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A S l A ’ S L E A D l N G m aga z l ne f o r t h e p las t l c s and r u b b e r l nd u s t r y
In this issue
Volume 37, No 263
publlshed slnce 1985
A S l A’ S L E A D l N G maga z l ne f o r the plastlcs and rubber lndustry
Features 10 Country Focus – China's carbon neutrality goals represent a pivotal point
in its economic development agenda, with its push to use hydrogen energy a major strategy in this 14 Blow Moulding – US-based manufacturer of IBMs, Jomar Corp features its IntelliDrive 855 IBM machine with improved energy use; Cypet Technologies, meanwhile, using its ISBM experience for large PET containers has extended its technology to stretch-blow-mould 1,000 l IBC containers from PET 16 Compounding – Coperion China has installed three Smart compounding lines for the production of PP and PA for Nanjing Julong Science & Technology Co 17 Packaging – With modern film designs becoming increasingly complex, ExxonMobil offers a new Exceed S performance PE to reduce the complexity of film formulations and designs, while improving film performance, conversion efficiency, and packaging durability versus current market references
20 Country Focus – While the last two years have taken a toll on most
economies around the world, with the opening of the borders as Covid-19 reaches an endemic stage, countries like Malaysia, the Philippines and Vietnam are expected to make an impact in the regional plastics sector
Publisher/Editor-in-Chief Arthur Schavemaker Tel: +31 547 275005 Email: arthur@kenter.nl Associate Publisher/Executive Editor Tej Fernandez Tel: +60 3 4260 4575 Email: tej@plasticsandrubberasia.com Senior Editor Angelica Buan Email: gel@plasticsandrubberasia.com Circulation Stephanie Yuen
Regulars
Email: stephanie@taramedia.com.my
2 Industry News 6 Materials News
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Supplements
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ISSN 1360-1245
According to Global Market Insights, robust automobile demand in APAC and Middle East regions and an increasing acceptance of electric mobility will influence automotive plastics demand Medical plastics allow healthcare devices and products to combine patient benefit and safety while also meeting the industry's sustainability goals TPEs are driving brands’ sustainable goals, with materials suppliers such as Avient, Teknor Apex and United Soft Plastics launching biobased TPEs Automation in Industry 5.0 is paired with human ingenuity to unlock the key to increasing manufacturing efficiency and sustainability Even with the Covid-19 pandemic, the 3D printing/additive manufacturing sector has expanded, with new materials/ technologies coming to the fore In response to a rising trend for safe and environmentally friendly transportation, more tyre makers are jumping on board the airless tyre market bandwagon PRINT/DIGITAL
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A S l A’ S L E A D l N G m A G A z l N E f o r thE pLAStlcS AND rubbEr lNDuStry
On the Cover The medical sector is increasingly veering towards a healthy environment with sustainable concepts, while maintaining the performance of devices
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United Mission Press Sdn Bhd (Co. No: 755329-X) 25 & 27, Jalan PBS 14/14, Taman Perindustrian Bukit Serdang, 43300 Selangor, Malaysia. is published 4 (four) times a year in English by Kenter & Co Publishers’ Representatives BV. Whilst every effort is made to ensure that the information contained in this publication is correct, the publisher makes no warranty, expressed or implied, as to the nature or accuracy of such material to the extent permitted by applicable law. © 2021 Kenter & Co Publishers’ Representatives BV No part of this publication may be reproduced, stored or used in any form, or by any means, without specific prior permission from the publisher. PRA is circulated free to trade readers in the plastics and rubber industry. Airmail subscriptions are available at US$160 within Asia and US$250 to all other countries outside Asia.
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APRIL 2022
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Industry News
M&As/Tie-ups/Investments •
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Texas-headquartered Ascend Performance Materials has acquired Formulated Polymers, an engineered materials manufacturer in Chennai, India. It includes a world-scale manufacturing facility as well as several warehouses throughout India. Ascend has also signed an investment agreement to construct a new HMD and specialty chemicals plant in Lianyungang, China. It will be Ascend’s first chemical production facility and the largest investment the company has made outside of the US. Mexico’s Alpek S.A.B. de C.V. is to acquire Oman-based Octal Holding for US$620 million. The acquisition adds over 1 million tonnes of installed capacity of PET, spread across four sites, to Alpek’s existing footprint. Germany’s Alpla Group has become one of the largest PET recycling companies in Germany, with the acquisition of recycling company Texplast from the FROMM Group and all of its shares in the joint venture PET Recycling Team Wolfen. It will increase its processing volume in Germany to 75,000 tonnes/year of PET bottles. French automotive parts maker Faurecia has completed its APRIL 2022
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acquisition of a controlling stake in lighting supplier Hella in a US$6 billion deal that is said to be one of the biggest in the European parts industry in the past three years. •
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To support expansion in solutions for civil construction and water treatment, US private equity firm Advent International has taken up a 25% stake investment worth around US$260 million in Grupo Tigre, a Brazilian specialist in solutions for civil construction and water treatment. Germany’s Evonik Venture Capital has invested in CircumFix Solutions, a US-based start-up that has developed a new sternal closure device to improve patient recovery after open chest surgery. Flexible packaging maker ProAmpac, which is owned by private equity firm Pritzker Private Capital, has acquired Belle-Pak Packaging, a Canadian manufacturer of flexible packaging products. Solvay Ventures, the venture capital fund of Solvay, is investing in Zurich-based startup 9T Labs to bring additive manufacturing of carbon fibrereinforced plastic (CFRP) parts to mass production.
Swiss adhesives provider H.B. Fuller Company has acquired Belgium-based Fourny, a provider of construction adhesives. The acquisition includes one factory and R&D centre based in Belgium. In other news, H.B. Fuller has finalised its purchase of Apollo, UK’s largest independent manufacturer of liquid adhesives, coatings and primers for the roofing, industrial and construction markets.
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US private equity firm Apollo Funds is to acquire Novolex Holdings, a manufacturer of diverse packaging products for the foodservice, delivery and carryout, food processor and industrial markets, from funds managed by Carlyle.
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German fund company Bregal Unternehmerkapital (BU) has sold Swiss firm ATP Group, a manufacturer of water-based adhesive tapes, to private equity firm Arsenal Capital Partners.
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Compounding firm Ensinger has acquired the StyLight thermoplastic composite materials business of Ineos Styrolution.
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Brazil’s Braskem, the largest polyolefins producer in the Americas, has invested in Nexus Circular, a
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Vertellus, a manufacturer of specialty materials has acquired Polyscope Polymers, a Dutch supplier of specialty additives for coatings, electronics applications and engineering polymers.
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SK Geo Centric, a subsidiary of SK Innovation, has made an equity investment of US$55 million in PureCycle Technologies, an American plastic waste recycling company. PureCycle will also open Asia's first recycled PP plant in Ulsan, South Korea, with a capacity of 60,000 tonnes/year and completion at the end of 2024.
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US-based Ineos Group company WL Plastics Corporation has completed the acquisition of PE pipe extrusion assets of Charter Plastics located in Titusville, Pennsylvania, US.
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Arxada, a global specialty chemicals business, has completed the merger with Troy Corporation. Troy specialises in industrial preservation with broad expertise in paints and coatings, wood protection and preservation, home and personal care, plastics and textiles, energy and metal working fluids.
INDUSTRY NEWS •
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Danish rigid food packaging supplier Faerch, which is a part of the A.P. Moller Group, has acquired Germany-based dairy packaging firm Paccor Packaging for an undisclosed sum, from its current owner, New York-based investment firm Lindsay Goldberg, which acquired Coveris Rigid in August 2018 and renamed it Paccor. Swedish chemical firm Perstorp has acquired GEO’s di-Methylolpropionic acid [DMPA] business, further emphasising its commitment as the sustainable specialty solution provider within the resins and coatings segment. Producer of pigments Heubach Group and private investment firm SK Capital Partners have completed the acquisition of Swiss speciality chemicals firm Clariant’s Global Colorants Business. Thailand-headquartered speciality chemicals firm Indorama Ventures Public Company Limited (IVL) is acquiring shares in Ngoc Nghia Industry, a PET converter in Vietnam. It has four manufacturing sites in Vietnam and a production capacity of 5.5 billion units of PET preforms, bottles and closures, or equivalent to a PET conversion of 76,000 tonnes/year. IVL has also tied up with biotech firm
Carbios to build a 50,000 tonne/yearmanufacturing plant operating Carbios’ PET bio-recycling technology at its PET production site in France. •
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Biopolymer firm TerraVerdae Bioworks is acquiring 100% of the equity of PolyFerm Canada, which has a technology portfolio of biobased and biodegradable elastomeric polymers. North American packaging firm TricorBraun has acquired beverage packaging firms Zuckerman Honickman and Vessel Packaging, strengthening the company's position in the beverage packaging market
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Compound maker The Compound Company has acquired the production site, product portfolio and customer base for Exxelor polymer resins from Esso Deutschland, ExxonMobil in Cologne, Germany.
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French speciality chemicals firm Arkema has finalised the acquisition of Ashland’s Performance Adhesives business, which supplies high performance adhesives in the US and is a wholly-owned subsidiary of Ashland Global Holdings.
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Swedish familycontrolled investment company Nordstjernan’s whollyowned subsidiary Rosti has acquired 100% of the shares in US company Plastic Components Inc (PCI), which produces engineered parts for the medical, plumbing, pool and aquatics, small engine and automotive markets. US speciality chemicals firm Element Solutions has acquired HSO Herbert Schmidt, a privatelyheld, multi-national developer of surface finishing technology and chemistry headquartered in Solingen, Germany.
US-based firm 8 Rivers Capital, which offers net-zero solutions for decarbonisation, has raised US$100 million from SK Group, along with the launch of a joint venture with the investor to deploy zero-emissions projects in Asia. In other news, the construction subsidiary of SK Group, SK ecoplant, has made a 100% acquisition of Singapore-based electronics waste management solution provider TES Envirocorp for US$1 billion from Navis Capital Partners.
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Sweden’s Hexpol is to acquire 70% of the shares in almaak international for EUR70 million from existing owners Olaf Eichstädt and Thomas Schmeinta. almaak is a specialist in recycled engineered polymer compounds based in Germany catering to the European automotive industry.
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Chemical firm Arkema is expanding its offer of engineering adhesives with the acquisition of Shanghai Zhiguan Polymer Materials (PMP), specialised in reactive hot-melt polyurethane (HMPUR) adhesives for the consumer electronics market. Arkema will also increase its global manufacturing capacity for Pebax elastomers by approximately 25% through an investment at its French plant.
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Mitsubishi Chemical Corporation (MCC) has transferred all MCC group's shares of Lucite International Japan to Tokyo-based Midorikawa Chemical Industry.
New Plants/Capacity Expansions •
US-based materials firm Eastman Chemical Co. will invest in a US$1 billion-molecular recycling facility for waste plastics in France, to recycle up
to 160,000 tonnes/ year of hard-to-recycle plastic waste. Eastman also plans to establish an innovation centre for molecular recycling, both to be operational by 2025. APRIL 2022
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Industry News
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Recycling firm Agilyx and Toyo Styrene Co, an affiliate of Denka Company, Nippon Steel Chemical & Material Co and Daicel Co, are entering into the construction phase of a 10-tonne/day chemical recycling facility in Japan, enabled by Agilyx depolymerisation technology. South Korea’s LG Chem is to use Mura Technology's advanced recycling technology to set up a plant in the country. LG Chem has also made an equity investment in Mura and purchased a process license from KBR, Mura’s exclusive global licensing partner. US technology firm Honeywell has formed a joint venture with Avangard Innovative to build a 30,000 tonne/ year-recycling plant in Texas, US. The facility will use Honeywell's UpCycle process technology to transform end-of-life plastic waste into recycled polymer feedstock that can be used to create new plastics. Polyolefins maker Borouge, a joint venture of Abu Dhabi National Oil Company and Austrian chemicals producer Borealis, has started construction of its fourth facility, the US$6.2 billion Borouge 4, within the polyolefin manufacturing complex in Ruwais, UAE. It is scheduled to be APRIL 2022
completed in 2025. •
Mitsui Chemicals is expanding its production facilities for meltblown nonwovens at its wholly-owned subsidiary Sunrex Industry Co.
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Sweden’s Nexam Chemical is investing SEK20 million in a new production line at its facility in Lomma, Skåne.
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Japanese compatriots Denka Company and Toyo Styrene are to construct a US$33 million chemical recycling plant for PS with a processing capacity of 3,000 tonnes/year on the premises of Denka’s Chiba Plant.
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In Germany, BASF has opened a new laboratory building for the development of automotive refinish coatings and innovations beyond paint at its site in Münster.
German chemical company BASF will increase production capacity for its hindered amine light stabilisers (HALS) at sites located in Pontecchio Marconi, Italy, and Lampertheim, Germany. BASF is also building a new hexamethylene diamine (HMD) plant in Chalampé, France, to increase capacity to 260,000 tonnes/year, by 2024. Furthermore, BASF will expand its PA6.6 production in Freiburg, Germany, starting 2022. Also, BASF (Malaysia) Sdn Bhd will expand the production capacity of its Ultramid PA and Ultradur PBT production by 5,000 tonnes/year in Pasir Gudang, Malaysia.
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India’s Bharat Petroleum Corporation Limited (BPCL) has set up a 200-tonne/ year superabsorbent polymer technology (SAP) demonstration plant at its Kochi Refinery, produced using the company’s in-house acrylic acid as feedstock. This pilot plant will be followed by the setting up of a commercial plant of 50,000 tonne/yearcapacity.
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US-based materials firm ExxonMobil and Sabic have started up their Gulf Coast Growth Ventures world-scale manufacturing facility in San Patricio County, Texas. The operation includes a 1.8 million tonnes/year ethane steam cracker, two PE units capable of producing up to 1.3 million tonnes/year, and a monoethylene glycol (MEG) unit with a capacity of 1.1 million tonnes/year.
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DuPont’s DuPont Interconnect Solutions, a business within the Electronics & Industrial segment, has completed the expansion project at its Ohio manufacturing site. The US$250 million investment
expands production of Kapton polyimide film and Pyralux flexible circuit materials. •
Materials firm Trinseo is planning a world-class chemical recycling plant in Europe together with technology provider Synova and engineering services company Worley. To start construction by the end of 2022, the plant will cater to 15 kilotonnes/year of recycled polystyrene (rPS) that will be converted into recycled styrene to enable further production PS and/or a styrene derivatives like ABS and SAN.
