Nov/Dec 2018
Cover Story | Page 4
Condition-based and predictive maintenance ENGEL explores avoiding downtimes with permanently monitored hydraulic pumps and hydraulic oil.
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From The Editor
Welcome back Welcome back to Middle Eastern Plastics as we celebrate another terrific year for the plastics processing industry in the Middle East and North Africa, including another successful outing for PlastPrintPack Nigeria, Iran Plast and Gulfood Manufacturing. With Plast Eurasia and ArabPlast 2019 to look
There is a big drive towards sustainability, echoing the position of many plastics processors and brand managers in Europe
forward to, it is little wonder the plastics industry is feeling buoyant about the coming year. I have noticed some big trends emerging in this part of the world – not only are innovations such as 3D printing and digitalisation being more widely adopted across the industry, but there is a big drive towards sustainability, echoing the position of many plastics processors and brand managers in Europe. I hope you enjoy reading MEP in print again, in particular our focus on ArabPlast 2019 and Plast Eurasia in Istanbul. As ever, if you are exhibiting at either show then we would love to hear from you and do not hesitate to contact the team via the website with your news. Rose Brooke, Editor
IN THIS ISSUE Pg 4
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COVER STORY: ENGEL
ARABPLAST 2019
Predictive maintenance and the rise and rise
The economy of the UAE is in a strong position
of digitalisation is order of the day for ENGEL,
with strong leadership, so we’ve assessed the
which is championing the future of injection
climate for ArabPlast 2019.
moulding with smart technology.
Pg 7
Pg 12
INDUSTRY NEWS
PLAST EURASIA
We home in on some of the news that caught
What can visitors expect from Plast Eurasia 2018?
our eye that has wider implications for plastics
Whether you have been before, are returning after
processing in the UAE, Iran, Saudi Arabia,
a few years, or you’re a first-timer, we can help you
Oman and North Africa.
prepare for your visit.
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Flip this magazine over for the latest from the European plastics market and the major shows taking place across the region.
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COVER STORY
Condition-based and predictive maintenance ENGEL explores avoiding downtimes with permanently monitored hydraulic pumps and hydraulic oil.
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nplanned production downtime can have far-reaching consequences in an injection moulding company. Depending on the nature and extent, it can even lead to delays in delivery with the corresponding consequences. In the form of e connect. monitor, ENGEL offers a solution for analysing the condition of critical machine components. Maintenance can thus be planned with foresight and unanticipated downtime avoided. Following the successful introduction of two modules for monitoring plasticising screws and ball screws, ENGEL is now presenting further e-connect.monitor modules for condition monitoring of hydraulic pumps and hydraulic oil.
With the increasing networking of production systems and the systematic utilisation of machine data, Industry 4.0 opens up new opportunities for injection moulding companies through conditionbased, predictive maintenance. At K 2016, ENGEL presented the first two modules of the new e-connect.monitor condition monitoring solution: for monitoring plasticising screws and online monitoring of ball screws. The demand for these solutions has been growing steadily ever since. ENGEL is therefore successively expanding the number of machine components that can be monitored. In autumn 2018, ENGEL presented two new modules for continuous monitoring of hydraulic pumps and hydraulic oil.
Even experienced machine operators and maintenance personnel find it very difficult to assess the condition of an injection moulding machine during ongoing production. In order to avoid unplanned production downtime, wear-prone components are replaced at fixed intervals in some operations as a precautionary measure. In this way, unplanned plant downtime can be avoided, collateral damage to other components ruled out and the downtime necessary for the planned installation of spare parts minimised. However, this maintenance strategy means that parts subject to wear are replaced earlier than actually necessary, and thus too often. Rising maintenance costs and falling plant availability are the consequences.
