Italian Machinery and Technology
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Italians gear up for plastics show with new offerings Over the past two years, the plastics and rubber machinery industry in Italy has achieved stable growth, according to Italian industry association Assocomaplast. Exports and production values were mainly fuelled by market demand from China, Germany, France and the US. In 2011, export value increased more than 20%, with Asia accounting for 19.2% of exports, and production value grew by 11% to hit EUR4 million. It is against this backdrop that Italian technology providers will introduce value addons to attract visitors to this year’s PlastMilan exhibition, to be held from 8-12 May.
More biodegradable, recyclable materials Besides promoting healthy living and sustainable transportation, cycling will become greener as Portugal-based Polisport has developed a biodegradable water bottle for cyclists. It is made from API’s Apinat bioplastic that performs just like PP or PE but decomposes under controlled composting conditions. Polisport says it has produced thousands of biodegradable bottles using extrusion blow moulding without modifying the equipment. Compounder Finproject will present Biolevirex (polyolefins) and Biofinpro (PVC) materials that can be used in multiple markets and are compliant with EU94/62CE for aerobic biodegradation. In machinery, granulator maker Exact has developed a system for recycling EVA edge trims produced from EVA roll stock used for manufacturing solar panels. Integrated with an extrusion line, the system recycles without the use of heat, thus allowing the recycled trim to be turned into sheet. Once the EVA film enters the unit, tension is controlled with a dancer system and the material is compressed. With thicker materials, heat is required for improved Exact’s new machines for recycling EVA compression. The material is then cut film trims into small wafers that are transported and mixed into the extrusion process. The closed loop system does not require additional handling of the chip, minimising cross contamination. Technopoly, a static and rotary machine specialist, is currently developing a special head to handle PU granules obtained from waste material. It will also showcase its latest mini head for micropouring as well as special heads for mixing PU that are said to be easy-to-use and self-cleaning. Having invested 5% of its sales into R&D, granulator maker Gamma Meccanica will show its GM65 Compac pilot line for recycling. It is made up of a cutter, GM65 extruder and filter. The cutter-compactor comes with the Ecotronic controller that allows materials with a residual moisture up to 15% to be recycled; a constant temperature with up to 40% energy savings and no use of water. For dry, non-degassing materials, a non-vented extruder can be used. Alternatively, an extruder can be installed with the standard double degassing vents. An in-line viscometer undertakes real time viscosity measurement.
Besides developing a PU waste handling system, Technopoly will introduce a new line of machines for the production of technical items
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Italian Machinery and Technology Expanding speciality materials Having worked together since 2005, chemical distributor Tecno Sintesi and Singapore-based McKinn International will set up an Asian office to market speciality chemicals to Southeast Asia and China. Though the office location has not been stated, the companies plan to market germanium catalysts, TiO2/PETbased masterbatch, ammonium polyphosphate and other specialities.
Italmatch’s FRs can be used in a range of products
Italmatch Chemicals will present its new Phoslite flame retardants (FRs) based on inorganic phosphinates. These undertake three different flame-retardant mechanisms, of gas phase, char forming and radical activity, in one molecule. The FRs can be used in injection moulding, extrusion and fibres and are adaptable to masterbatch production. Other characteristics of the low-halogen FRs are the low smoke toxicity and opacity, high GWIT values and ability to overcome large scale testing. New Phoslite grades recently developed are available for engineering polymers like PA6 or PBT as well as for PC and alloys, TPU, TPE and epoxy resins. Latest machines for blown/cast film and foil/sheet Extrusion machinery maker Bandera will feature a three-layer blown film line for multi-layer film applications in technical flexible packaging (lamination, heat shrink and stretch hood films). Designed to produce 15200 micron film with a winding width of 2,600 mm, the line has an output of 700 kg/hour. It comprises a 100-mm extruder and two 65-mm extruders, with a 400-mm die equipped with a new cooling ring. A supervisory system with PC integration and a double-station winding system complete the line.