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Chemical firm PPG will invest over US$10 million to expand production of automotive OEM coatings at its site in Weingarten, Germany.
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German PMMA maker Röhm is investing a doubledigit million amount in the expansion of a production plant for Plexiglas compounds in Shanghai, China. Last year, Röhm had announced the expansion of a production plant for Plexiglas moulding compounds in Worms (Germany).
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Styrenics maker Ineos Styrolution has started up its 50,000 tonne/ year-ABS production in Wingles, France, having completed
INDUSTRY NEWS the conversion of an existing PS line to the production of ABS. •
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Chemical firm Solvay is further extending its position in the lithium-ion battery market by expanding its production capacity of Solef polyvinylidene fluoride (PVDF) at its site in Tavaux, France, to 35 kilotonnes. Sumitomo Chemical is building additional production lines for its liquid crystal polymer (LCP) Sumikasuper, which is a super engineering plastic, at its Ehime Works in Japan. This expansion will increase the group’s production capacity by approximately 30% by 2023.
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Kaneka Corporation will increase production capacity for Kaneka biodegradable polymer Green Planet, with an additional 15,000 tonnes/year production of PHA to its current 5,000 tonnes/year. Teijin Automotive Technologies, the core company of the Teijin Group's automotive composites business, has begun commercial operation of a new composites manufacturing facility in Changzhou, China. The company is also constructing a third plant in China, and will begin operating this plant, with 13,000 sq m of work floor in 2023.
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Solvay is expanding its US-based sulphone business, including a capacity increase for Udel PSU of over 25% by 2024 at the company’s production site in Ohio. Likewise, production capacity for DCDPS, a common building block used in all sulphone polymers, will also be expanded by more than 25%. India’s Supreme Petrochem is to expand its EPS plant at Nagothane, Maharashtra by 30,000 tonnes/year. A secondline with a capacity of 1 million sq m and masterbatch and compounds capacity has also been increased by 50,000 tonnes/year.
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German materials firm Covestro has started up two PC compounding production lines at its plant in New Delhi, India.
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US-based performance chemical supplier SI Group has expanded capacity to make phenolic ester antioxidants at its factory in Jinzhou, China. The chemicals are used in lubricants and plastics.
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Austrian integrated oil, gas and chemicals company OMV and Alba Recycling, are looking to jointly build and operate a sorting plant in Walldürn, Germany. A final investment decision is expected in 2022.
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24.03.2022 13:15:38
Materials News
Novel ways to reclaim Asia’s “waste” opportunities Innovations such as refillable solutions to sachets and waste barrier technology to collect plastic waste from rivers are shaping circular goals in Indonesia, which is said to be one of Asia’s largest polluters, according to Angelica Buan in this article. Plastics are “canceledt“ The Covid-19 pandemic has not only halted economic activity, but it has also stalled discussions on major issues such as climate change and waste pollution. Plastics got the break they deserved, morphing from a major polluter to a life-saving material for product packaging, personal protective equipment (PPEs), and single-use medical devices due to their versatility, light weight, sterility, and low cost, particularly in mass production. However, as pandemic restrictions began to ease around the world, calls to phase out plastics resurfaced. This is not due to a prevalent "canceledt" culture, but to statistics indicating that the environment is already overburdened with plastic waste. Every year, the world generates over 2 billion tonnes of waste, with 33% of that waste being improperly managed. Currently, only 9% of waste is recycled, which could lead to a waste increase of 3.4 billion tonnes by 2050. According to World Bank data, high-income countries account for 34% to 683 million tonnes of total global waste, while East Asia and Pacific region and South Asia are expected to generate 602 million tonnes/year and 466 million tonnes/year by 2030, respectively, and rising annually to 18.6% and 41.8%, respectively, by 2050.
Asia has become a crisis zone for plastic pollution, with East Asia/Pacific and South Asia regions expected to generate 602 million tonnes/year and 466 million tonnes/ year by 2030
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APRIL 2022
Asia, as a consequence of urbanisation and economic growth, has become a crisis zone for plastic pollution. Furthermore, its waste disposal infrastructure has struggled to cope with the growing waste in the region. Overconsumption of plastic has amplified the current waste management situation, which has caused landfills to overflow, rivers to become clogged, and marine ecosystems to be jeopardised. On the other hand, this jarring situation has prompted markets to explore other plastic material options and technologies that could minimise plastic pollution. Meanwhile, cooperation and alliances to reduce plastic waste have already been formed; watershed policies, such as the European Union's plastic tax on non- recycled plastic packaging and the US's push to achieve 100% recycling and reuse of plastic packaging by 2040; and the monumental UN Environmental Assembly (UNEA) resolution, which is expected to produce a "legally binding" treaty by 2024, are attempting to turn the tide of plastic pollution. Breaking away from sachets with refillable solutions According to the World Economic Forum, Indonesia generates around 6.8 million tonnes/year of plastic waste, a figure that is growing at a rate of 5% per year and could double by 2040 if no action is taken to prevent it. Alarmingly, much of the waste is mismanaged through open burning, landfilling, or depositing in uncontrolled dumpsites, with a significant portion of it leaking into waterways as a result. While plans have been laid out to increase collection and recycling – which is currently at around 10% – it is believed that innovative solutions can complement planned efforts to achieve a 40% recycling rate by 2040 and eliminate the consumption of more than 1 million tonnes of plastics/year by 2025 by significantly reducing the use of non-recyclable and unsafe degradable plastics and using more plastic-free alternatives. However, sachets, wrappers, and other single-use multi-material plastic packaging, while still popular among households and retail consumers, pose a problem for recyclers.
Materials News These packaging types have little or no value in the recycling market, and collecting those takes time. As a result, informal/private collection sectors and recyclers continue to focus on the highest-value materials, such as post-consumer PET bottles and rigid HDPE containers. Some businesses have stepped in to offer solutions for delivering products to consumers without the use of these packaging. Koinpack, a deposit and reward-based returnable and reusable packaging system provider from Zero Waste Living Lab (ZWLL), is a programme of Jakarta-based Enviu. The company claims to have replaced more than 50,600 sachets with its packaging so far. Original products supplied directly by the producer or distributor of products ranging from home-care to personal-care products are contained in the Koinpack packaging. The easy-to-clean, sterilise, and refill packaging allows for a 24-month shelf life and can be stored at 40°C. Koinpack's current bottle packaging can be reused up to 20 times before being recycled and made into a brand new bottle. The empty packaging can be returned to a partner outlet or picked up for a cash rebate. Siklus delivers personal care and home cleaning products in reusable packaging to customers' homes in mobile refill units
Koinpack, an Indonesian deposit and reward-based returnable and reusable packaging system provider, has replaced over 50,600 sachets with its packaging
Koinpack bottles must be durable enough to keep the product safe from contamination and spills while also being able to withstand repeated washings. For this reason, and to drive the transition from single-use sachets to reusables, Koinpack partnered with Austrian plastics manufacturer Alpla Group, which has provided Koinpack with 100 ml reusable PET bottles and PP fliptop caps. Siklus (Cycle) is another fast-growing company, collaborating with popular fast moving consumer goods (FCMG) brands such as P&G, Nestlé, Wings, Total Chemindo, Reickitt, Godrej, and Mars Petcare, and providing a similar refillable service to address the rising amount of used sachets in the environment.
Siklus, which was launched in 2019, uses apps and some social media platforms to reach customers and allow them to order products. It brings sachetfree personal care and home cleaning products to customers' homes in mobile refill units, where they can refill the products as much as they want using their own containers. Prices are said to be 5% to 40% lower than those in supermarkets and roadside stalls. Siklus is launching a pilot project in Labuan Bajo this year, tying up with the Indonesian Waste Platform (IWP) in its bid to reduce plastic waste in Indonesia's Rural & Remote Communities (RRC). IWP has pledged to assist Siklus in expanding its refill business to other rural areas in Maluku, Sumatera, NTT, Bali, Java, and Sulawesi. Waste collectors in Asia’s polluted rivers According to a 2018 study from the Helmholtz Centre for Environmental Research, Asia has eight of the top ten most polluted rivers, which carry between 88-99% of the plastic that ends up in the ocean. RiverRecycle, a Finnish start-up, aims to keep waste out of the oceans while also promoting the circular economy in communities. RiverRecycle, which was founded in 2019, is active in nine countries, with ongoing projects in the Philippines, Vietnam, Bangladesh, India, and Indonesia. RiverRecycle intends to install 500 river cleaning systems over the next five years, which are expected to collect approximately 3 million tonnes/year of plastic waste from rivers. APRIL 2022
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Materials News RiverRecycle's technology can catch 40-60% of riverborne floating plastic and debris before it reaches the sea. It gathers floating waste from rivers and concentrates it for easy removal. When possible, the collected waste is sorted into material types and sold for mechanical recycling, while organic waste is composted. The remaining low-value plastic waste that usually would be disposed of in landfills with the risk of spilling in the environment is employed in pyrolysis. The pyrolysis-derived oils are sold, with a portion of the proceeds going back into the hosting community to help keep the system running. Simple trash barriers to stem marine litter The ambition to prevent as much trash from entering the oceans as possible has led Sungai Watch, an Indonesian environmental organisation, to develop a simple technology to achieve this task. Founded in 2020, Sungai Watch deploys simple trash barriers and operating a collection, sorting and upcycling system. It is currently expanding its operations in Bali and Java, Indonesia (where an estimated 33,000 tonnes of plastic enter the rivers each year), as well as in Asia and Latin America. By 2023, Sungai Watch aims to install 1,000 barriers.
Sungai Watch deploys simple barriers that collect both organic and non-organic waste, sort and upcycle the waste
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APRIL 2022
The barriers collect both organic and non-organic waste, including bamboo, tree trumps, palm leaves, and coconuts, as well as glass, fabrics, metals, and up to 15 different types of plastics, including PET, HDPE, PP cups, plastic bags, single- use sachets, styrofoam, and other materials. To date, the group has organised 122 clean-ups, installed 105 trash barriers, collected 333,336 kg of nonorganic waste and 393,749 kg of organic waste, and audited 227,842 pieces of trash. The barriers are of various types: floaters, which come in two types: mini- floater (for smaller waterways of less than 5 m width) and the common floater consisting of multiple elements connected by two thick metal cables that wrap around a metal or concrete anchor on either side of the river. A floater can have up to 24 elements attached to it that can fit and safeguard a 20-m wide river. Each element is customisable by height and width to correspond to a river’s characteristics, Sungai Watch said. The main floating device is a PVC pipe, and a metal grid is attached beneath the PVC pipe. The metal grids of the floater and mini floater sit 30-40 cm below the surface of the water, catching the majority of the floating debris. Meanwhile, Sungai Watch's biggest current barrier is the walker, which is made up of multiple elements, each with four large blue drums serving as the floating mechanism. It has a large walking platform that allows the team to easily walk on top of it and manually access and remove trash. The main frame and front grid are made of metal and are connected by metal wires that secure the system to concrete, metal foundations, or large trees. The walker is designed for rivers that are too deep for the team to navigate without the use of a boat or vessel. During a clean-up, the team also classify plastic packaging by material and brand, allowing them to identify the companies most responsible for Bali's plastic pollution. The so-called 53% branded wastes are made up of approximately 550 parent companies and over 800 brands, with the remaining 47% made up of unbranded wastes that do not bear a visible brand logo. Meanwhile, recyclable plastics such as PET bottles, hard plastics (HDPE), metal (primarily aluminium), and Tetra-packs are sold to recyclers to meet the current demand for recycled materials. Most PET bottles in Indonesia are repurposed into yarn, and most PP cups are recycled into plastic sheets. Plastic bags and sachets with low to zero value are upcycled, while the organic waste collected by our barriers is converted into compost, which is a good way to repurpose and reuse plastic waste floating in the oceans.
Advertorial
KRAIBURG TPE develops next generation medical resealing compound for Asia Pacific
K
RAIBURG TPE, a global manufacturer of a diverse range of thermoplastic elastomer products and custom solutions for a variety of industries, is introducing its latest HC/RS/AP resealing series, under the ® THERMOLAST H range of TPE compounds for healthcare and medical resealing applications. Seals have a significant impact on the functionality of medical devices, as well as the condition of the substance delivered by the device, and the success of the treatment for which it is employed. Seals for medical, pharmaceutical, biotechnology and other life sciences applications are used to prevent contamination, leakages, and spillages. They must also exhibit good mechanical performance, chemical resistance, biocompatibility, and other capabilities. Finding the right material to fit the requirements of innovative designs, especially for medical device components such as resealing systems, is vital for optimizing functionality and performance. Hence, thermoplastic elastomers (TPEs), which offer many material advantages over traditional medical rubbers or plastics, are becoming increasingly popular in the medical and healthcare sectors. As the global competence leader in thermoplastic elastomer compounds, KRAIBURG TPE offers highquality, custom-engineered TPE compounds that match
the challenges of medical device designs, such as sealing applications. ® "By manufacturing the THERMOLAST H compounds in Malaysia, at our facility in Seri Kembangan, we will be able to provide our Asian customers a high-quality product with quick lead times. Coupled with application and technical support, and product customization, customers will be able to rely on us for their needs," commented Aditya Purandare, Project Manager of the Market Launch of ® THERMOLAST H Asia Pacific. Material solutions with seal of approval ® KRAIBURG TPE’s THERMOLAST H HC/RS/AP family of compounds boasts good adhesion to PP and PE, making it ideal for medical and healthcare resealing applications such caps, closures, membranes, and plugs. Furthermore, the series has a low density and can be sterilized by autoclave at 121°C and EtO, making it ideal for use on resealing caps for sample and test tubes, medical vial closures, as well as the membranes in disposable insulin syringes. Available in translucent color and various color options, the compounds are able to cater to the flexibility of innovative designs. The compounds are safe for use, complying with ISO10993-5 and GB/T 16886.5 (cytotoxicity) standards, as well as many worldwide food contact and medical standards, including China GB 4806 – 2016, US FDA CFR 21, Regulation (EU) No 10/2011, REACH, and RoHS, and resealing performance is tested according to the DIN ISO 15759. “Customers are assured of the ® THERMOLAST H product value. We are confident of delivering material solutions that meet the medical standards in Asia Pacific, all thanks to our dedicated market support and expert knowledge in TPE products,” says Lee Jia Yin, Product Specialist, KRAIBURG TPE. APRIL 2022
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Country Focus
State of play of China’s green energy China's carbon neutrality goals represent a pivotal point in its economic development agenda. Its push to use hydrogen energy is backed by major industry players, says Angelica Buan in this report.