The heart and blood of an injection molding machine Injection moulders commonly refer to the hydraulic pump as the heart and the hydraulic oil as the blood of a hydraulic injection moulding machine. This comparison with a living being is appropriate in that if the pump fails, the machine stops and that the machine can no longer offer 100 per cent performance with aged hydraulic oil. With increasing operating time, the water content and the particle concentration in the hydraulic oil increase. As hydraulic systems operate with very small gaps for high energy efficiency and
Injection moulding companies have three different strategies for monitoring hydraulic oil: no monitoring at all, manual or automatic oil control
e-connect.monitor enables predictive, condition-based maintenance with the aim of avoiding unplanned plant downtime and optimally leveraging the service life of critical machine components.
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Critical and warning limit Result Main pump: Critical condition
Result Auxiliary pump: Good condition Trend data
A wide variety of factors influence oil quality. As the hydraulic oil ages, the particulate content increases, especially in the range > 4 µ m, thus changing the oil properties.
precision, particles in the oil can lead to wear or failure of the hydraulic components. Such impurities cause up to 80 per cent of all failures in hydraulic systems. Friction of existing particles with the metal surfaces of components such as cylinders or valves releases increasing numbers of particles; the water in the oil also contributes to this. On evaporating, the microscopically small water vapour bubbles implode under the high pressure and cause pressure peaks which tear further particles off the surfaces. All told, the water causes a significant deterioration in the system's friction properties and also leads to corrosion. In addition to contamination by particles and water, chemical oil aging is a third factor that makes it necessary to regularly check the hydraulic oil. In chemical aging, oxidation processes decompose the basic components and additives and change the composition of the hydraulic oil. High oil temperatures accelerate this process.
Different oil monitoring strategies Injection moulding companies have three different strategies for monitoring hydraulic oil: no monitoring at all, manual or automatic oil control. The strategy of not carrying out any monitoring at all means that a check only occurs if there is a problem. This often results in increased, highly advanced wear. The majority of companies carry out manual checks. Oil samples are regularly sent to a laboratory. Depending on the result, the processor then filters the oil manually or replaces it completely. The third strategy, automatic oil maintenance, involves stationary filter systems keeping particle contamination, and thus wear, low. Automatic filtering can slow down the chemical aging of the oil, but not completely prevent it, so that the oil needs to be changed at certain intervals, even with this strategy. What all established strategies have in common, however, is the lack of transparency in terms of oil quality. On top of this, none of the three strategies supports the goal of optimally leveraging the service life of the oil. Either the oil remains in the system for too long, which can lead to damage and even a breakdown of the machine, or the oil is changed at too short an interval, and thus too often, as a precaution.
Thanks to special sensors in the oil circuit, ENGEL now supports online monitoring of the hydraulic oil quality. The benefits of permanent oil monitoring: there is no longer any need for manual and time-consuming oil checks, the user receives recommendations on filtration time and duration and, in addition, the injection moulder is able to precisely plan the oil change based on the predicted condition. Monitoring the oil quality also ensures early detection of critical conditions and thus averts damage and unplanned failures. The relevant measurement data is recorded during ongoing production without negatively affecting it. The data is transmitted to ENGEL via a secure data connection, and automatically evaluated and interpreted there using specially developed mathematical models. The results are immediately visible on the ENGEL customer portal e-connect where they are displayed in a clear-cut view. If desired, the system can automatically send notifications or warnings.
Monitoring of fixed displacement pumps Not only the hydraulic oil can now be monitored using e-connect. monitor, but also the fixed displacement pumps in servohydraulic injection moulding machines. As a rule, and unfortunately, plastics processors only notice a critical pump condition when the machine cycle changes significantly or – in the worst case – when the machine fails. The pump – the heart of the machine – is a part subject to wear; it reaches its end of life after a certain time, depending on the load spectrum. Over the service life of the pump, its efficiency decreases continuously due to wear and tear; energy consumption increases as a result. ENGEL therefore began at an early stage to build up its own in-house pump expertise. Pump test beds and monitoring of various pumps in ongoing production provide the data from which the ENGEL experts model the algorithms that precisely and conveniently show the customer the condition of their pump. With the help of e-connect.monitor, the pump data is automatically recorded and analysed without affecting the production process. The results are not only intended as information, but instead to give the user a basis for deciding whether or not they want to replace the pump and, if so, when. For this reason, e-connect does not simply display the measured value, but an easily understandable wear value.
