adjusts the focus to the optimal position. The system is remarkably compact and needs only to be connected to a power supply and a compressed air line for operation. It is small enough to be equipped with rollers and fits through every laboratory door.

LPKF Tel: +49 5131 70950 Web: www.lpkf.de 36 • WWW.EPPM.COM • SEPTEMBER 2013

K 2013: THE PREVIEW High end applications to hit the halls Bayer MaterialScience will exhibit a host of high-end developments, including microcellular, rigid polyurethane foam based on the Baytherm Microcell system. The lightweight material is used in the solar aircraft to insulate the cabin against icy or hot conditions. The group claims that refrigeration equipment manufacturers are showing interest in the product.

The long-standing joint collaboration between Bayer MaterialScience, the CAT Catalytic Center of RWTH Aachen University and the utility company RWE, known as “Dream Production”, has also made advances which will feature at the show.

Since the last K, a pilot plant in Leverkusen (pictured) has begun producing polyols, a component of flexible polyurethane foam, from CO2 with the help of a special catalyst.

Production was recently switched from batch to continuous mode.

Polyols manufactured from CO2 are expected to hit the market in 2015 and will initially be used in mattress production. They could later also be used for the production of thermoplastic polyurethanes and then coatings and fibres. “Bayer is using the greenhouse gas CO2 to support a safe supply of raw materials,” said Thomas.

In the healthcare sector, the HAL exoskeleton from Cyberdyne is being used successfully in rehabilitation applications. It is also being used in Japan’s damaged Fukushima nuclear power plant.

Bayer MaterialScience is collaborating with Cyberdyne and its founder and CEO, Prof. Yoshiyuki Sankai, in the development of high-tech materials.

Both companies are looking for additional potential applications for the robot suits and last year conducted an international design competition. Many promising developments by various designers demonstrate that there may be opportunities for the technology in areas besides health and caregiving applications, such as sports and recreation and physical labour.

Bayer MaterialScience Web: www.materialscience.bayer.com

Group to show aerospace applications using engineering plastics Victrex Polymer Solutions (VPS) will present new applications and products based on its high-performance polymers.

“Each new product and application development is all about identifying market trends early and taking them into account whilst facing new challenges at the same time,” said Rainer Müller, Commercial Manager Europe, with reference to the overarching motto of Victrex Polymer Solutions for K 2013.

“This directly benefits OEMs and ultimately their customers, too.”

The latest glass fibre-reinforced product from Victrex is PEEK 90GL30BLK EU. The product meets the current requirements of both the American and the European regulatory authorities, including the EU Commission Regulation10/2011 (Plastics Implementation Measure, PIM) which will be fully implemented by end of 2015.

In aerospace, Victrex PEEK 90HMF40, which was recently qualified by Airbus, is claimed to offer weight savings of up to 40% versus aluminium. The highstrength polymer is characterised by up to 100-times longer fatigue strength and up to 20% higher specific strength and stiffness as compared with aluminium 7075-T6 used in the aerospace industry under the same conditions. So broad use of the high-performance polymer is bound to reduce weight, fuel consumption and emissions.

Victrex Web: www.victrex-k2013.com SEPTEMBER 2013 • WWW.EPPM.COM • 37

K 2013: THE PREVIEW Chemical firms to team up and pool knowledge at K Three polyolefin producers have announced their intentions to exhibit at K 2013 as a team. Borealis, Borouge and NOVA Chemicals will exhibit with the message “Open Your Mind” at the show.

The three companies are part of the International Petroleum Investment Company (IPIC), OMV and the Abu Dhabi National Oil Company (ADNOC) family of companies.

In particular the trio will be hoping to discuss new developments with visitors, including Borealis’ new catalyst plant in Linz, Austria (pictured), in addition to polymer solutions for those who need sealing performance for flexible products.

“Our customers have told us they need

to stay ahead of the game with innovative products, combined with the best quality and service to drive productivity improvement,” said Alfred Stern, Borealis Executive Vice President Polyolefins.

“The theme Open Your Mind speaks to this. In addition to creating the next new technology, we work with our customers to explore different ways of doing what they do every day. Innovation is about new approaches and smart and simple value creation.”

“By coming together at K 2013, we have a unique opportunity to demonstrate the benefits of our technologies, the diverse markets and applications we serve and

our global reach,” said Wim Roels CEO of Borouge (Marketing & Sales Company).

“There are many ways in which we create value for our customers, through our commitment to growth, innovation and sustainability. We look forward to the continued strengthening of our relationships throughout the value chain.”