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hina, the world's largest energy producer and tonnes, and triple to 90 tonnes by 2060. Given the rise of consumer, is also a significant carbon emitter, electric vehicles, the transportation sector may account accounting for one-third of global CO2 emissions. for the lion's share of hydrogen in final energy use. While It contributes roughly half of total global production as an increased use of hydrogen/hydrogen-derived fuels in the world's largest coal producer. Its reliance on nonroad freight, shipping, and aviation is projected. renewable energy to generate electricity and power its industries impacted the country's air quality. As Blueprint for green hydrogen a result, shifting to clean energy sources to achieve Hydrogen must be produced from low-carbon energy carbon neutrality aligns with China's wider sustainability sources in order to make a meaningful contribution to objectives. reducing carbon emissions. The only type of hydrogen that is produced in a climate-neutral manner is green The government has set targets to achieve peak carbon emissions before 2030 and carbon neutrality hydrogen. by 2060, as outlined in the 14th five-year plan, jointly China, already the world's largest producer and consumer of hydrogen, accounts for 20% of global released in March by the National Development and Reform Commission and the National Energy demand, according to S&P Global Commodity Insights. In 2020, 63.5% of China's hydrogen supply was Administration for the periods 2021-2025. It also plans generated through coal gasification, 21.2% through to source 20% of its total energy consumption from nonfossil fuels by 2025. While coal dominated the energy industrial processes such as refining, 13.8% via natural mix, accounting for 60% in 2020, its share has decreased. gas, and only 1.5 % through water electrolysis. China's hydrogen development strategy focuses on In line with this, a hydrogen development strategy was developed. By 2025, China proposes to have a transitioning to green hydrogen based on renewables, comprehensive hydrogen energy industry development which has a higher production cost than coal mechanism in place. When fully implemented, the gasification-based hydrogen. China Energy Corporation, along with 18 other country expects to produce between 100,000 and 200,000 tonnes of hydrogen from renewable energy per sponsors from the energy production, equipment year. This transition, which is expected to be expanded further by 2035, will result in significant carbon emission reductions ranging from 1 million to 2 million tonnes/ year. Hydrogen's growing popularity can be attributed to the fact that it is a clean fuel. When used in a fuel cell, it only produces water. Natural gas, coal, nuclear power, biomass, and renewables such as solar and wind can all be used to produce hydrogen, which can be grey, blue, or green depending on the method of production. It has the potential to decarbonise industries that are difficult to reduce emissions, such as longhaul transportation, chemicals, and iron and steel. By 2030, total hydrogen demand in the The China Hydrogen Alliance (CHA), which presently has 87 members, was country is expected to increase by 20% to 31 formed in 2018 to support the growth of China's hydrogen sector
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Country Focus manufacturing, transportation, and metallurgical materials sectors, as well as prestigious universities and research institutes, launched the China Hydrogen Alliance (CHA) in 2018 to support the development of China's hydrogen sector, improve capabilities, and lower costs of green energy production in China to US$4/kg by 2025 and US$2.40/kg by 2030. It currently has 87 members worldwide. Its functions include promoting national and state "hydrogen energy and dual cell applicational zones," as well as establishing national hydrogen energy and fuel cell equipment production and standardisation of application settings.
The joint venture between General Electric (GE) and Harbin Electric Corporation is also expected to contribute to China's decarbonisation goals. The General Harbin Electric Gas Turbine (Qinhuangdao) Co, Ltd will supply
What’s driving your bottle production?
Paving the clean energy roadmap Meanwhile, as China transitions to green energy, strategic collaboration among key industry players to boost China's hydrogen market is intensifying. Linde, a global industrial gases and engineering company that is a member of the Global Hydrogen Council and the CHA, and Baowu Clean Energy Ltd, a subsidiary of the Baowu Steel Group, one of the world's largest steel manufacturers, are working together to develop hydrogen infrastructure and solutions for mobility and other industrial applications. The collaboration, which was first announced in 2019, aims to improve hydrogen accessibility for industries, deploy hydrogen mobility solutions, augment China's hydrogen ecosystem - from production to storage and distribution - and invest in liquid hydrogen plants.
Jomar’s IntelliDrive™ Series of injection blow molding machines redefines quality, energy efficiency, and output. For over 50 years, Jomar has set the global standard for injection blow molding technology. Our latest machines continue that tradition. Our IntelliDrive Series use servo-driven hydraulics to achieve the energy savings and precision of electric machines, while retaining the robust strength and economical replacement costs of hydraulic components. • Three exceptional models to choose from: 85S (72 US tons); 135 (135 US tons); 175 (175 US tons) • 40-50% typical energy savings vs. standard hydraulic models • 40% less hydraulic oil required • Less heat emmited, so far less cooling tower water and AC to keep them cool • Faster cycle times; higher output; lower production cost
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Country Focus The Guangdong Huizhou power plant receives two 9HA.01 heavy duty gas turbines from the GE and Harbin Electric joint venture
two 9HA.01 heavy duty gas turbines to the Guangdong Huizhou power plant, which is operated by the stateowned Guangdong Energy Group Co, Ltd (GEG). The project showcased the joint venture's first localised 9HA.01 production in mainland China. The joint venture, formed in 2019, focuses on heavy duty gas turbine (HDGT) localisation, with the goal of providing “efficient and dependable” support for China's natural and hydrogen-blended gas power plants. In addition, Harbin Electric will supply the Guangdong Huizhou power plant with a steam turbine, generator, and balanceof-plant equipment. The gas turbines, which are designed to burn up to 10% by volume of hydrogen blended with natural gas when they begin operation, will be the first in China to do so. The project is expected to be completed in 2023, supplying 1.34 GW of power to Guangdong. Hydrogen-blended natural gas-fired generators have the least CO2 emissions of any fossil power generation fuel—a 10% hydrogen-blended natural gas-fired combined cycle plant emits roughly 40% less CO2 than a comparable-sized coal plant, and emits less mercury, NOx, SOx, and particulate matter. GEG has long relied on GE and Harbin Electric as suppliers. The latter chose two GE 9F gas turbines for the Xinhui Power Plant. Furthermore, GE is currently assisting the plant operator with the transition from coal to gas at its Dongguan Ningzhou power plant. GEG also selected three GE 9HA.02 gas turbines and a stream turbine, generator, and other auxiliary equipment from Harbin Electric for the Dongguan Ningzhou combined cycle power plant in Guangdong. Securing green hydrogen supply China plans to make 50,000 hydrogen fuel-cell vehicles (FCEVs) by 2025, with 20% being buses and trucks and 40% being cars. More than 1 million FCEVs are expected to be commercially available by 2030. With such a large demand potential, it is imperative for China to ramp up its hydrogen production, with a focus on strengthening a domestic supply chain. Several global energy industry titans are supporting in unlocking this potential in order to meet the demand for hydrogen fuel cell systems.
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Toshiba Energy Systems & Solutions Corporation (Toshiba ESS) and Shandong Energy Group Co have formed a technical partnership on a pure hydrogen fuel cell system to fulfil rising demand. Toshiba ESS will facilitate the development of a stationary pure hydrogen fuel cell system for Shandong Energy, a state-owned company engaged in coal, electricity, chemical, industrial equipment and renewable energy. In a related undertaking, the power-to-hydrogen electrolysers project in Zhangjiakou, Hebei Province - a joint venture of Shell (China) Limited (47.5%), Zhangjiakou City Transport Construction Investment Holding Group Co Ltd (48.5%), and Zhangjiakou Zhiqing Technology Partnership (Limited Partnership) (4% share) - has started producing green hydrogen in early 2022. Shell's first commercial hydrogen development project in China, which took only 13 months to complete, is one of the world's largest of its kind. The project used onshore wind power to provide green hydrogen to a fleet of over 600 fuel cell vehicles at the Zhangjiakou competition zone during the Winter Olympic Games, which began in February. The hydrogen will then be used for public and commercial transportation in the Beijing-Tianjin-Hebei region, aiding in the decarbonisation of the region's mobility sector. FCEVs can be refuelled in a matter of minutes and emit no greenhouse gases from their exhaust. The fuel emits no emissions throughout its life cycle because it is produced using renewable energy sources such as wind. The first phase includes a 20-MW power-to-hydrogen electrolyser and hydrogen refueling stations in Zhangjiakou. In Phase 2, the companies intend to scale up to 60 MW in the next two years. State-owned energy firm China Petroleum & Chemical Corporation (Sinopec) is currently producing approximately 3.9 million tonnes/year of hydrogen, and leads China's first 10,000-tonne photovoltaic (PV) green hydrogen pilot project.
Shell's first commercial hydrogen development project in China used onshore wind power to provide green hydrogen to a fleet of over 600 fuel cell vehicles at the Zhangjiakou competition zone during the Winter Olympic Games
Country Focus The Sinopec Xinjiang Kuqa project, which is expected to be completed and operational in June 2023, aims to produce 20,000 tonnes/year of green hydrogen, making it the world's largest PV green hydrogen production project. With a total investment of US$470 million, this hydrogen production plant will directly use large-scale PV power generation. The plant has five sections: PV power generation, power transmission and transformation, hydrogen from water electrolysis, hydrogen storage and hydrogen transport.
The facility's green hydrogen will be delivered to Sinopec Tahe Refining & Chemical to replace natural gas and fossil energy currently used in hydrogen production. The project, which is expected to generate US$2.82 million in tax revenue and contribute an average of US$20 million to the local GDP, is considered to lower CO2 emissions by 485,000 tonnes/year. The PV modules, the "heart" electrolyser in waterelectrolytic hydrogen production, hydrogen storage tanks, and hydrogen pipelines are all made in China, as are all of the major equipment machinery and core materials used in the project's construction. Furthermore, as an official partner of the 2022 Winter Olympics, Sinopec has provided clean energy for the construction and operation of the game's infrastructure. Beijing Yanshan Petrochemical Company, a subsidiary of the company, built a hydrogen purification unit in 2020 that produced hydrogen with The Sinopec Xinjiang Kuqa project, which is slated to start operations in 2023, aims to produce 20,000 tonnes of green hydrogen per year a purity of over 99.9%, achieving a daily production capacity of 500 kg Additionally, Sinopec will construct a new PV power of battery hydrogen products that suit market demand. station with an installed capacity of 300 MW and power Sinopec has also built hydrogen refuelling stations in generation of 618 million kWh/year, an electrolysed Guangdong, Shanghai, Zhejiang, Guangxi, and other water hydrogen plant with a capacity of 20,000 tonnes/ provinces, in addition to 10 oil-hydrogen year, a spherical hydrogen storage tank with hydrogen mixing stations. storage capacity of 210,000 standard cu m, and hydrogen At the current rate of development in China's transmission pipelines with a capacity of 28,000 standard renewable energy sector, it is not unreasonable to cu m/hour (including supporting power transmission and predict the country is to become the world's green transformation facilities), as part of the project. hydrogen superpower.
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www.sml.at 13 APRIL 2022 28.10.21 09:18
Blow Moulding Jomar’s IntelliDrive 855 IBM machine
Jomar Corp., US-based manufacturer of injection blow moulding (IBM) machines for the pharmaceutical, healthcare, personal care, beauty, food and beverage, and household products industries, has launched a series of next generation injection blow moulding (IBM) machines incorporating a custom designed,servodriven hydraulic system.
Jomar’s new Intellidrive series features servodriven energy-saving hydraulics
The new IntelliDrive series enables significant improvements in energy consumption, production and performance, while occupying the same footprint as its standard hydraulic counterpart. In addition, this series features a servodriven hydraulic system that reduces power consumption by 40%-50% and offers a no-load cycle time of 1.8 seconds, significantly faster than standard hydraulic machines. Jomar engineers worked in collaboration with Bosch Rexroth, Charlotte, NC, to develop the servodriven hydraulic technology that drives the plasticiser. "We have taken injection blow moulding to a new level with the new IntelliDrive series. We have developed a machine that lowers operating costs and increases production, bringing greater profits to our customers," said Ron Gabriele, Sales Manager for Jomar. Along with low energy and utility costs, the IntelliDrive series features a reinforced main plate that reduces the chance of deflection. It also features a closed-loop machine clamping system that offers exact control over clamp speed and position, creating faster open and close speeds while reducing impact on tools, which prolongs the useful life of the moulds. In general, the IntelliDrive series has a greater degree of control over the internal functions of the machine, resulting in more efficient use of energy. Also, the machine requires 40% less hydraulic oil,
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uses less than half the cooling tower water, and emits much less ambient heat than standard hydraulic machines, dramatically reducing total operating costs. "Over the last two years we have received numerous questions about our intentions to develop a fully electric machine. The IntelliDrive series is a preferable alternative for Jomar as we have achieved energy savings comparable to fully electric machines, while maintaining our robust and versatile hydraulic system," said Carlos Castro, President of Jomar. Energy savings depend on machine model, container specification and material process. Jomar's development work on hybrid and all-electric machines consistently came to a standstill due to components that did not produce optimal benefits and were characterised by high replacement cost, according to Castro. "We think the IntelliDrive series makes the most sense for our customers who want to save energy, but not have to contend with expensive and complicated repairs," he added. The IntelliDrive Series hydraulic system greatly improves the energy efficiency and control of the machine, but does not require expensive components that could account for up to 15% of the entire machine. In fact, this line of machines will only cost 10%-15% more than the standard hydraulic machine and replacement parts will be available at a cost comparable to its fully hydraulic equivalent. Jomar's confidence in the IntelliDrive series hydraulic system has allowed the company to extend the warranty by two and a half times the length of a standard warranty. "Not only are we reducing our customers' cost-per-part with savings on services, but we're offering a solution that has a very low cost of ownership. This is consistent with our overall effort to deliver short-term and long-term value to our clients," added Castro. Other key features include a quick-change mounting system for the preform cylinder that dramatically reduces the time required for cylinder maintenance, a digital displacement transducer for better control and clamping speed, and a variable frequency drive for a secondary motor. Jomar Seeks Agents: At a time of great interest in its IntelliDrive and TechnoDrive series IBM machines, Jomar is looking to expand its footprint in East and Southeast Asia by contracting with new agents. Manufacturer representatives in East and Southeast Asia can send inquiries to sales@jomarcorp.com
Blow Moulding
Cypet to change IBC market with PET IBCs for a circular economy
Cypet Technologies, European manufacturer of PET injection stretch blow moulding (ISBM) machines, is about to change the global Intermediate Bulk Container (IBC) market. Using its extensive ISBM experience for large PET containers and following an intensive development programme, Cypet has extended its technology, to stretch- blow-mould 1,000 l IBC bottles from PET. Cypet adds that it is looking to strike a strategic co-operation, for a partnership to implement the PET IBC bottle project globally. Converting an IBC bottle from the current HDPE to the new PET has huge environmental and economic benefits as follows: • The PET bottle’s 35% lower weight has the potential to reduce the plastic used in IBCs by 150,000 tonnes/year. • Less energy expended to produce and transport the bottles, with the associated reductions in carbon emissions. • Low cost PET bottles would make rebottling of used IBCs more attractive than washing, eliminating consumption of water and cleaning chemicals. • PET bottles can be 100% recycled and used again to make new bottles or other PET containers, for a circular economy. • Unlike HDPE bottles, PET bottles can be produced with glass transparency, providing the capability of visually inspecting the IBC contents. These advantages make PET bottles ideal for the rebottling of used IBC’s, offering a costeffective alternative to washing, especially for food contact applications. Cypet saw the market potential for PET IBC bottles and invested in the design and engineering of a larger, more advanced production system for these containers.