Outlook The e-connect.monitor condition monitoring solution by ENGEL, now consisting of four modules, is currently the only system on the market that allows condition-based and predictive maintenance of injection moulding machine components. As a first step, the two new modules for monitoring hydraulic oil and pumps will be offered for injection moulding machines of the current CC300 control generation. Retrofit solutions for older control generations are in preparation. www.engelglobal.com
The condition of the hydraulic oil and the pumps (shown in the screenshot) is clearly displayed on the ENGEL e-connect customer portal. The system can automatically send status messages and warning messages.
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INDUSTRY
3D dreams
EVs in the force
Dubai has seen numerous 3D printing innovations pop up over the past few years, and now the city is set to get a new 3D manufacturing hub. Gulf Business reports that Dubai-based Jumbo Group is launching a new application development centre for additive manufacturing technology, investing in HP 3D printing solutions and other technologies for dental, architecture and other applications for the new facility. Based in Jebel Ali Industrial Area, the facility will offer customers a range of training and service options including consulting for young entrepreneurs, proof of concept development, financing options and product design assistance. Jumbo has said it will be expanding its range of additive manufacturing technology to include the very latest in colour, concrete and metal in the coming months.
Dubai Police is investing in the environment and the future of automotive by announcing its latest arrival on four wheels: the Chevrolet Bolt EV. The Bolt is the latest electric vehicle to join the fleet, with the first eight units patrolling the roads as of November. With an impressive lineup of hybrid and electric vehicles in the police force already, the Chevrolet Bolt EV offers long-range practicality of up to 520 km on a single charge. “This partnership with Chevrolet is part of our ongoing commitment to better serve the citizens and residents of Dubai while also leading the way in Dubai’s green initiative,” said Brigadier Dr Muhammad Nasser Al Razooqi, Director of Transport and Rescue. “The addition of eight Chevrolet Bolt EV cars to our Dubai Police electric fleet will make a big impact in our mission to raise awareness around the benefits of electrification within the Emirate.” The Chevrolet Bolt EV brings together a long history of automotive manufacturing with green technology, falling in-line with the Dubai Police’s own goals for sustainability as well as excellence.
www.jumbogroup.com
www.dubaipolice.gov.ae
Economic engine
Optimism in Iran
Member of the Iranian Parliament Mohammed Reza Kouchi has said the petrochemicals industry remains the engine of Iran’s economy. He noted that decision-makers in Tehran should be supporting the development of the Iranian petrochemicals industry as an “economic driver”. Kouchi
The VDMA, the German plastics and rubber machinery manufacturers’ association, has reported that it remains optimistic about business with Iran despite a challenging first half of 2018. Last year, the export balance for German plastics and rubber machinery manufacturers was positive. Whether this trend will continue remains to be seen. In 2017, global export deliveries of plastics and rubber machinery to Iran had a total value of €206 million. China held the largest share with €99 million, while Germany came in second with €38 million in exports to Iran. In the first half of 2018, the German plastics and rubber machinery industry exported to Iran machines valued at €22 million - a downturn of 11 per cent compared to the first six months of 2017. Consequently, in the ranking of major export destinations for Germany, Iran falls from 25th to 28th place. kug.vdma.org
said that petrochemicals companies could bring the greatest revenues to the country and that the balanced development of the industry and the production of end-user items could lead to the generation of more valueadded products in the domestic market. Kouchi’s colleague Fereydoon Hassanvand added that the availability of skilled labour in Iran is one major advantage of developing petrochemicals projects in the country, noting that the pertochemicals route would be the easiest way to boost Iran’s economic progress. www.iranplast.ir
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INDUSTRY
What goes around
EV investment
Saudi Arabia’s plastics pipes and fittings industry is set to be worth $640 million by 2022, according to Ken Research. Changes in consumer preference towards high quality plastic pipes are having a major impact on the sector, driven by manufacturers’ efforts to produce plastic pipes in a range of materials and sizes optimised for various different applications. Moreover, Saudi Arabia is braced for greater demand for new homes, as the population’s rising income due to recovering oil prices means modern dwellings, with more properties needed for flourishing urban areas. Construction of affordable housing is anticipated to increase as the government aims to grow the number of Saudi Arabian homeowners from 47 per cent of the population in 2016, to 52 per cent by 2020.