Chris Bezaire, NOVA Chemicals Senior Vice President Polyethylene said: “Every

product and service offering we provide starts with listening to our customers and understanding their challenges.

“We look forward to highlighting our market focused approach in North America. By understanding our customers' challenges and drawing on our technical and market knowledge, NOVA and its customers together turn insights into innovation and opportunity.”

Borealis Web: www.borealisgroup.com Borouge Web: www.borouge.com NOVA Chemicals Web: www.novachem.com

Materials group to showcase infrared reflecting pigment Huntsman Corporation will showcase its new ALTIRIS infrared reflecting pigment for polymers.

ALTIRIS is a titanium dioxide based pigment that preferentially reflects infrared radiation (heat) from the sun.

When mixed with coloured pigments the result is higher solar reflectance in a range of colorful polymers including dark and vibrant shades.

Polymer products with high solar reflectance can stay cooler under the sun’s intense heat, helping to reduce overall heat build-up which can prevent heat distortion and premature failure.

Increasing the solar reflectance of polymers can help open up new markets for polymer products as they become less prone to warping. This means polymer products could be used in warmer regions of the world where they would have previously been unsuitable.

Sean Reid, business development manager at Huntsman said, “Expanding customer choice when it comes to building materials provides impetus for innovation and exterior polymer products are no exception. We believe that there is scope for a new generation of polymers that are colourful and can better reflect the heat. ALTIRIS pigment is designed to substantially increase the solar reflectance properties of a very wide range of colored polymers and has the potential to deliver energy efficiencies and expand customer choice. The pigment delivers a unique set of benefits: tailored solar reflectance from a single additive and in almost any color customers need. This combination was not available before Huntsman’s ALTIRIS pigment.”

Huntsman Web: www.huntsman.com/pigments 38 • WWW.EPPM.COM • SEPTEMBER 2013

Come and see us at Hall 11, Stand H25

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K 2013: THE PREVIEW Mould release and process aid additives on show for K visitors Axel Plastics Research Laboratories (AXEL), a USbased manufacturer of proprietary mould releases and process aid additives for all types of plastics, rubbers, and urethanes, will be exhibiting at the K Show in hall 5, stand E30. The company also provides formulated mould releases for decorative laminates, concrete, abrasives and many other markets.

AXEL’s focus at the K Show will include special attention to the company’s trademarked MouldWiz process aid additives. This is an extensive line of products aimed at improving flow, release, dispersion, surface characteristics of moulded parts and improving productivity in both masterbatch production and injection moulding operations. MouldWiz process aid additives are specialty chemical formulations, available in pellet, powder and liquid forms. This line includes products that are suitable for a variety of thermoplastic and thermoset resins, including food grade moulded products and applications requiring optical clarity.

AXEL will also feature many new products at the K, including: two new process additives for improving flow in nylon; a new, food grade water-based mould release for silicone rubber; new mould releases for rotational moulding, including a product from XLPE; and several new mould releases and process aid additives for epoxy and urethane.

AXEL is a privately held, ISO 9001 registered, and REACH compliant company that serves the global

market through direct sales and a network of stocking distributors and technically trained representatives.

AXEL says it is experiencing strong business growth and is interested in adding new distributors to its network. The company encourages interested parties to visit the stand E30 in Hall 5.

Axel Plastics Research Laboratories (AXEL) Web: www.axelplastics.com

Extra large moulds designed for extra large containers Haidlmair Tool GmbH, a specialist in tools for logistics and disposal containers has commissioned new production capacities for extra large parts and the assembly of extra large injection moulds. The group’s mould making options now cover the entire size range from the slip box to large waste bins with a mould weight up to 120 tonnes. These new capabilities will be at the centre of the company’s presentation in Hall 12 at K. Haidlmair moulds incorporate compactness gained from a design that is said to optimise power distribution within the mould system itself.

The basic principle is the indentation of the container exterior through a 4-sidecore system with the separation lines along the container corners. The outer side cores are located on the fixed mould side and are locked within the mould assembly on both sides in a tapered holding frame with wedge-shaped cross-

section, where they are simultaneously centered and fixed. With that system a high percentage of the lateral pressure applied on the side cores is transmitted to the adjacent mould structure.

This mould construction consists of a minimum of platens and components and allows for a minimum shut height and cross section.