Cypet has exhibited the production of 120 l PET drum at K2019
“Cypet’s technology is taking PET where it has never been before. This opens up a new range of opportunities, yet to be explored. We are very excited to see how this leap in PET processing technology will improve the environmental impact, economics and performance of IBCs in the bulk packaging industry,” said Constantinos Sideris, Managing Director, Cypet Technologies. Previously, Cypet has used its technology to mould very large PET containers. This has enabled PET packaging to enter into new applications, not accessible to it in the past: 50 l drums; 50 l beer kegs; 55 l crates and 120 l drums. The company adds that it also holds the world record for the biggest PET container in production, with 120 litre open-mouth PET drums of 400 mm neck diameter. Cypet has exhibited its K 53 machine at the K2019 fair, producing Cypet says it is about to “disrupt the global IBC market with PET IBCs for a circular economy” 120 litre drums. APRIL 2022
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Compounding
Coperion commissions three lines for PP/PA at Nanjing Julong
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aving been awarded three Smart Compounding Lines from Nanjing Julong Science & Technology Co for the production of PP (polypropylene) and PA (polyamide), Coperion China says all three lines have been successfully installed and are in full operation. Coperion’s Smart Compounding Lines are pre-configured turnkey solutions from a single source. Developed in best-practice design, the compounding lines are tailored with focus for the Asian market.
The result comprises a high level of automation and digitalisation of Julong’s plants. Central functions are performed by the DCS Control System which has an interface and signal exchange with Julong’s Manufacturing Execution System and supports and improves Julong’s automated processes from order handling to manufacturing and thus increases the efficiency of the entire production. ZSK twin-screw extruders The three Smart Compounding Lines are each equipped with a ZSK 70 Mc18 twin screw extruder with a screw diameter of 70 mm and a specific torque of 18 Nm/cm3. ZSK extruders are ideal for processing products with a high torque requirement, such as PP and PA. The ZSK 70 Mc18 twin screw extruders are locally assembled at Coperion’s manufacturing site in Nanjing, China. Chinese customers benefit from local added value, transport, and tax savings as well as from shorter delivery times. Even the after-sales services are customised to local parts and needs, it adds.
Coperion China was awarded three lines from Nanjing Julong, which have been successfully installed and are in full operation
Coperion’s scope of the Nanjing Julong project included the engineering and design of the three lines as well as their installation supervision and commissioning. Coperion delivered the entire solution from raw material handling receiving to the handling of finished goods, including three ZSK 70 Mc18 twin screw extruders assembled locally at Coperion Nanjing, strand pelletisers from Coperion Pelletizing Technology, a silo washing system and the Distributed Control System (DCS). Up to now, the new Smart Compounding Lines are said to be running reliably at the highest throughput rates and Coperion will further support Nanjing Julong as a service partner. Coperion also says it will provide the site and spare parts service for the entire plant. High level of automation Together with Julong, Coperion’s engineering teams in Shanghai and Nanjing have planned, developed and designed the entire factory from layout to commissioning. Based on the extensive know-how collected from more than 150 installed compounding lines, one of Coperion’s main focuses was on user-friendly plant design by improving the working conditions for the operators at every step of production.
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The ZSK 70 Mc18 twin-screw extruder, which is the heart of the three lines, is assembled locally at Coperion Nanjing
Coperion’s SP treasure strand pelletisers Julong’s three Smart Compounding Lines are equipped with Coperion’s SP 320 treasure strand pelletisers. This strand pelletiser series was developed through close cooperation between Coperion Pelletizing Technology, Offenbach, Germany, and Coperion Nanjing. Coperion Pelletizing Technology is responsible for the design and manufactures the cutting chamber. The remaining pelletiser assembly is manufactured locally in Nanjing. The SP 320 treasure strand pelletiser is ideally suited for processing of highly abrasive strengthened products. It has a working width of 320 mm and can process up to 88 strands at throughput rates of up to 2,500 kg/hour. Key design features of the SP treasure pelletiser include high throughput rates, easy accessibility and ease of cleaning. Besides the use of tried-and-tested components within Smart Compounding Lines, Julong will continue to benefit from available local spare parts, avoiding time-consuming and expensive import procedures, and allowing Julong to achieve quick return on investment, says Coperion.
Packaging
ExxonMobil’s new Exceed S for less complex film designs
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odern film design is a story of increasing complexity and compromise between performance and processability that is accepted to ensure durable packaging and high customer satisfaction. Multi-component resin blends in coextruded and laminated films with high layer counts are commonplace. Every step of producing and converting printed film into durable packaging is prone to complexityinduced inefficiency, scrap and human mistakes. What if the resin used could help simplify all of this? As well, trends such as the growth of E-commerce for convenience are driving higher requirements for packaging integrity and survivability. Not forgetting the demand to increase recycled content, which requires high performance polymers to maintain mechanical properties of the final product. Taking this into account, US materials firm ExxonMobil has commercialised Exceed S performance polyethylene (PE) resins, which are said to deliver industry leading combinations of stiffness and toughness while being easy to process. Utilising the company’s latest innovations in polymer science, the new PE platform provides opportunities to reduce the complexity of film formulations and designs while improving film performance, conversion efficiency, and packaging durability versus current market references. ExxonMobil adds that the development of the new PE was guided by both learnings from its Exceed XP products and the feedback it received from customers. Thus, Exceed S performance PE compared to Exceed XP performance PE extends the higher performance to much stiffer resins while maintaining the easy processing of the XP 8000 series products such as Exceed XP 8784 PE. So, the Exceed S and Exceed XP product families complement one another, says ExxonMobil.
Silage bags for farming can benefit from the new resin due to the increased puncture, impact and tear resistance properties
Simplifying film designs “Exceed S performance PE resins deliver simplicity without compromise,” said Tom Miller, Exceed S Marketing Manager, ExxonMobil. “Now converters can get high performance with easy processing, stiffness and toughness with less blending, and resin solutions that can simplify operations and improve package durability. It is a platform of performance polyethylene grades designed to do so much, so simply.” It enables converters to rethink film design for simpler solutions: - Utilising Exceed S functional layers to maximise performance - Leveraging increased performance to help facilitate solutions with sustainability benefits - Reducing the need to add HDPE for stiffness or LDPE for easy processing - Creating flatter, less extensible films to increase print and package line efficiency - Delivering more durable flexible packaging contributing to consumer satisfaction and helping to reduce food waste - Creating stiff, tough, functional core layers using a single Exceed S grade - Freeing-up skin layers to further enhance package sealing, optics, and haptics - Enhancing stiffness and toughness of full-PE packaging Asian packaging sector to benefit Many flexible films and packaging in Asia, and indeed globally, can benefit from Exceed S performance PE, including laminated and non-laminated food and institutional packaging, medium and heavy duty sacks, and agricultural packaging, says ExxonMobil. The first three commercially available grades are designed to ensure low melt pressure and high output on blown film lines. The combined benefits of Exceed S resins allow the creation of a broad range of packaging and film applications, ExxonMobil adds. (See Figure 1 for grade information). Figure 1: Commercially available grades of Exceed S performance PE Exceed S 9272ML Exceed S 9243ML Exceed S 9333ML
Density g/cm3
Melt index dg/min @ 190°C, 2.16 kg
0.920 0.926 0.925
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Packaging Launching three grades of Exceed S performance PE provides the industry with options for each of these segments. For instance, Exceed S 9333ML was designed as a 2MI product to help it run well on equipment that is more sensitive to high melt pressure or temperature limitations. Benefits for packaging The biggest challenge in producing high performance flexible films for packaging, agricultural and industrial applications is optimising the balance of stiffness, toughness, and ease of processing. A film designer looking to improve the relatively low toughness of a generic, cost- effective coextruded structure will likely upgrade to metallocene linear low density polyethylene (mLLDPE). To then make processing easier, LDPE is often added to lower melt pressure and increase melt strength, which can lead to higher output. HDPE is then often added to make the film stiffer, but this can reduce toughness. So, adding either LDPE or HDPE introduces compromise and increases operational complexity. Exceed S can be used for bubble wrapping for wine bottles
ExxonMobil says simpler solutions are now available thanks to Exceed S PE resins. For instance, large format heavy duty sacks used in industry and agriculture along with silo bags for farming benefit from increased puncture, impact and tear resistance. The resin’s combination of low melt pressure and high extrusion output can help increase converter’s production capacity. In primary packaging, non-laminated co-extruded films used in pouches and bags containing liquid, food, or other goods can benefit from improved toughness and are less likely to break when transported or dropped. Multi-wall bladders used in hot-filled bag-in- box packaging exhibit exceptional resistance to heat-induced blocking and flex cracking. Exceed S PE resins can create the most value when used in the core of three-layer coextruded structures or the core and sub-skins of coextruded structures with a high layer count.
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With the core layer delivering high stiffness and toughness, the skin layers of the film are available to improve other aspects of performance like sealing, hermeticity, optics or haptics that brand owners value in the final package. Exceed S PE resins thereby, simplify blend formulation while creating opportunities to better optimise film and finished package durability and consumer appeal. Plus, the ability to create stiff, tough, core layers can enable the use of lower density or other higherperformance skins that further improve package bag drop survivability, enable faster sealing rates, improve clarity and gloss, or enhance package feel. The result can be more durable PE packaging that can better resist breaking or leaking during transportation to, or during use by, the consumer. For e-commerce, for example, this can mean fewer product complaints and returns, which may help reduce the cost associated with refunds or supplying replacement products. A more efficient value chain; sustainability tackled, too The flexible packaging industry value chain is quite complex, ranging from resin producers to film producers, a multitude of secondary operations to cut, slit, print, laminate, and make packages that brand owners sell to consumers through various retail channels. Offering toughness across a wide range of stiffness, Exceed S performance PE can create value by simplifying – reducing complexity, scrap, and complaints – at every step of the value chain, adds ExxonMobil. It can help designers do more with less by helping deliver high performance that can facilitate the manufacture of lighter and thinner plastic films and packaging. It also supports design for recyclability by helping enable solutions of high-quality mono-material packaging structures that can be mechanically recycled in communities with programs and facilities in place that collect and recycle plastic film.
Exceed S already has collaborations with over 75 customers globally working on over 100 different applications
Packaging PE//PE laminates with improved stiffness, toughness “ExxonMobil has been at the forefront of polyethylene and bag drop survival help facilitate larger pouch sizes innovation for nearly 30 years. The new Exceed and accommodate more aggressive contents, helping S platform embodies our most advanced product to expand market usage of mechanically recyclable and process development informed by deep, longpackaging. standing partnerships with our customers,” said David Exceed S performance PE can help designers increase Hergenrether, Vice President Polyethylene, ExxonMobil. recycled resin content – solutions that enable recycled “The innovation opportunities that Exceed S content incorporation while still meeting final product performance polyethylene offers has already resulted in performance requirements. Converters can work with their successful collaborations with over 75 customers globally ExxonMobil representative to purchase certified circular working on over 100 different applications,” he explains. Exceed S performance PE with Exxtend technology. Furthermore, ExxonMobil says that providing such solutions are a focus within its four-pronged approach of using performance polymers to help facilitate solutions with sustainability benefits. (See Figure 2 for more Figure 2: *Recyclable in communities with facilities in place to collect and recycle plastic film information).
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Country Focus
Asian countries claw back from pandemic While the last two years have taken a toll on most economies around the world due to the pandemic, with the opening of the borders as Covid-19 reaches an endemic stage, countries like Malaysia, the Philippines and Vietnam are expected to make an impact in the regional plastics sector. Malaysia on track to become a hub in SEA The plastics industry in Malaysia is on a growth path despite the challenges and the market is projected to register an annual growth of 3% for the period 20212026, according to Mordor Intelligence. Major growth drivers are sectors such as food & beverage packaging, consumer products, electronics and construction. Meanwhile, the Malaysian Plastics Manufacturers Association (MPMA) says that sales of manufactured plastics increased by 23% year-on-year to RM38.68 billion in the first eight months of 2021, with exports of plastic products posting a 21% rise during the period due to the opening of both domestic and international markets. Malaysia’s total household plastic packaging consumption reached over 520,000 tonnes in 2020.