Saudi Arabia has shown its interest in the growing electric vehicle (EV) market, with the Kingdom’s Public Investment Fund (PIF) agreeing to invest more than £1.3 billion in Lucid Motors. Reuters reported that this financial boost for the California-headquartered company puts it in competition with Tesla and will enable Lucid to achieve the commercial launch of its Lucid Air vehicle 2020. Lucid is competing with numerous other carmakers including BMW and Audi in its efforts to gain market share in the luxury EV space. Lucid Chief Technology Officer Peter Rawlinson was quoted by Reuters as saying: “It’s all the capital we need for three things: to continue the development of the car, to construct the factory in Arizona, and to initiate the rollout of our global retail strategy and that will commence in the US because that’s our first market.” Founded in 2007, Lucid Motors was established by former Tesla Vice-President Bernard Tse.
www.kenresearch.com
lucidmotors.com
Overseas interest
PlastPrintPack potential PlastPrintPack Nigeria, which took place in Lagos in March 2018, grew by 30 per cent to 142 exhibitors, proving the North African marketplace is hungry for packaging and plastics processing technology. Exhibitors represented 21 countries and were visited by 1,554 delegates from 26 countries – 81 per cent of them decision-makers. Of visitors, 97 per cent were Nigeria, while the remaining three per cent were from other parts of West Africa, all of whom were there to establish new business contacts, learn about the latest industry innovation and attend the accompanying conference programme. Exhibitor Mohamed Ikar, Sales Manager at Kautex Maschinenbau, said: “Nigeria is one of the major markets in Africa with a big potential for growth in near future – especially in agrobusiness. Therefore we as Kautex Maschinenbau GmbH are dedicated to be part of this growth and support our old and new customers in providing solutions for the extrusion blow moulding systems and services.” www.ppp-nigeria.com
Foreign investment in Oman reached 9.7 billion rial ($25 billion) in the second quarter of 2018, which is 1.4 billion more than the same period in 2017. The National Center for Statistics and Information (NCIS) data finds the UK is still the largest source of foreign direct investment (FDI) in Oman, reaching 4.7 billion rial at the end of the April-June period, compared to 3.7 billion rial over the same period in 2017. After the UK, the UAE and Kuwait were the next largest sources of FDI, bringing in one billion rial and 425.9 million rial respectively. Oil and gas in Oman accounted for the country’s bulk of FDI, reaching 55 billion rial in Q2, while FDI in manufacturing hit 1.07 billion rial. www.ncsi.gov.om
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Photos: istock
an Pavilion! m r e G e h t 9 in abplast 201 r A t a s u it Vis
all 5C100 Booth Nr. H
Multi-layer thermoforming sheet extrusion – leading solutions for food packaging • 15 – 20 % energy savings compared to traditional systems • Excellent melt quality • Trouble-free processing of high regrind amounts • Lowest sheet tolerances • High cooling efficiency by adjustable post cooling
Multi-layer extrusion line with five high-speed extruders & vertical roll stack
• Intuitive control system
www.youtube.com/BattenfeldCincinnati www.battenfeld-cincinnati.com
INNOVATIVE USE OF PLASTICS
INNOVATIVE INNOVATIVE USE OF PLASTICS USE OF PLASTICS
Glass Reinforced XIRAN ™ SGH30EB in Composite Guide Rails for Roller-Blind Sunroof Module
Glass Reinforced XIRAN™ SGH30EB Glass Reinforced XIRAN™ SGH30EB in Composite Guide Rails for Roller-Blind in CompositeSunroof Guide Rails Module for Roller-Blind Sunroof Module
www.polyscope.eu
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What’s the outlook for ArabPlast 2019?