In Hall 15 Engel will be moulding the “S + Smart Cube”, a special container developed under the project management of Haidlmair in cooperation with raw material producer Borealis, measurement technology company HDEMC, hot runner manufacturer PSG and in-mould label manufacturers Viappiani and Engel itself. The design object features large label areas on all four sides, surrounded by a space frame structure in paper crease (pictured). In addition to the 4-sided labelling application, the gasinjection technique will be applied to compensate shrinkage and increase precision in upper body structure. This is said to be achieved through eight specifically incorporated hollow local areas along the upper container rim with the four gripping areas.

Haidlmair claims that the cooperation project is “the current state of the art in container moulding.” It will be moulded on an Engel e-duo 5440/700 (with 700 tonnes of clamping force).

A second demonstration of a Haidlmair mould will also take place at Wittmann Battenfeld’s stand in Hall 16. A Battenfeld HM 300/2250 ServoPower will produce a hockey stick from glass fibre reinforced PP. Again, Haidlmair’s gas injection technology will be used, as the 120 cm long handle of the hockey stick is a lightweight hollow profile.

Haidlmair Web: www.haidlmair.at

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K 2013: THE PREVIEW Additives group to focus on a sustainable future

All-in-one bottle production to run at K Mould & Matic Solutions GmbH, a member of the Haidlmair Group, will present equipment for high-volume manufacturing of thin-walled cups and the latest version of the “Blowliner” injection stretch blow moulding system.

Developed by Mould & Matic, the Blowliner machine combines a vertical injection moulding machine clamping unit with a stretch-blowing station including automation. The preforms injectionmoulded on the vertical machine (up to 400 tonne clamping force) are removed by a linear handling action featuring a bolt gripper and transferred into the blowing station (up to 80 tonne clamping force). The finished containers are automatically removed and either routed

directly to a filling line or stacked on pallets. The machine can produce containers ranging from 5ml to 10,000 ml volume in size-related output rates between 15,000 to 250 pieces per hour.

The system can be tailored to have cavity assemblies with one row or an optional stack arrangement with two parallel product lines. For single-row assemblies, the possible neck openings of the container range between a minimum of 15 mm and maximum of 150 mm. For the double row execution between 15 and 110 mm. The body-diameter of the bottles can vary between 250 mm (single row) or 120 mm (double row). The maximum bottle height is 325 mm. Tool changes can be carried out using mould change tables, without the need for a crane.

Blowliners are stand-alone-systems that can be operated as independent production cells including palletising and foil wrapping stations or integrated directly into filling lines. Mould&Matic provides the base machine, the injectionand blow-moulds, the handling facilities, a 100 percent leak test, and packing equipment.

The group also manufactures moulds and downstream equipment for the thermoforming of thin-walled cups of all types and sizes. Products include takeout and packaging units, which can be matched to the particular type of thermoforming machine or container type produced.

A “Pick-up Stacker-Compact-Unit” will be demonstrated in production on the stand of Italian thermoforming machine manufacturer AMUT in Hall 16. It will be demonstrated as part of a production cell for manufacturing a 73 mm thin-wall cup with a 45-cavity mould. These cups are stacked to approximately 580 mm long cup-stacks and afterwards packed with a capacity of up to 35 stacks per minute in 600 x 400 mm standard cartons.

Polymer additives supplier Addivant will display a collection of products and services focused on sustainable shelter, potable water, power, food safety and fuel efficiency.

The company’s powder-free additive solutions are claimed to offer physical properties that allow productivity, increased production up-time, improved health and safety, and higher throughput in extrusion applications.

"Productivity is a key driver across Addivant's portfolio," said Peter Smith, President and CEO of Addivant.

"Customers using Addivant’s additives can save material, save energy, save time and save money, all while achieving high quality end products. In addition, the assurance of reliable supply and technical support helps our customers maximise their processes and applications.

Processors, designers and brand owners attending K 2013 will get a valuable insight into the exciting possibilities generated by our cutting-edge development, for applications from food storage containers and beverage cups to interior automotive components."

New products in the following ranges will be on show: Anox and Lowinox phenolic antioxidants; Alkanox, Weston and Ultranox phosphite antioxidants; Octamine and Naugard amines; Naugard thioesters; Anox and NDB blends and others.