As well, Transparency Market Research (TMR) estimates that Malaysia’s chemical and petrochemical market is set to expand at a CAGR of 4.2% from 20212025 due to demand for petrochemicals and chemicals in several end-use industries. Despite the estimated 5% to 15% decline in foreign direct investment into this industry, companies are redesigning their work processes and enhancing the operations of their plants to alleviate the impact of the pandemic in the country. In terms of sectors, Malaysia’s annual per capita plastic packaging consumption is high among all the Southeast Asian countries at 16.78 kg/person. In 2020 alone, total household plastic packaging consumption reached over 520,000 tonnes. Furthermore, a recent report by MarketResearch.com on the Malaysian packaging industry says the sector is set
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grow from 17.6 billion units in 2020 to 20.2 billion units by 2025, at a CAGR of 2.9%. According to Mordor, flexible packaging accounts for a majority share followed by rigid plastics. It has also been noted that rigid plastic packaging will post the fastest growth from 2020-2025 due to the high demand for e-commerce and food delivery services, as well as its advantages as being lightweight, durable and economical. Circular economy trends to push demand in Philippines In Southeast Asia, the Philippines suffered heavily from the impact of the pandemic, with the high number of cases putting a lot of pressure, not only on the country’s medical and healthcare industry, but also on its economic growth. In 2020, the country’s GDP fell to a -9.6%, the biggest annual decline recorded. However, the country is now putting its industrial production back to operation and the elections in May is expected to encourage domestic spending, with analysts and think- tanks projecting a growth from 5% to 7% for 2022. For the Philippine plastics industry, the pandemic presented opportunities due to the heightened demand for food & beverage packaging as well as medical supplies. While the country’s downstream plastics industry is composed largely of plastic fabricators and manufacturers that convert plastic resins to industrial and consumer finished products, it also provides strong linkages to such industry as home appliances, electronics/ electrical, building and construction, drugs and cosmetics, etc. Dominated by small to medium-scale enterprises, there are some large companies that are increasingly utilising advanced production technologies and materials from suppliers in Asia and Europe. Against the many challenges, the Philippines plastics market is poised to record more than 5% annual growth up to 2026, according to Mordor Intelligence. The report states that despite the slowdown in the automotive and transportation, consumer goods and electronics industries due to the lockdowns and trade issues, the packaging industry posted remarkable performance due to strong
Country Focus e-commerce business that demand for smart packaging has never been that robust especially in the food and healthcare sectors. The packaging sector in the Philippines is expected to reach 69 billion units by 2024, at a CAGR of 3.3% up to 2024, according to GlobalData. The sector is driven mainly by the growth in rigid plastics packaging, which is forecast to register the fastest volume CAGR of 6.4% in the next two years. The report further states that flexible packaging accounts for more than 33% of the market share. Meanwhile, the country is on track to achieving a circular economy and reducing the country’s carbon footprint, with well-known brands accepting the circular economy concept. The United States Agency for International Development (USAID), through its Clean Cities, Blue Ocean (CCBO) programme, has partnered with Nestlé Philippines to help local government units understand the link between climate change and solid waste management. In this collaboration, Nestlé Philippines provides tips on improving local solid waste management as it implements its Climate Change and Solid Waste Management Education Program. Nestlé Philippines has also committed to increase its use of recycled materials in its packaging. The integration of upcycled items to reduce dependence on virgin materials is one of the important steps to achieve its circularity targets, and many machinery producers are responding to this trend. Vietnam: an upcoming destination for plastics Vietnam’s rapidly expanding plastics market is an attractive proposition to providers of innovative technologies. The country’s plastics market is projected to register a CAGR of more than 10% yearly from 2021-2026, according to Mordor Intelligence. This promising prospect places Vietnam’s plastics industry among the fastest growing in the Southeast Asian region. While the impact of Covid-19 in the first half of 2020 saw work stoppages and slowdown in manufacturing activities, Vietnam has been resilient and production in some sectors have resumed under the new normal. In terms of industry, Vietnam’s plastics industry continues to supply leading sectors depending on plastics such as packaging, electrical and electronics, construction, automotive, household products, among others. Packaging accounts for around 68% of the plastics market share. The Vietnam Plastics Association (VPA) report places plastic packaging companies at around 460 out of 2,000 plastic companies operating in Vietnam and these packaging companies contribute to over 60% of Vietnam’s yearly export sales. Aside from packaging, Vietnam’s construction industry is a thriving sector as it accounts for about 25% of plastics industry’s output. As the construction industry recovers and more infrastructure and housing projects get implemented, the demand for plastics as input is expected to rise.
Another important industry is automobile production which is being developed as Vietnam aims to become a regional hub for auto production. Car assembly and auto parts production is seeing growth with investments from foreign companies. Overall, sustained high demand from major applications is anticipated to boost demand for plastics in Vietnam in the period 2022-2025. Rising personal consumption, rapid urbanisation and the growing middle class are important factors in Vietnam’s plastics market’s development. Currently, there are more than 2,000 plastic companies in Vietnam mainly located in Ho Chi Minh City (84%). Domestic plastic companies account for 85% while foreign ones account for only 15% in number but 40% in investment capital. It has been reported that the Vietnamese government is divesting from domestic plastic companies, and foreign investors are likely to take this opportunity to increase their market penetration. In the first 9 months of 2021 alone, foreign investors’ new capital registered in Vietnam amounted to US$22.15 billion, up by 4.4% in the same period the previous year, according to official government statistics. Many foreign companies, in partnership with local Vietnam-based entities, are pouring large amounts of investments into Vietnam’s plastics manufacturing sector. For instance, in the construction plastics segment, Tien Phong Plastic JSC (NTP) and Binh Minh Plastic JSC (BMP) account for the bulk of the total market share. There are also major companies in Vietnam’s plastics market that are engaged in the production of plastic resins and compounds such as Far Eastern New Century, Nghi Son Refinery and Petrochemical (NSRP), Hyosung Chemicals, Billion Industrial Holdings, and SCG Chemicals Co, among others. Thailand-based integrated PET supplier Indorama Ventures has also acquired shares in Ngoc Nghia Industry (NN) in Vietnam, strengthening its market position for PET conversion in Asia.NN is a leading PET converter in the region with long-standing relationships with major brands. It has four manufacturing sites in both the North and South of Vietnam and a production capacity of approximately 5.5 billion units of PET preforms, bottles and closures, equivalent to a PET conversion of 76,000 tonnes/year. Indorama Ventures has acquired shares in Vietnam's Ngoc Nghia Industry, a leading PET converter
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Injection Moulding Asia Automotive
EV adoption and sustainability reinforce automotive plastics industry trends Automotive plastics Automotive plastics have captured a notable share of the total vehicle configuration, replacing heavier metal options like steel in some critical components. The applications of polymers in automobile include many electrical components, power train and even the chassis, apart from numerous interior and exterior aesthetic parts. Under the hood parts like pipes, connectors and cables, manifolds, cam covers, fluid tanks, among others are being produced using plastics. It is, therefore, become necessary to study the latest trends in automotive plastics market and understand the mutual impacts it has on the developments in the transportation domain. In regions like Asia Pacific (APAC), the Middle East and Africa (MEA), where new vehicle production and sales is expected to grow at a substantial rate, efforts for enhancing fuel efficiency and promote vehicle electrification will undoubtedly foster the consumption of plastic components. These regions are also home to a large number of chemical companies and polymer manufacturers, which seconds the above argument.
Robust automobile demand in APAC and Middle East regions and an increasing acceptance of electric mobility will influence automotive plastics demand, says Global Market Insights in this article.
T
he global focus on carbon footprint reduction has pegged the transportation sector as a key target, invariably shifting the crosshairs on automotive plastics industry. The symbolic Paris Agreement on climate change has set out bold targets over the coming decades, with the overall goal of carbon neutrality by 2050. The IEA reports that around 18% of direct CO2 emissions worldwide are from road vehicles and gradually, investments toward making considerable advancements and adjustments in vehicle production have taken a front seat. Apparently, emissions from transportation grew by less than 0.5% during 2019, which was a promising statistic considering the 1.9% annual increase since 2000. The major reasons behind this are improved efficiency, electrification as well as a growing adoption of biofuels. From these factors, better efficiency of ICE automobiles is achieved through several ways, including the change in materials used for manufacturing certain components.
ABS emerges as a preferred polymer Considering the importance of vehicle safety and durability over a long term, the selection of base materials is critical. Acrylonitrile butadiene styrene (ABS) is a
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Injection Moulding Asia Automotive thermoplastic exhibiting high impact strength and toughness, making it a strong candidate for numerous automotive applications. Some of these uses include dashboard parts, door handles and liners, seat belt parts, instrument panel components, among others. Substituting polymers for metals in these applications can help lower the overall vehicle weight noticeably. ABS has robust physical properties like good insulation, impact resistance, weldability, abrasion resistance and high rigidity. It is consequently one of the clearer alternatives for metallic components. A crucial factor expanding ABS consumption in APAC and MEA is the presence of notable manufacturers of the substance, such as Sabic, Mitsui Chemicals, CHIMEI, Asahi Kasei Corporation, China Petroleum & Chemical Corporation, Kumho Petrochemical and LG Chem. The most commonly known benefit of plastic materials is reduced fuel consumption and emissions due to lighter vehicles. However, they can also enhance the safety parameters to a great extent. For instance, car bumpers manufactured using polymers like ABS, PP, PU and others, combined with glass fibres can absorb up to five times more energy on impact, while weighing up to 50% less. Reportedly, a new car with around 1,500 kg weight can comprise of up to 20% of plastic materials, with the percentage expected to go up as more innovations are made in the transportation sector. The scope for ABS demand is certainly strong over the next few years, with trends like EVs and hydrogen-cell powered vehicles taking shape. According to Global Market Insights Inc. (GMI), the share of ABS in automotive plastics industry will record a promising 10.5% CAGR up to 2027.
EVs usually become heavier than ICE vehicles, due to the addition of large battery packs and other electrical components. As such, the onus of reducing the weight of electric cars, to enhance the driving range per charge, falls highly on plastic materials. For EVs, lightweighting by around 10% can enhance the driving range by close to 13.7%. Demand for battery packs with lower weight will be a prime factor impacting plastics consumption, since they are one of the heaviest components in an EV architecture. On the other hand, efficient cost cutting measure can help enhance the manufacturing process by using materials which meet the recommended physical characteristics but are not high-cost engineered polymers. For instance, electric cars do not require as much under-the-hood temperature resistance compared to ICE vehicles, bringing into focus plastics like PA in place of PP or PU. Nylon/PA is being widely utilised for battery brackets and other enclosures for EVs. As evident, the emerging trend of EVs and autonomous vehicles will present a vast challenge in terms of lightweighting strategies, albeit offering considerable opportunities for automobile plastics manufacturers from applications like electric component housings, battery racks, energy storage systems, charging stations, as well as innovative solutions like swappable battery stations. Evaluating automotive plastics industry scope across APAC and MEA According to OICA, more than 3.02 million vehicles were manufactured during the first three quarters of 2021 across China, India, Japan, Malaysia and South Korea. The figures represent a considerable recovery from the Covid-19 pandemic impact. EVs adoption has been observed as a widespread trend across the APAC region, influencing the automobile materials segment to a large extent. The Middle East region is not behind in pursuing electric vehicle adoption, in line with the climate goals of regional governments. Saudi Arabia has set a target of ensuring EVs make up nearly 30% of regional car sales by 2030. Further, an Audi Abu Dhabi survey in 2021 revealed that more than 29% residents in the UAE are ready to purchase an EV. GMI estimates that APAC automotive plastics market size could witness more than 9.5% CAGR through 2027, while the market in MEA region will expand at a robust 12% CAGR. The strong support for future mobility across the APAC and MEA has encouraged polymer companies to invest in developing suitable products, expand capacities, undertake major deals and partnerships, among other strategies to strengthen their position in automotive plastics industry. Some of these companies include BASF, Sabic, Solvay, Dupont, LG Chem, Arkema SA, Evonik Industries and Teijin Limited, among others.
Electrification of vehicles to augment automotive plastics outlook Referring again to the 2050 carbon neutrality agreements, one of the milestones in the strategy is ensuring that nearly 60% of all car sales worldwide are electric by 2030. That target does not seem farfetched anymore, as almost 6.5 million plug-in and fully electric vehicles we sold during 2021, which was a 109% jump over the previous year. With numerous EV and autonomous transportation start-ups taking birth globally, these numbers will only go up. Even major automakers from countries like China, India, South Korea and Japan are speeding up their electrification efforts. China’s BYD has confirmed the launch of three new EVs this year alone, whereas other brands in the region like Geely and MG also making strong moves. Tesla already has a major presence in the country. In India, Tata Motors has found tremendous success for its new EV models, while brands such as Hyundai and MG have also registered increasing sales here. Since a common ICE private or commercial vehicle already boasts a significant share of plastic components, the use of these materials in EVs will definitely go higher with the elimination of metal-intensive components like the engine, gears and the traditional axels. However, 2 APRIL 2022
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Injection Moulding Asia Automotive Sabic, one of the largest chemical names worldwide, has recently introduced a PC alternative for replacing glass in automotive applications. The company conducted a study on rear-quarter windows and found that the new PC material provides better lightweighting, cost benefits and design flexibility as compared to glass. In another example to tackle weight reduction goals of customers, Sabic also partnered with China’s Dongfeng Motors for the development of a long glass fibre PP for a glass composite. The material can be used in making a strong, light-weight toolbox to be mounted on trucks, being 30% lighter as compared to the same design made using steel. In terms of upcoming trends, the increased focus toward plastics recycling can also impact automotive plastics market forecast over the next few years. LG Chem has already announced its entry into the chemical recycling sector with the construction of a plastics recycling facility in South Korea, to enable plastic waste to be upgraded into new plastics. Sabic, too, has made progress in the foray and has introduced automotive grade PC and PP resins containing up to 29% recycled content. Although the Covid-19 outbreak in 2020 has dented the manufacturing sector to a large extent, the resumption of production units and supply chains has
been at a commendable rate. The economic importance and robustness of the transportation sector will sustain automotive plastics market growth, while emerging trends in innovations and sustainability alter the overall industry dynamics over the coming years. Sabic has collaborated with Dongfeng to produce a lightweight truck-mounted toolbox in a plastic/composite hybrid mix
Medical Sector
Technology shifts that make a difference Today’s medical plastics allow healthcare devices and products to combine patient benefit and safety while also meeting the industry’s sustainability goals, says Angelica Buan in this report.
found that the amount of medical waste generated was significantly higher than that produced by individuals. Asia accounted for 73% of all plastics discharged, followed by Europe (11%), and the rest coming from other regions. Ultimately, consumers and producers are urged to be more conscious of the environmental impact of personal protective equipment (PPE) and other plastic products, as well as the development of much more sustainable materials and new waste management technologies. After all, plastics are required for the development of more effective, safe, and accessible medical devices. In response to this need, materials companies Solvay and Mitsubishi Chemical Advanced Materials (MCAM) recently collaborated to recycle medical equipment made with Solvay’s Udel high-performance polysulphone (PSU) thermoplastic at the end of its service life. The two companies – Solvay, with its One Planet sustainability roadmap, and MCAM, with its product sustainability Kaiteki vision, are currently investigating the implementation of logistics for the recovery, recycling, and reprocessing of PSU resin used in medical components, to be reused in original applications.