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For producing rigid foil/sheet for thermoforming, Bandera will show a three-layer line for processing PET/PP/PS/PLA. It will be equipped with the latest co-rotating L/D 52 twin-screw extruder, featuring melt purification and a horizontal cooling and polishing roll stack calendar. This is equipped with a cross-axis system for extruding thin PET foil and thick PET sheet with a width ranging up to 1,420 mm. The line has an output of 1,200 kg/hour and will be equipped with an in-line film lamination system; a latest generation fully automatic winding and reel collection system and a supervisory system with PC integration. Another extrusion machinery maker Dolci Extrusion will present its latest cast stretch film line for producing ultra-thin films with a speed ranging from 500-600 m/ minute for 8-12 micron film. With a 2-4 m net width, the line features an updated version of the firm’s Rotowind 2000 automatic winder for producing hand and machine rolls on 2” and 3” carton cores. Dolci will also introduce a cast film line based on a multi-section chill roll for the production of film for lithium ion batteries. Based on PP and polyolefin blends, the film is used as a separator between the anode and cathode. In blown film technology, the firm will present its three to seven-layers Extru-Convert combined line for extrusion and converting. It will also showcase a multi-layer MDO blown film line for modified atmosphere and freezer bags. Converting equipment solutions Web guiding system maker Re Controlli Industriali will unveil a film centring checking system with fish-eye sensors for bubble extrusion web guides. Mounted at a suitable distance from the film, it is able to read the film edge. Two sensors are connected to the new MWG10 web guide check with its LCD display and function keys that allow easy change of parameters. Powered by stepping motors, the
web guide has no maintenance. Printing machine maker Moss will present the SMV-3 multi-colour silk-screen printer operating at an output of up to 150 pieces/minute. Controlled by a PLC with digital bus field system and servomotordriven, the machine works in sync with the container rotation. The company will also feature its Hybrid decoration unit with linear motor-driven printing and electronic control. Other equipment on display will be hot stamping, digital transfer and cameras for quality control. Rotomark will exhibit a 700mm wide and 30 m/minute speed embossing line for 0.5-5 mm thick PVC and ABS films. It comes with “intelligent” features such as the ATC (Automatic Temperature Control), allowing detection of temperature and automatic adjusting of IR power. Corona surface treatment maker Ferrarini & Benelli will present new patented heating systems for pipe extrusion and the Atmospheric Plasma Treatment, a process that enhances wettability properties of polymer-based materials and metals for good adhesion of inks, glues and coatings. Bfm will present a servodriven bag making machine. The BM250 W-EL 800 model will be configured in wicket stacking with eight rotary arms and a vacuum system. It can also be configured to six rotary arms for 600-mm bags and eight rotary arms for 400-mm bags. The machine is suitable for processing HDPE, LDPE, LLDPE and PP bags for diapers and bakery products as well as freezer and grocery bags. The line has an un-winder unit for 1,000-mm diameter reels and an automatic edge guide unit. Bfm’s new wicket bag maker
Italian Machinery and Technology Mobert, a developer of welding machines for bags on roll, will present the Nastrosac welding unit. With a patented system for inserting the draw tape, it will be completed by a four-station winder for reduced cycle time. With an output of 250 cycles/ minute, Nastrosac can produce bags in a roll with side sealing and draw tape and also bags with bottom sealing. The line consists of a 1,100 mm reel holder with motorised reel lifter. Profile/pipe equipment and tooling Pipe/profile machine maker Sica, which celebrated its 50 years in business this year, will present the Duet 200 in-line planetary cutting machine that cuts and chamfers PP, HDPE and PVC-U pipes up to 200 mm-diameter. In addition to the standard disc and chamfer models, there are also the Duet/K versions (for swarfless knife cutting) and Duet/C (for chamfering and knife cutting without producing chips and dust inside the pipe). The Duet 125 can produce 500 mm-length pipes at an output of 2,300 pipes/hour.
Sica will also display its Multibell 75 in-line belling machine that sockets by means of an oven with recirculated and thermoregulated hot air; for doubleextrusion lines for PVC-U pipe
Eprotech, a producer of extrusion tools, will be presenting its window profile and panel tooling that are able to process a wide range of materials at an output up to 700 kg/hour. Its die system, with separated heater bands, is designed to follow the rheology of the materials to be
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processed. Extra heating zone systems are added to improve the gloss of the profile surfaces while a calibrating system allows for high output of window profiles.