Mould & Matic Solutions GmbH Web: www.mouldandmatic.com

Addivant Web: www.addivant.com

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ADVERTISERS’ INDEX

EPPM CLASSIFIEDS MATERIALS

Company Page Abbey Masterbatch 15, 42 ACS/Cumberland 11 AGC Chemicals 28 Air Control Industries 23 Albis 13 Ametek 25 Axel Plastics Research Laboratories 30 Battenfeld-Cincinnati 39 Bausano 42 Birmingham Granulators 42 Boussey Control Europe 42 Colines 22 Colloids 26 Croda 30 Dalesway 43 DB Automation 42 DME Europe 29 Erema 8 Equipnet 43 Euromold 8 Eurotec 35 Ferromatik Milacron 38 Flambeau (Advertorial) 24 FRX Polymers 41 Gala 26 Hasco 40 Herbold 42 Interplas 44 Koch-Technik 17 Krauss Maffei 42 Lanxess 7 Maguire 9 Maschinenhandel Borowski 43 Max-Robot 18 Meusburger 31 Mediplas 16 Milliken 39 Mold Masters 36 Plastico Trading 42 PMH GmbH 43 Polyone 1 Process Control 39 PTI-Europe 43 Ray-Ran 25, 29 Rawmec 43 Renmar 11, 42 SciLabware 37 S.i.S.e 28 Starlinger 30 Stäubli 33 Tappex 42 TransXL 43 Unicor 2 Vinyl GB 43 Windmöller & Hölscher 32 Zerma 42 Zumbach 34 X-Rite (Advertorial) 27 42 • WWW.EPPM.COM • SEPTEMBER 2013

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

blowers – cyclones – pipework – conveyors blades – screens Contact: Dick Monkhouse Tel: 01928 734724 Email: sales@herbold.cu.uk

Speciality Engineering Polymers DISTRIBUTORS REQUIRED For a number of key areas Whitelands Mill, Whitelands Road, Ashton-under-Lyne, OL6 6UG, UK Tel: Fax: Email: Web:

(44) 0161 308 2550 (44) 0161 343 2026 aml@abbeymb.com www.abbeymb.com

PROCESSING EQUIPMENT To Advertise Here...

Contact Tim Guest Tel: +44 (0) 7581 398 723 Email: tim.guest@rapidnews.com

eppm

ANCILLARIES, AUTOMATION & TESTING EQUIPMENT

Krauss-Maffei Automation AG Tel: +49 89 88 99 0 Fax: +49 89 88 99 22 06 Web: www.kraussmaffei.com

For further information: T: +44 (0) 1789 206600 F: +44 (0) 1789 206651 E: sales@enquires.co.uk Or scan the QR code below:

Renmar Ltd Tel: +44 844 6933225 Email: info@renmarltd.com Web: www.renmarltd.com

www.tappex.co.uk

RE-PROCESSING EQUIPMENT

Granulators Shredders Pulverisers Blowers-cyclones All spares Contact: Dick Monkhouse Tel: 01928 734724 Email: sales@zerma.co.uk

To advertise here please contact Tim Guest: Tel: +44 (0) 7581 398 723 Email: tim.guest@rapidnews.com USED MACHINERY

USED MACHINERY

PRINT EQUIPMENT

Extruder and Extrusion Lines

Tel: +49-2244-83041 email : pmh.gmbh@t-online.de www.pmh-extruder.com

OTHER

Manufacturing Equipment

BUY

SELL

MANAGE

Find what you need, sell what you don’t, and manage what you have.

EquipNet has been providing asset management sales and solutions to leading corporations in the plastics and chemical industries for more than 12 years. The EquipNet.com MarketPlace is the world’s largest online venue for buying and selling pre-owned manufacturing equipment.

www.EquipNet.com/EPPM Sales@EquipNet.com • Tel: +44.118.901.6161 ®

Maschinenhandel Borowski

FOR SALE PVC Used plastic processing machines Injection moulding, blow moulding and accessories Tel. 0049-2173-8950790 Fax 8950799 www.mhborowski.de info@mhborowski.de

Rigid and flexible compounds in the following formats

Prime Reprocessed Regrind Pulverised As well as composition raw materials For all of your PVC requirements please call +44(0)1691 664256 / fax +44(0)1691 664235 Email: enquiries@vinylgb.co.uk The Fort Offices, Artillery Business Park, Oswestry, SY11 4AD ® The Vinyl GB logo is a registered trade mark

Over 35 Years of Service

500 x 350mm Kiefel Model Kmv 50d.

Thermofomer. 2002 Unwind stand. Top and bottom heaters. Forming station. Punch station and stacking station.

1300mm Battenfeld coextrusion sheet line; 2 x 90mm single screw extruders. 1300mm x 600mm 3 roll polishing stack+ haul, 2 station winder, 1995.