First, do no harm to the environment Hospitals and healthcare institutions are central to healthcare systems. While this sector works tirelessly around the clock to save lives, it also contributes significantly to carbon emissions due to the amount of medical waste generated and energy consumed. According to the 2019 Healthcare’s Climate Footprint report, healthcare’s climate footprint is equivalent to 4.4% of global net emissions, comparable to annual greenhouse gas emissions from 514 coal-fired power plants. Medical waste is a major issue, particularly in areas where solid waste management systems are inadequate. The pandemic has made the situation even worse. As per a study published in the journal Proceedings of the National Academy of Sciences, over 8 million tonnes of pandemicrelated plastic waste has been generated globally, with over 25,000 tonnes entering the global ocean. It was also 3 APRIL 2022
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Injection Moulding Asia Medical Sector Similarly, French chemicals firm Arkema has introduced a biobased and recyclable high rigidity advanced biocircular PA11 medical polymer that is intended to replace metal and traditional polymers in demanding medical applications. The new Rilsan MED grade, which is formulated with a high content (65%) of glass fibres, has a tensile modulus of 18.5GPa, making it suitable for the production of surgical tools. Arkema’s PA11 medical polymer is derived from its flagship amino 11, which is sourced from castor bean oil
Solvay has partnered with Mitsubishi Chemical Advanced Materials to recycle end-of-life medical components
The project may be able to demonstrate that it is possible to recycle high- value Udel PSU parts used in the medical field, resulting in significant CO2 emissions savings throughout the production and supply chain. The project entails combining MCAM’s expertise in washing and mechanically purifying the material with Solvay’s ability to evaluate the chemistry of the end-of-life polymer to establish a recycling strategy that will provide customers with materials that fully meet all specifications. MCAM has previously collaborated with Solvay on the reclamation and recycling of other high-performance polymers, such as KetaSpire PEEK material.
The new polymer, derived from Arkema’s flagship amino 11, which is sourced from castor bean oil, is said to offer a combination of physical performance, lightweight, and sustainability. It also has favourable biocompatibility properties (which have been successfully assessed according to USP Class VI, ISO 10993-4, ISO 10993-5, and ISO 10993-10 standards), easy processability, lightweight, high resistance to aggressive chemical agents and repeated sterilisation cycles, and other properties.
Advanced materials to optimise device performance Modern medical devices and intervention tools rely on advanced and functional materials to improve their capabilities and enable better patient compliance and outcomes. German materials supplier Covestro is one of these companies that is assisting in the ongoing development of medical plastics technologies. Covestro’s Makrolon M6011 FR, a medical PC, and Makroblend M5005 FR, a medical PC/polyester blend, have been introduced by the company for medical device housings and hardware. The materials have a differentiated composition of properties that improve chemical resistance while employing next-generation flame retardants with the most stringent UL rating – UL 94 V-0. These materials are also said to demonstrate enhanced impact strength, rigidity, UV resistance, and improved flowability.
New approaches in infection control Demand for new therapies, breakthrough medicines, and effective drug delivery systems reflect the need to protect against emerging diseases and other unavoidable health risks. One of the most important lessons from the coronavirus pandemic, for example, is the relevance of infection prevention via hygiene protocols and the effective use of antimicrobial solutions. Berry Global and Pylote are introducing a firstto-market multi-dose ophthalmic dropper with a high barrier and antimicrobial protection
Covestro’s Makrolon and Makroblend materials are suitable for medical device housings and hardware applications
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Injection Moulding Asia Medical Sector A tie-up between Berry Global, a US-based packaging manufacturer, and Pylote, a French industrial mineral chemistry company, makes the case for antibacterial solutions that can help users stem infections. The partners are introducing a first-to-market multi-dose ophthalmic dropper with a high barrier and antimicrobial protection. Pylote’s mineral breakthrough innovation, which helps protect patients/users from the risk of microbial infections, is combined with Berry’s competence in sustainable healthcare packaging design in this new offer. The multi-dose ophthalmic dropper is fully compliant and biocompatible, and has been shown to be effective against Adenovirus type 3 (conjunctivitis), Escherichia coli, and Staphylococcus aureus bacteria. Certified non-irritant and non-cytotoxic technology (ISO10993:2010), the product ensures the cleanliness and safety of all applications. Most importantly, when compared to mono-dose solutions, the dropper reduces plastic waste by 16 times over the course of one month, say the partners. Likewise, a value chain collaboration between US materials firm Dow and Sartorius, a German pharmaceutical and laboratory equipment supplier, and Südpack Medica, a German sterile packaging manufacturer, ensures safe production and transportation of coronavirus vaccines globally with bioprocessing bags.
Pharmaceutical companies use the bio-reactor bags and 3D bags it manufactures to cultivate important vaccines, such as the coronavirus vaccine. Südpack, one of Sartorius’s polymer film supply partners, offers multi-layer films that ensure safe vaccine production. The bio-reactor films promote the reproductive growth of the sensitive cell lines. Excellent cell viability and density reduce the risk of batch loss or inconsistency, resulting in high product purity and increased productivity. Curbing the spread of Covid-19 with vaccines Meanwhile, the widespread use of the Covid-19 vaccine has resulted in syringe shortages in some areas. The collaboration between Germany-based chemical firm BASF and South Korea’s Lotte Chemical ensures that quality PP syringes are available to fill this gap. To deliver the PP for syringes used in Covid19 vaccinations, Lotte uses BASF’s Irgastab, a nondiscolouring processing stabiliser, with the added benefit of reducing vaccine waste.
BASF’s Irgastab enables Lotte to deliver high-clarity medical PP for syringes
A medical syringe manufacturer in South Korea used Lotte’s medical PP in the development of LDS (low dead space) syringes. These specialised products are made to reduce the amount of drug that remains in the device after injection, resulting in less vaccine waste. As a result, LDS syringes are in high demand around the world, as they are estimated to allow 20% more people to receive the vaccine dose with the same amount of vaccine. Sterilisation is required for plastics used in medical applications. The polymer degrades and discolours as a result of this. Irgastab is said to keep medical PP safe and usable by providing processing stability without discolouration during compounding and injection moulding, which is critical for LDS syringes because the materials must be certified for high-clarity. Lotte, on the other hand, adds that it is broadening its development of special PP materials in order to ensure strict production quality control of medical materials. It is also considering expanding the use of Irgastab to fibres and sheets due to its good performance in terms of colour retention and transparency.
Dow, Sartorius and Südpack Medica are producing sterile bioreactor bags made of multilayer films
The partners are producing sterile bio-reactor bags with a capacity of up to 2.000 l made of multilayer films, which can aid in achieving exceptional speed, quality, and flexibility in the vaccine development process as well as commercial manufacturing operations. They are designed for high oxygen transfer and efficient mixing, making them ideal for mammalian cell culture – processes that require a high cell density or rely on microcarriers. The 3D flexible bags are designed for storage and shipping of large volumes of biopharmaceutical solutions and are dedicated to sterile and ready-to-use solutions. Sartorius’ technology aids in the production of both current and emerging vaccine technologies. 5 APRIL 2022
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Injection Moulding Asia Thermoplastic Elastomers
TPEs drive brands’ sustainable goals
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ithout a doubt, the sustainability of plastics is critical to building a circular economy. Plastic material advancements ensure that plastics are imbued not only with appropriate mechanical properties, but also with attributes that align with the environmental goals of the entire value chain. Thermoplastic elastomers (TPEs), in terms of processability and customisation, outperform thermoset rubber. Leading industry players are formulating new TPE grades and compounds that demonstrate versatility and durability while remaining non-toxic and recyclable, thus meeting the criteria for environmentally friendly materials. According to research group Freedonia, TPE suppliers focusing on Asia will benefit from the region’s expanding markets, including motor vehicle markets in China, India, and Thailand, where TPE usage rates stutters behind those in developed countries. It forecasts a 3% annual growth to 7 million tonnes through 2024, owing to continued TPE penetration in both developing and developed economies, as well as the development of new TPE grades and compounds.
This PCR content formulation, according to Avient, performs similarly to prime TPEs and can provide a more sustainable option in applications like toothbrush grips and other personal care items, as well as foodcontact items like reusable crates. It’s naturally grey, colourable, and can be injection-moulded or overmoulded onto PP. Environmentally-responsible materials For Teknor Apex, being environmentally responsible is at the crux of sustainability goals of brands. Thus, the US-based compounder is putting forth its new Monprene TPEs that contain 25-35% recycled content, which meets consumer and regulatory demands for higher levels of recycled content in products. According to Teknor Apex, this significant added value helps brands achieve their sustainability goals.
Sustainability an important factor An example of sustainability being tackled in TPE grades is a new TPE formulation with recycled content, newly introduced by Avient, a US-headquartered manufacturer of specialised polymer materials. The reSound REC TPE formulation for use in certain food-contact applications has a Shore A hardness of 65 and contains 25% postconsumer recycled (PCR) PP content.
Teknor Apex’s Monprene TPE can be overmoulded
The Monprene RX CP-15100 series, formulated with PCR content allows brands to meet consumer and regulatory demands for recycled content within their products. These TPEs are available globally and manufactured around the world with locally sourced raw materials from waste diverted from households, or commercial, industrial and institutional facilities. The Monprene RX CP-15100 series is available in standard grades from 55 to 80 Shore A, and can also be tailored for a customer’s specific requirements. Manufactured according to the standards of ISO-9001 and ISO 14001 in the US, Singapore and Germany, with strict formulation control and traceability, these grades are available in consistent light, natural colour, similar to their prime offsets. They are designed for injection moulding applications, including overmoulding onto PP. The grades are said to perform and process like prime TPE and are ideal for personal care products, lawn/garden tools, writing instruments, appliances, sporting goods and dunnage. Teknor Apex says Monprene RX not only reduces plastic waste but also ensures that products are fully recyclable at the end of their useful lives.
Avient’s reSound REC TPE contains 25% post-consumer recycled PP content and can be used in applications like toothbrush grips, personal care items and food-contact items
It has received a no objection letter (NOL) from the US FDA, which confirms that the recycled material included in this formulation can be used for manufacturing certain food-contact articles This grade is part of Avient’s reSound TPE portfolio, which also includes recycled-content and bio-based formulations. 6 APRIL 2022
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Injection Moulding Asia Thermoplastic Elastomers Likewise focused on delivering TPE solutions for an eco-conscious market, United Soft Plastics (USP), a US manufacturer and custom compounder of TPEs has developed a series of sustainable solutions, produced from renewable, post-consumer, post-industrial, and biobased sources. Its first commercially available grades, based on styrene-ethylene-butylene- styrene (SEBS), are made of up to 100% PCR and post-industrial materials. The grades have the typical soft touch, anti-slip properties, adhesion, and haptics. The injection moulding grades are available in 45-65 Shore A hardness and are suitable for a variety of consumer applications, including personal care. Three other series of sustainable TPE solutions are currently being commercialised. These low-cost SEBS grades contain up to 70% renewable products such as wood flour, rice hull, and/or hemp. These have a limited performance threshold, which excludes use in highly engineered TPEs. Also in commercial development phase are biopolymers, which utilise
non- fossil-based materials with up to 100% content. These biobased TPEs deliver almost similar performance as standard materials for injection moulding applications (although available quantities are limited), and hold considerable potential of market impact and carbon emission reduction, USP said. Bio-hybrid TPEs, which can combine renewable, postconsumer, post- industrial, and biobased content up to 100%, are also included in USP’s sustainable TPE portfolio.
USP offers sustainable TPEs produced from renewable, postconsumer, postindustrial, and biobased sources
Industry 5.0
Human touch in robotic-enabled industries Through collaboration with robots, human ingenuity unlocks the key to increasing manufacturing efficiency and sustainability, adds Angelica Buan in this report. Robots uprising: threat to human jobs? The fourth industrial revolution (Industry 4.0) has been a game changer in reshaping smart industries, which aim to improve productivity by enabling collaboration and data sharing among vendors, producers, suppliers, and other entities in the supply chain, with the help of big data, artificial intelligence (AI), and the Internet of Things (IoT). Robotics is an integral automation technology in Industry 4.0. Robots can perform high-volume, repetitive tasks with greater accuracy and at a relatively low cost and are now used throughout the advanced process chain, from part installation to packing and labelling, to ensure consistent and timely production, shorter cycle times, and higher throughput.
The dominance of robots in automation systems has ignited concern, particularly about impact on the workforce. In the face of a labour shortage, robots are widely perceived to displace workers or low to mid-skilled jobs, and are discreetly viewed as competitors, particularly because they are less likely to make errors than humans. An AI takeover or a robot uprising, according to conspiracy theorists, is plausible in an Industry 4.0 scenario.
Robotics in Industry 5.0 places emphasis on human workers
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Injection Moulding Asia Industry 5.0 In his 1930s essay, Economic Possibilities for our Grandchildren, English economist John Maynard Keynes speculated that growing technological innovations, such as automating industrial processes with “less human effort”, would lead to “technological unemployment” - owing to the “discovery of means of economising the use of labour.” The current ambivalence about robots’ hegemony in the manufacturing space can be summed up in this statement.