ArabPlast 2019 is due to take place in Dubai in January, but what economic conditions will form the backdrop to this essential meeting place for the Middle Eastern plastics industry? WORDS | Rose Brooke
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rabPlast is arguably the most important plastics and rubber industry event in the Middle East and it comes at an important time for the GCC region, which is bolstering its non-oil economies by investing more in Dubai was founded manufacturing and technology.
on trade, not oil
Markit Economics reports that the UAE’s nonoil private sector improved at its fastest rate in May 2018, with the economy experiencing sharp growth both in terms of output and new orders driving expansion. Moreover, new export business hit a 30-month high along with reports of strong demand from neighbouring GCC countries. Businesses have responded very well to such robust market conditions, and new project wins, reporting their highest confidence levels since the beginning of 2012. Commenting on this positive data, Head of MENA Research at Emirates NBD said: “The strong PMI reading in May was partly due to a rebound in export orders - reflecting improved external demand conditions - as well as significant price discounting domestically.”
Ripe for export This ripe environment for export is why ArabPlast 2019 is so well positioned, identifying itself as a much more international affair than in previous years, not least because of the fast-approaching Expo 2020 which will take place in Dubai celebrating the very pinnacle of human ingenuity. This spectacle will be the jewel in the crown for the Emirate, which thanks to its forward-thinking and outward looking leadership, is
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playing a much greater role on the world stage than its GCC counterparts, particularly when showcasing the region’s architecture, medical sector and commitment to innovation. Indeed, in the words of Sheikh Mohammed bin Rashid Al Maktoum himself, Dubai was originally founded on trade, not oil. As such, at Arabplast 2017, some 972 exhibitors and 19,080 visitors from 39 countries demonstrated the potential for plastics and rubber processing technology in the UAE and wider Middle East. The theme that echoed feelings about plastics and rubber processing in Europe and North America the most was sustainability, which is a topic visitors can expect to hear a lot about at the next edition of the show. Recycling machinery such as the FF Drawer Gate Magnet technology brought to the event by Bunting played a pivotal role on the show floor, as did machinery that is energy efficient such as the Allrounder Golden Electric from Arburg, and the WM Thermoforming Twist 500 tilting concept. On the materials side, packaging and agriculture loomed large, with A. Schulman and NATPET highlighting their Polyfort and Polyflam PP joint venture, while Milliken shone the spotlight on its technology-leading clarifiers and nucleators for PP resin, and Borouge hosted thought-leadership sessions on advanced materials solutions for packaging, agriculture and energy.
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Petrochemical power
ARABPLAST FACTS
The non-oil economy may be thriving, but the petrochemicals market is still a strong one for the UAE. The Gulf states account for 11 per cent of the world’s $600 billion petrochemicals industry and over the next five years, the GCC market share of this enormous pie will expand to 17 per cent. Indeed, the GCC region is set to become the world’s largest source of polyethylene and polypropylene. In addition, by 2020 demand for plastics in the GCC is anticipated to grow by eight per cent. Dubai will never
settle for anything less than first place
In 2017, impatience for growth was already palpable at the last edition of ArabPlast – which took place under the banner ‘together we innovate’. ICIS reported that the GCC and Iran exported 19.83 million tons of polyolefins to the world market in the year to January 1st 2017, and in the following year these exports grew to 20.59 million tonnes, with over seven million tonnes going to North East Asia and 4.5 million tonnes going to the rest of Asia, and 5.4 million tonnes heading for Europe.