Tel: +44 (0) 1793 827666

1850mm Battenfeld Gloenco PP PE Cast Film Line: 120mm+60mm extruders, feedblock. 1650mm Cloeren auto die, 1850mm Chill roll, haul off, winder.1993.

Email: sales@transxl.co.uk

890mm Welex World Standard sheet Line.

90mm Extruder. Gear Pump 900mm Die. 890mm Welex Stack winder. 1997.

SHEET LINES

Web: www.transxl.co.uk

45mm Kuhne single screw extruder model K45E 30D plugged vented. 20-204 rpm. 24kw dc motor.

1000mm Omv Coextrusion Sheet Line.

120mm Omv Extruder, 60mm Coextruder, Melt Pump, 1000mm X 500mm Roll Stack, Haul Off, Winder.

GRANULATORS 500mm Zerma model GSH-500/600 660 x 350mm Cumberland model 6/84.

2300mm Omipa Pmma Extrusion Line 1800mm Virginio Mai 3 layer coex line 1700mm Bandera/virgin Mai ABS Line.

EXTRUDERS

1500mm Bandera 3 roll stack 1350mm Welex/Union line 1350mm Welex 3 roll stack 1900mm wide Oman Polishing unit, 3 x 1900 x 400 mm diameter rolls in line saw haul off and Cross cut Saw.

1300mm Battenfeld coextrusion sheet line.

1040mm Welex Coex sheet line.

60mm Cincinnati Alpha60 extruder with inverter drive powering a 37 kW motor , cooling. 2003.

1040mm Welex 3 roll stack

1000kg/hr Colourtronic 3 component Gravimetric Blender Feeder with hopper loaders 2004.

1000mm Esde 3 roll Stack 1000mm OMV co ex sheet line 890mm Welex Pet sheet line

115mm Welex Extruder, 30d 100mm Union extruder.

90mm Welex single screw extruder 80mm Cincinnati Titan twin screw 90mm John Brown Egan single screw extruder 70mm Battenfeld-kuhne Extruder 60mm Cincinnati coextruder 50mm Welex co extruder. 25:1 l/d ratio.

50mm Betol extruder 25:1d 45mm Kuhne model K45E 30D

863mm wide EDI Ultraflex H75 flex lip sheet die. 0-1.9mm die gap. 240 V heating.

THERMOFORMING DIES

700mm Illig RDM 63/15B cup forming line 605mm Kiefel KL2 SH Thermoformer,

500mm Illig RDM 50/3 Lid Thermoformer

660 x 350mm Cumberland model 6/84 Granulator 15kw ac motor.

Rapid Kurf 205 edge trim granulator with powered nip feed rolls for side trim granulation.

980mm EDI model Ultraflex HR75 915mm EDI flex lip sheet die 900mm Kuhne model BDF 90F 863mm EDI Ultraflex H75 flex lip sheet die 500mm Masterflex flex lip cast film die 1987

500mm wide Illig RDM 50/3 lid thermoformer, Double heaters, Motor Indexing. Auto Rail Spreading, Counter/ Stacker, 1982 very good condition.

1700mm Bandera Virginio Mai PMMA ABS sheet extrusion line. 80mm extruder, 1600mm Simplas die, 2-7mm thickness. Complete line 1987.

100mm Union single screw extruder. 35D vented with fan cooled barrel. Vacuum vent.

110kw dc motor and drive. Temperature panel 1987.

1450mm wide Kaufman Repiquet sheet extrusion line. 120mm Kaufman extruder, Omipa die, 1450mm 5 roll polishing stack, pump group, haul off, guillotine. 1991.

540mm Kiefel KL2EH vacuum former 1350mm wide Welex coextrusion sheet line with 115mm and 50mm extruders. 1270mm wide sheet die, 1350mm x 450mm rolll stack, haul off, winder.

1040mm Welex sheet extrusion line: 90mm Welex extruder with gear pump, die head, 1040mm wide Welex 3 roll polishing stack, haul off and winder.

500mm Kiefel Model Kmv 50d. Thermofomer

300mm wide Schwarbentham 2 roll laboratory mixing mill. Polymix 110 P.

60mm Betol/Corelco pipe corrugation lines model EC255LLV complete with die head and corrugation dieset, cooling bath, hauloff & fly cutter,!!!

TRANSXL INTERNATIONAL THORNHILL SOUTH MARSTON SWINDON WILTSHIRE SN3 4TA ENGLAND MORE MACHINERY, MORE PHOTOS ON THE WEB: www.transxl.co.uk

SEPTEMBER 2013 • WWW.EPPM.COM • 43