Robots are used for menial, redundant jobs and even tasks in hazardous environments where humans are not present. The benefit of industrial robots in this context is demonstrated in Stäubli Robotics’s robots to make demanding processes more efficient. Stäubli’s robots are designed to prevent ESD in order to safely handle electronic components
Labour-intensive cobots Nonetheless, several companies struggling from labour gaps are adopting robots to augment manpower for demanding tasks and avoid operational downtimes. Especially during the Covid-19 pandemic, companies that had to deal with challenges of rising delivery expectations, and expanding order volumes, turned to collaborative robotics (cobots) manufacturers like Universal Robots, to provide them with required automated solutions.
For example are Stäubli’s Electro Static Discharge (ESD)-variants of its Scara and six-axis robots for use in in all possible areas of the electronics and battery sectors. Stäubli’s larger TX2-140/160 six-axis robots, as well as the TX2-40, TX2-60 and TX2-90 models, which are UL certified and comply with safety level SIL3/PLe, have been developed for assembly, testing and packaging processes of sensitive electronic components – from control units and various assemblies to battery packs. The four and six-axis robots are designed to prevent ESD in order to safely handle electronic components. They can operate in EPA (ESD protected area) for various applications such as PCB assembly, any kind of part inspection or testing and packaging of electronic consumer goods. Robotic solutions, such as those provided by Stäubli, protect employees while also increasing output productivity. Human workers can be reassigned to appropriate roles in engineering, programming, administration, and technical support as a result of the implementation of robots. In short, Industry 5.0 exemplifies a positive, cooperative relationship between automation systems and human intelligence, as well as the fact that humans are the driving force behind technological advancements.
Universal Robots’ UR10e has a high payload of 12.5 kg lift suitable for machine tending, palletising, and packaging applications
Last year, Denmark-headquartered Universal Robot demonstrated its automated solutions for hard-to-staff tasks, such as box erecting and palletising. The UR10e has a 25% increase in payload at 12.5kg, which translates to moving more per pick, usage of heavier tools, and processing heavier parts, supported by the 1,300 mm reach and small footprint. According to the cobot manufacturer, the enhanced UR10e’s greater payload also takes more weight off from the hands and shoulders of humans, leading to improved ergonomics and working conditions.
Sustainability with IoT, robotics Robots are widely used in the plastics industry. One of the most important aspects of Industry 5.0, is that automation improves production efficiency, which significantly reduces material waste and production costs. Swiss industrial robot manufacturer ABB commissioned a global study titled “Billions of better decisions: industrial transformation’s new imperative,” that was released this year. The study looks at how digitalisation is being used now and how it can help improve energy efficiency, reduce greenhouse gas emissions, and drive change. According to the study, 96% of the polled 765 decision-makers believe that digitalisation is “essential to sustainability.” While only 35% of companies surveyed have implemented Industrial IoT solutions at scale, 72%
Humans, driving force in innovations If Industry 4.0 is defined by digitalisation, the fifth industrial revolution or Industry 5.0 is defined by personalisation. This new production model reflects the need for industries to meet the rapidly changing needs of markets. Industry 5.0 also emphasises the importance of human labour in the expansion of industrial manufacturing. While robots remain an essential component of Industry 5.0, they are not presumed to be superior to their operators. 8 APRIL 2022
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Injection Moulding Asia Industry 5.0 Jefferson Enterprise Energy, a compostable packaging factory powered by renewable energy in the US.
are increasing IoT investment specifically to address sustainability goals. The single most important factor in a company’s increased focus on sustainability, according to 46% of respondents, is the organisation’s “future competitiveness.” In industries such as manufacturing, energy, buildings, and transportation, the adoption of relevant digital solutions to enable better decisions and achieve sustainability goals must accelerate, according to the respondents. Meanwhile, 57% of survey participants said the Industrial IoT has had a “significant positive effect” on operational decision-making, and a number of respondents said cybersecurity vulnerabilities are a major roadblock to improving sustainability through the Industrial IoT. ABB’s partnership with Zume, a manufacturing technology company focused on food packaging, emphasises automation with robots that enable sustainability and contributes to reducing plastics in packaging. The objective of the deal is to create plant-based compostable packaging and Zume will receive robotic cells from ABB, allowing it to automate its production. Over the next five years, ABB will integrate and install more than 1,000 moulded fibre manufacturing cells (MFC) - including up to 2,000 robots - at Zume customers’ sites around the world. ABB will use its programme management capabilities and automation experts to enable the scale, modularity, and speed required to launch the solutions, which have the potential to produce millions of pieces of sustainable packaging annually. Zume’s moulded fibre cells are integrated with two ABB IRB 6700 robots to produce the plant-based containers, with each cell processing up to 2 tonnes/day of material and producing 80,000 pieces of sustainable packaging. Zume expects to equip factories with up to 100 robotic cells in collaboration with ABB. With the MFC’s automation, speed, and scalability, each site could process 71,000 tonnes/ year of agricultural material, potentially producing yearly up to 2 billion pieces of packaging. Similarly, Zume and ABB also started a pilot project at Satia Industries Limited, one of India’s largest wood and agro-based paper manufacturers, where they set up a facility with ten manufacturing cells that will process 20 tonnes/day of wheat straw, resulting in 100% compostable packaging for a variety of industries. Other planned pilot installations include Parason Group, India’s pulp and paper machinery supplier, and
AI for circular economy Efficient sorting of plastic waste, a complicated part of the recycling process, requires a technological genius. The introduction of AI in recycling aims to tackle this issue. To date, the largest known deployment of AI-guided robots with a North American reclaimer is AMP Robotics’ extended partnership with Evergreen, one of North America’s three largest producers of food-grade rPET. Evergreen, which has expanded from its original facility in Clyde, Ohio, to four locations across North America through acquisitions, now has 15 of AMP’s robotic sorting systems guided by AI installed or planned across three facilities. Evergreen has added six robots in California, and Evergreen uses AMP robots to improve the purity will soon add of recycled bottles and increase pick rates of the bottles at its facility three in New York, in addition to the six in Clyde. The AMP Cortex high-speed robotics system automates the sorting and identification of recyclables in mixed material streams. It is able to identify materials like PET, HDPE, LDPE, PP, and PS as well as the recyclability by recognising different colours, textures, shapes, sizes, patterns, and even brand labels. The robots are then guided by Neuron, which is designed to run 24 hours a day, to pick and place the material to be recycled. AMP’s technology recovers recyclables from municipal collections, precious commodities from electronic scrap, and high-value materials from construction and demolition debris, with deployments in North America, Asia, and Europe. In the same way, the AMP robots’ capabilities allow Evergreen to achieve a significant improvement in purity as well as pick rates of up to 120 bottles/minute, a 200% increase. At the Clyde facility, the robots remove up to 90% of contamination on average across different lines. Due to expansion and infrastructure investments, Evergreen’s capacity of rPET has increased to more than 70,000 tonnes, up from 20,000 tonnes a year ago. The number of waste PET bottles collected and recycled each year has increased from 2 billion to 11.6 billion bottles, according to the company. This is just yet another example of how robots can help industries achieve their sustainability and circularity goals faster.
ABB has installed moulded fibre cells at Zume’s customer sites
9 APRIL 2022
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Injection Moulding Asia Additive Manufacturing
Strong growth expected in AM industry Wohlers Associates, which was acquired by ASTM International last year, in its annual report on the additive manufacturing (AM) industry, pictured significant growth and maturing in the AM sector as compared to last year, against the back of recovery from the pandemic. The report also details the increased consumption of polymer powders, overtaking photopolymers for the first time. This marks the 27th consecutive year of publishing the annual report.
consumption grew 43.4% in 2021, a significant amount, to be sold in greater quantities than photopolymers for the first time. Evonik/Asiga collaborate on photopolymer-based 3D An example of increased photopolymer usage comes from a collaboration between German specialty chemicals company Evonik and Australia’s 3D printer manufacturer Asiga. Both companies aim to drive forward 3D printing large-scale industrial manufacturing by extending today’s capabilities of photo-curing technologies. Evonik is contributing its expertise in development and manufacturing of ready-to-use photopolymer materials. Asiga, in turn, is bringing its strength in DLP 3D printers with their open material architecture to the joint effort. “The cooperation with Asiga, once again, confirms the growth approach we are focusing on with our new product line of Infinam photopolymer resins launched last year. We are sending an important signal to our customers who will now benefit from an even broader access to our high-performance materials with excellent processability properties on Asiga’s DLP 3D printers to explore new infinite applications,” said Rainer Hahn, Head of Evonik’s photopolymer market segment within the Additive Manufacturing Innovation Growth Field. Evonik’s new Infinam photopolymers are ready-to-use highperformance formulations that can be processed seamlessly on Asiga’s DLP 3D printers. Asiga is an innovation driver in desktop stereolithography, launching the world’s first LED based DLP 3D printer in 2011. Today, the company continues to focus on a range of process monitoring technologies which control part accuracy and production stability across many industries including medical and general manufacturing. Asiga’s product line covers a broad range from powerful desktop 3D printers including their MAX series to large format floor standing such as the PRO 4K. “As we continue to strengthen our open material architecture we are delighted to provide our customers access to Evonik’s new range of Infinam photopolymers. Combining the latest material developments in additive polymer science from Evonik with our industrial grade 3D printing hardware creates robust additive manufacturing solutions with endless possibilities,” Graham Turner, Global Operations Manager, Asiga.
Latest trends to note Even against the back of the pandemic, last year proved to be a stellar year for AM, with a growth of 19.5% in 2021. This is a significant increase from the 2020 growth of a 7.5% increase due to the impact of the pandemic, though it still has not quite yet reached preCovid levels, the ten-year average before 2020 was 27.4% growth. According to Terry Wohlers, Head of Advisory Services and Market Intelligence at Wohlers Associates, “As expected, the industry has returned to a period of advancement and investment. This expansion cuts across aerospace, healthcare, automotive, consumer products, energy, and other sectors.” The year 2021 also witnessed a number of mergers and other signs of a healthy market, with 75 mergers, acquisitions, and initial public offerings. This is almost double what was found in last year’s report as Wohlers Report 2021 commented on 74 early-stage investments and 35 acquisitions and public offerings. Though not related directly to growth, it does suggest the maturing and success of the companies, an indirect sign of a flourishing industry. The report also notes that more and more companies are using AM for custom products and series production, which could be identified as more industrial applications for the technology. A sign of this is that polymer powders have officially overtaken photopolymers this year. Polymer powder
New product line of photopolymers Last year, Evonik introduced first ready-to-use formulations of its new photopolymers product line for industrial 3D printing applications. Infinam TI 3100 L leads to high toughness and impact-resistant 3D parts which can withstand strong impact or permanent mechanical effects such as pressing or impact. ST 6100 L is setting-up a new benchmark in the category of high strength polymer resins. It combines tensile strength of 89 MPa, flexural strength of 145 MPa and HDT of 120°C, and thus fills the material gap in ultra-high strength photopolymers. Meanwhile, RG 3101 L combines impact resistance with high-temperature resistance while exhibiting long-lasting thermomechanical performance
Growth of polymer powder (yellow) compared to photopolymers (orange) in millions of dollars. Source: Wohlers Report 2022
10 APRIL 2022
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Rubber Journal Asia Industry News • Bridgestone Americas has taken up a minority investment in tyre sensor and data management company Tyrata. Using an automated and cost-effective drive-over solution that measures tyre tread, Tyrata collects tyre wear data and provides actionable, cloud-based analytics. This strategic investment accelerates Bridgestone’s efforts to deploy advanced mobility solutions that improve fleet safety, efficiency and sustainability. • Carbon black supplier Cabot Corporation has completed its previously announced acquisition of Tokai Carbon (Tianjin) Co. from Tokai Carbon Group. The acquisition expands Cabot’s manufacturing capacity to support the growth of its battery materials product line, while continuing to serve existing carbon black customers. The site can currently produce up to 50,000 tonnes/year of carbon black. Meanwhile, Cabot has broken ground on a new specialty compounds facility in Cilegon, Indonesia. The new facility is co-located with Cabot’s existing carbon black manufacturing site and will add 20,000 tonnes/year of global capacity for specialty compounds, including black masterbatch and conductive compounds. It is expected that the facility will be operational at the end of 2022. • CECO Environmental Corp (CECO), a US-headquartered industrial company, is acquiring Florida-based industrial flow control leader General Rubber (GRC) that manufactures nonmetallic (rubber) expansion joints and flow control products. The acquisition will be integrated into the company’s Effox-FlextorMader (EFM) joint venture with Chartwell Investments Entrepreneur & Founder Capital (Chief Capital).