• 13TH EDITION IN 2019 • 9 HALLS • OPEN FROM 10.00-18.00 • 28 YEARS IN THE MAKING • 40> PARTICIPATING COUNTRIES • 27,000> VISITORS • 12>% INCREASED EXHIBITION SIZE • 16 COUNTRY PAVILIONS
There are lots of reasons why ArabPlast 2019 will be a show to remember – and arguably one of the most effective places to expose yourself to the best cross-section of the Middle Eastern plastics processing marketplace. The event continues to thrive, with all the big injection moulding and downstream players present to showcase the innovations that are driving growth in the Middle East, in terms of infrastructure, consumer convenience, transport and healthcare. The show truly lives up to the words of Sheik Mohammed: “Dubai will never settle for anything less than first place.” www.arabplast.info
ARE YO U AN ARA B EXHIBI PLAST TOR? If you a re
exhibitin g at email us your sh ArabPlast then ow pre www.mid eastplas view for t.com. Write to G r a c eN grace.no lan@rap olan at with a s uitable im idnews.com age (not and we a logo) will pub lish your sto ry onlin e.
Credit: Dubai World Trade Centre
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Market on the ascent Plastics is one of Turkey’s most consistent and rapidly-growing industries and the best of the world’s sixth-largest plastics processing market will be on show in Istanbul at the 28th Plast Eurasia.
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last Eurasia 2018, the 28th international plastics industry fair, will take place from December 5th – 8th 2018 showcasing a plastics industry star on the rise.
Plast Eurasia Istanbul Fair offers high quality and excellent value, competing with the extremely high standards in Europe
Turkey is one of the fastest-growing markets in the world and its strategic location in the heart of Turkey, bridging Europe and the Middle East, makes it the perfect place to explore new markets and strengthen your brand.
The plastics industry is one of the fastest and most consistently growing industries of Turkish economy. Plast Eurasia Istanbul Fair offers high quality and excellent value, competing with the extremely high standards in Europe in order to run alongside the mature market there. Within the scope of the fair, the latest technologies and innovations about plastics machinery, chemicals, raw materials, machinery auxiliary industry, heat and control equipment, mould, hydraulic and pneumatic machinery, and recycling will be on show.
Representing the world Last year’s outing brought together 1,087 companies and company representatives from 43 countries and 53,919 professional visitors from 101 countries. In addition, Plast Eurasia hosted procurement committees from 31 countries including Algeria, Azerbaijan, Belarus, Benin, Bosnia Herzegovina, Bulgaria, Egypt, Georgia, Greece, India, Iran, Iraq, Israel, Jordan, Kosovo, Lebanon, Libya, Macedonia, Moldova, Morocco, Oman, Palestine, Romagna, Russia, Saudi Arabia, Serbia, Slovenia, Sudan, Syria, Ukraine and
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Uzbekistan. Visitors came mostly from Iran, Algeria, Bulgaria, Ukraine, Iraq, Russia, Tunisia, Serbia, Saudi Arabia, Greece. By industry, visitors represented: plastics, packaging, raw materials, machinery, chemicals, automotive, moulding, recycling and more and according to visitor survey results 97 per cent of the visitors recommend the fair to their colleagues and 42 per cent of the visitors stated that they established new connections at the fair.
6th largest In 2017, the Turkish plastics industry produced 9.6 million tons and $36.8 billion of plastic products and compounds, making Turkey the sixthlargest plastics producer in the world and the second-largest in Europe second only to Germany.
In 2017, the Turkish plastics industry produced 9.6 million tons and $36.8 billion of plastic products and compounds
Plast Eurasia, thanks to its long history, is considered a high-value industry event all over the world and organiser Tüyap is preparing to bring together more than 1,100 qualified participants and over 60,000 professional visitors to the Tüyap Fair Convention and Congress Center this year.
Organised annually in cooperation with PAGEV (the Turkish Plastics Industry Foundation), Plast Eurasia will take place from December 5th-8th, 2018, and visitors can attend free by following the online invitation links on the website.
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www.plasteurasia.com
medtech | digital healthtech | medical plastics manufacturing | software | inspection and metrology regulation | design | early stage innovations pharmaceutical manufacturing
MED-TECH INNOVATION
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2019
MAY