• Dutch supplier of OTR tyres Magna Tyres is to acquire Industra Ltd, which it adds “has a very strong position in Poland as it is the biggest supplier of speciality tyres services”. The company works with three product categories: industrial tyres (from forklifts to port handling machines), tyres for earthmoving machinery and the agricultural sector (tyres, wheels and tracks). • Norwegian silicones maker Elkem has obtained financial support from the French government as the company accelerates its investments in specialty silicones production in Saint-Fons in the Rhône region. Elkem adds that the capacity extension of its upstream silicone intermediate units in Roussillon (Isère), announced in October 2021 for an amount of EUR36 million, is one of the winners of the Resilience programme of the France Reliance plan. • Purcell Tire & Rubber Co., based in Missouri, has acquired Colorado-based tyre dealership Callender Tire Inc. Purcell, one of the largest retreaders in the US, expects the acquisition to broaden the market reach of its specialty retread product. Purcell has reportedly grown to 65 service locations and five retread plants in 15 states as a result of the acquisition. Terms of the transaction have not been disclosed. • Zhongce Rubber Group Co Ltd (ZC Rubber), China’s largest tyre maker and ranked number nine in the list of the top 75 global tyre manufacturers, has acquired Tianjin United Tire & Rubber International Co (Tutric), the manufacturer of Tianli tyres, for about RMB1.3 billion. Zhongce is currently one of the largest suppliers of OTR tyres in the
world, offering tyres for wheeled loaders, articulated and rigid dump trucks, port applications, underground mines, industrial and forklift operations. It adds that the acquisition of the Tutric “will further strengthen” the group offering to its customer base. • Azelis, a provider of specialty chemicals and food ingredients, has acquired 100% of the shares of Whitfield Chemical Group, the ultimate parent company of WhitChem, a distributor focused on CASE (coatings, adhesives, sealants and elastomers) and R&PA (rubber & plastic additives) in the UK. This acquisition reinforces Azelis’ position in industrial chemicals, and specifically in the CASE and R&PA market segments in the UK. WhitChem’s long-standing relationships with blue-chip principals and product portfolio strengthen Azelis’ lateral value chain in the UK, whilst their wide customer base and strong local technical sales team further expands the Group’s product offering and customer reach. • China’s Qingdao Sentury Tire is to invest EUR523 million to construct a car and light truck radial tyre plant in Galicia, northwest Spain, to cater to European demand. It will be the Chinese car tyre maker’s third production facility worldwide and will increase output by almost 50%. The project will have a capacity of 12 million tyres upon commissioning in late 2025, a big jump from the 22 million tyres it is currently making a year, adds Sentury. The first phase should be finished by the end of 2024 with an output of 6 million tyres/year. • Against the back of a graphene global market expected to surpass US$400 billion by, OCSiAl, the world’s largest manufacturer
1 APRIL 2022
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Rubber Journal Asia Industry News of graphene nanotubes, has been granted approval by Luxembourg authorities for a production plant, together with an associated R&D centre, in Differdange, Luxembourg. OCSiAl plans to invest EUR300 million in the development of the facility, designed to minimise the usage of energy and resources. • Japanese tyre manufacturer Yokohama Rubber Co is increasing production capacity at its Ibaraki plant for highpressure hydraulic hoses. The installation of a new line for spiral wire hoses, which are mostly used in construction machinery, is expected to expand the plant’s continuous production lines’ capacity by 1.5 times. Yokohama is also expanding the spiral wire hose capacity of its China plant in Hangzhou, which will triple production capacity by September. Furthermore, Yokohama is restructuring the production of automobile hoses and couplings in the US and Mexico • Technology firm Continental plans to significantly expand its capacities in Brazil with an investment of EUR25 million. It adds that the additional capacity will allow it to meet the growing need for high strength belts – with a strength higher than 600 N/mm and up to 10,000 N/mm – used in mining operations in South America. • Japanese firm Shin-Etsu Chemical Co. is investing US$700 million in its silicones business. It has increased its production capacity of silicone monomer, the intermediate material of silicones, at its two bases in Japan and Thailand by about 1.5 times, compared to the previous level. • Malaysia’s Hong Seng Consolidated Bhd and Japanese
global trading and investment firm Mitsui & Co Ltd’s subsidiary Mitsui & Co (Malaysia) are to form a partnership to set up Hong Seng’s 960 kilotonne/year-nitrile butadiene latex (NBR) plant at Kedah Rubber City in the northern state of Kedah as well as integrated logistics services business in Penang. • Trelleborg Wheel Systems and its Indian joint venture partner, Yogesh Agencies & Investments, have started trial production of two-wheeler tyres in a factory constructed in Bharuch, Gujarat. Trial production began in December 2021, ahead of the projected start of commercial production in the first half of 2022. The company will produce Mitas motorcycle and scooter tyres. • Japan’s tyre maker Bridgestone Corp. is expanding its production capacity for premium passenger car tyres at four of its manufacturing facilities in Japan, at its Tochigi, Hikone, Hofu, and Tosu plants. Construction will start in the first quarter of 2022. Entailing a total investment of approximately US$70 million, the production capacity expansions of premium passenger car tyres are projected to result in an increase of approximately 6,200 tyres per day (more than 10% of current capacity) within 2025. • South Korea’s Kumho Tire, a subsidiary of China’s Doublestar, has tied up with Saudi Arabia’s Blatco (Black Arrow Tire Co.) to establish a factory in Riyadh for tyre production, since currently there is no tyre production in Saudi Arabia. Several sources have said that the factory’s production capacity will reach 15 million tyres/year and that production is expected to start in the third quarter of 2023.
• North American tyre recycling service provider Liberty Tire has opened a new manufacturing facility in Sanford to produce rubberised mulch, a sustainable and resilient alternative to traditional mulch made from recycled scrap tyres. By recycling more than 190 million tyres/ year, Liberty Tire reclaims 1.3 million tonnes/year of rubber. • US carbon black supplier Orion Engineered Carbons has commissioned the first new reactor for carbon black production in the European Union in over 40 years at its plant in Italy, and has started commercial sales with the line. The new 25-kilotonne line at the facility in the northern city of Ravenna produces both specialty and technical rubber carbon blacks, primarily for the European market. • Minnesota Rubber and Plastics (MRP), a provider of highly engineered elastomer and thermoplastic solutions for the medical, water and specialty industrial end markets, has acquired Primasil Silicones, a UK-based custom silicone rubber compounder, mixer and manufacturer specialising in the medical, HVAC and specialty industrial end markets. • Japanese firm Shin-Etsu Chemical Co. will implement over US$700 million in facility investments for its silicones business, one of its main businesses, with the aim of further expanding and strengthening this business. Since 2018, Shin-Etsu has increased its production capacity of silicone monomer, the intermediate material of silicones, at its two bases in Japan and Thailand by about 1.5 times, compared to the previous level.
2 APRIL 2022
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Rubber Journal Asia Tyres
Moving closer to an air-free tyres future In response to a rising trend for safe and environmentally friendly transportation, more tyre makers are jumping on board the airless tyre bandwagon with new prototypes set to enter commercial production in the coming years, according to Angelica Buan in this report.
When driven, however, airless tyres can disperse the heat that builds up. New developments, on the other hand, are being made to improve the properties of airless tyres in order to eliminate performance issues and expand their application to a wider range of vehicle types. No to flat tyres, yes to low carbon emissions The global airless tyre market is expanding as demand for maintenance-free tyres grows and the adoption of allterrain and military vehicles, such as armoured trucks, backhoes, and cranes, increases. Airless tyres may also become a standard feature for concept cars and electric vehicles in the coming years. Several tyre manufacturers, in fact, are already developing and testing prototypes of next-generation airless tyres that ensure safe, blow-out-proof transportation while emitting low carbon emissions. Japanese tyre maker Toyo Tires has been researching airless tyres since 2006 and in 2012, showed a prototype at a technology exhibition. From then on, the company has introduced changes to the tyre structure, creating better prototypes with improved performance and says its “noair” concept tyre continues to evolve. The basic tyre structure is made up of special highrigidity resin spokes from the inner core to ensure adequate strength to support the load. The use of a rubber material for the outer tread that comes into contact with the road surface also improves basic tyre performance, namely “drive, turn, stop” functions. The section between the spokes and the rubber tread, known as the outer diameter ring, is reinforced with carbon fibre-reinforced plastic (CFRP), which helps to reduce the load on the spokes.
Airless tyres for lower maintenance Since road traffic accidents are one of the leading causes of fatalities worldwide, vehicle safety is essential for avoiding collisions and lowering the risk of serious injury, and tyres are an important component of vehicle safety. Preventing blowouts or sudden loss of air pressure require checking for inflation and wear and tear on a regular basis; and avoiding potholes or other road debris, as well as overloading. Tyre maintenance, on the other hand, is both inconvenient and costly. Drivers expect both safety and convenience when travelling from point A to point B, and tyres must meet these expectations. It is not surprising that non-pneumatic tyres (NPTs) or airless tyres have piqued consumer interest due to the fact that they are low-maintenance and environmentally friendly. How is this even possible? Because it is not supported by air pressure, an airless tyre is punctureproof. It also has less suspension and higher rolling friction than pneumatic tires of similar shape and size.
Toyo Tires’ Noair basic structure consists of special high-rigidity resin spokes from the inner core to ensure adequate strength to support the load
3 APRIL 2022
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Rubber Journal Asia Tyres In Bridgestone’s version, the spoke structure within the tyre is made of reusable thermoplastic resin, and the materials used in the tyres, along with the rubber in the tread portion, are 100% recyclable. Its second generation NPT was launched in 2013 with an optimised spoke structure using high-strength, flexible high-performance resin as a material and employing finite element method (FEM) simulations in the design to reduce stress and deformation in the tyre’s inner part. Bridgestone adds that it has also used proprietary materials and simplified the tyre structure, thereby resulting in a significant Bridgestone’s non-pneumatic reduction in energy loss. Its tyre spoke structure is made pneumatic fuel-efficient tyres of reusable thermoplastic have a low rolling resistance resin and 100% recyclable similar to its low rolling rubber in the tread portion resistance. Bridgestone, which adapted the air free concept in 2017 to develop puncture-free bicycle tyres, said that it is advancing development of the air-free concept tyre and aims to bring about commercial use in a wide range of vehicles as soon as possible.
Previous prototypes supported the load via an elliptical spoke configuration, according to Toyo Tires, but the latest version has progressed into an x-shaped spoke configuration that alternately crosses the width of the no-air tyre from the outside to the inside and vice versa. Durability has been improved by achieving a completely unique support configuration form, it adds. Moreover, relative to the earlier model, the number of spokes has been doubled (100 pitch), distributing contact pressure, reducing impact sounds from the spokes when they come into contact with the ground, thus achieving an even quieter ride, Toyo Tire explained, adding that it is constantly conducting research to improve its tyre and resolve certain design issues before it is put into practical use. DSM’s Arnitel TPE offers a unique combination of high strength, flexibility, temperature resistance and processing characteristics for airless tyres application
Similarly, Dutch materials firm DSM, has joined the airless tyre market with its Arnitel TPE polymers and compounds. Since 2005, DSM has been working with tyre manufacturers and OEMs to find the best material solution for NPTs. In its concept, DSM says the airless tyre is typically made up of a metal central hub that connects to the axle, an elastic Arnitel “web” structure, and an outside rubber thread. Arnitel also allows NPTs to have a service life that is up to three times longer than a traditional tyre that wears out faster. Apart from the flex fatigue endurance, high load bearing capability, dynamic creep and tear resistance, Arnitel’s thermal properties allow an NPT to perform consistently in a variety of climate conditions from -30 to +100°C. Meanwhile, Bridgestone is another key forerunner in the development of airless tyre concepts, having announced in 2011 that it had developed its version that could prove to be a viable and more environmentally friendly alternative to conventional tyres in the future. Despite the potential benefits of such concept tyres, they have previously been impractical to mass-produce and Bridgestone stated that this technology was developed with the goal of mass producing.
Technology with cost benefits Heavy vehicles used in industries such as agriculture, mining, and construction can also benefit from airless tyres. US-based engineering company Global Air Cylinder Wheels (GACW) is tackling the cost savings benefits of its newly introduced Air Suspension Wheel (ASW), a patented airless mechanical design constructed primarily of steel with in-wheel suspension. GACW has raised over US$2.5 million on StartEngine, a crowdfunding platform, to continue developing its wheel technology, which has been tested in real-world conditions. Since 2015, the company has been working on the ASW for OTR mining vehicles. GAWC plans to boost wheel production this year in collaboration with its partner, OTR Wheel Engineering. The company anticipates that ASW will be fully commercialised within the next two years, with rapid adoption into mining fleets.
4 APRIL 2022
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Rubber Journal Asia Tyres The ASW is made up of an inner steel hub and an outer steel drum that are connected by 8-12 nitrogenfilled air cylinders and four to six oil-filled dampers. Individual bolt-on steel or polyurethane treads are installed on the outer drum. The treads can be replaced without removing the wheel, a process that can take up to eight hours with OTR rubber tyres. GACW says its concept tyre is simple to install and does not require any specialised equipment. Nonetheless, it is durable and built to last as long as the vehicle (roughly 10-15 years), which means lower replacement costs and less time spent swapping out damaged tyres. What’s more, it saves at least 8% fuel, cuts costs per hour/mile by up to 60%, and reduces CO2 and NOX emissions with up to 30% less rolling resistance. Partnerships driving commercial adoption French tyre maker Michelin has developed its own airless mobility solution for passenger vehicles called Uptis (unique puncture-proof tire system). As a co-development partner for Uptis, automotive firm General Motors (GM) and Michelin have signed a joint research agreement. The partners plan to develop this airless wheel assembly and plan to put it on passenger vehicles by 2024. Constructed with an aluminium wheel and a flexible load-bearing structure made from glass fibre-reinforced plastic (GFRP), the Uptis prototype, according to Michelin, eliminates flats and blowouts and has the ability to decrease the use of raw materials and waste. The concept, according to GM is consistent with its vision of “a world with no crashes, no emissions, and no traffic congestion”.
The airless tyre concept made its debut at the 2021 Munich Motor Show, where it was demonstrated on a Mini Cooper SE. Michelin and GM are also collaborating to equip Chevrolet’s next-generation Bolt EV with Uptis, which is expected to be released in the coming years. The Uptis prototype will be fitted to a fleet of vehicles and tested intensively in real- world conditions for two years. Engineers will use the data gathered during this period to enhance the prototype in preparation for its market launch. A related collaboration shows the versatility of airless tyres in diverse forms of mobility. US tyre firm Goodyear has developed a specially engineered airless tyre designed to extend tyre life and reduce maintenance for Starship Technologies’s delivery fleet. The tyre manufacturer is testing a custom-engineered airless tyre for the Starship delivery robots – these are six-wheel electrically autonomous robots that carry and deliver packages, groceries and food directly to customers.
Goodyear developed airless tyres for six-wheel electrically autonomous delivery robots
The Uptis prototype is constructed with an aluminium wheel and a flexible load-bearing structure made from glass fibre-reinforced plastic
Starship, a Goodyear Ventures portfolio company, has more than 1,000 of the robots in its network. The technology has begun in-field testing at Bowling Green State University in the US to assess vehicle and tyre dependencies. Early data from on-vehicle tyre testing has revealed promising results in terms of treadwear, braking, and vibration dampening. With efforts in high gear, it is clear that tyre manufacturers are going to great lengths to develop the ideal tyres that will meet the criteria of a mobility society that places priority on human and environmental health.
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Do you know what actually has a lasting impact? The power density of your drive! The planetary roller screw drive of our hybrid and electric ALLROUNDERs is the best you will find on the entire market, and not just in this respect. Make sure you get the best results! In terms of noise emission, cooling, power transmission, load capacity, compactness, and spare parts supply – we deliver, right across the board. And on top of that there’s a five-year warranty. Our planetary roller screw drive: one of a kind! www.arburg.com
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