Piovan will showcase its Modula dryers
Gamut of auxiliary equipment In dehumidification, Piovan will showcase the Modula trolleymounted system. Made up of the DP644 dryer and PTU1000, PTU800 e PTU600 hoppers, unlike traditional central systems, the system automatically adjusts and controls all operating parameters for each individual hopper, hence reducing the energy use. This is made possible through specific software that interfaces the settings for each hopper with the data collected by the sensors installed on the system. The firm will also showcase its Lybra gravimetric and volumetric dosers for dosing masterbatch additives and recycled material. Introduced at K2010, the machine is now available in different configurations to meet specific requirements. Lybra GR is suitable for masterbatch dosing in PET applications while for precision injection moulding, extrusion and blow moulding, new Lybra solutions, both gravimetric and volumetric, with two and three stations, will be on display. In feeding and handling, Piovan will showcase its Easy3 System material receivers and Varyo vacuum units for compressed air-powered granule conveying that regulates loading cycles to eliminate mechanical stress on the polymer and reduce energy use. Mould conditioning systems and innovations in refrigeration complete Piovan’s display.
In feeding systems, Wamgroup will showcase its loss-in weight system for handling powders and granules. It comprises a micro-batch feeder with a body made of stainless steel and Sint engineering polymer, a stainless steel feeder pipe and drive guard and platform scales on a microprocessor-controlled load cell. When feeding and metering small quantities, the MBF-BE system is able to assess variations in weight and adjust the feed rate by varying the speed of both discharging and feeding devices. Internal mixer specialist G3 will show a hydraulic hopper as an alternative to the traditional pneumatic hopper. The firm says besides reducing energy and maintenance costs, it provides a uniform and repeatable working pressure in the different mixing stages. It can be installed for use in any brand of internal mixer.
PGV’s new equipment is designed for small batch operations
PGV will present its FUN 9000 equipment for nylon, a material where humidity needs to be restored before being used. Said to be the smallest appliance in the range, it is suitable for small production batches. Another novelty will be a dehumidifier that dries granules using a rotorcassette system. It can be paired with traditional drying hoppers from the firm’s GL range.
Italian Machinery and Technology
Moretto’s Eureka system is made up of the OTX hoppers
Moretto will display its Eureka dehumidifier for PET drying, based on its X Max, Flowmatik and OTX technologies. The modular X Max dryer allows for large drying systems up to 20,000 cu m/hour, with up to 32 drying hoppers, without the use of compressed air or cooling water. The integrated Flowmatik, meanwhile, enhances air distribution in the multi-hoppers, supplying the exact quantity of process air needed by the hoppers. OTX hopper, which comes in a new shockproof Spyro finish, allows for uniformity in material flows, managing the drying phase by keeping the process inside the hopper under control. Round-up of PU machinery Magma s.a.s di Paolo Guaglio will showcase dosing machines for twocomponent high pressure mixing with an output range of 3-20 kg. The self-cleaning, pneumatic mixing head is moved by linear tracks to render a speed of up to 2 m/ second. By using special adapters, material can be sprayed or cast. The hydraulically-driven volumetric pumps reach a 150 bar pressure. A
Magma’s machine for adhesive and bicomponent foam spraying and coating
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touchscreen panel allows working and control parameters to be managed, including resin delivery and machine cycles. Foam equipment maker Tec Mac exports almost all its output like the Isolblock foaming plant for producing TDI or MDI-based flexible foam, rigid foam for insulation as well as PIR, semi-rigid and phenolic foams. Isoltec, meanwhile, is multi-purpose high pressure spray equipment for applications such as roofing, building insulation, pouring, gluing, priming for PIR panels, waterproofing, elastomers, coatings and polyurea. The fully automated TML-A is a cutting unit for rigid/flexible PU foam.
Tec Mac Isolblock equipment
Another equipment maker SAIP will present its new elastomer casting machines for processing prepolymer-based MDI elastomers. The EL series lowpressure machines are available in a range of outputs and ratios, with modularity allowing up to five components and colour dosing lines. Impianti OMS will introduce its continuous and discontinuous plants that help enhance the thermal and fire properties of flexible, metal and rigid boardfaced composite panels. Testing solutions for improving processing Instrument producer Gibitre will be presenting a UV-absorber ozone concentration measuring device. Another novelty is the low temperature check instrument (for testing TR and brittleness) in a new, more compact structure. Other new equipment include a tensile tester with new 2 KN structure, with the thermal chamber directly controlled via the instrument control software.
Plastiblow’s blow moulder enables the recovery of kinetic energy
Electric blow moulders take centre stage Plastiblow will exhibit its ten-year electric technology. The PB10E/SXL single-station servodriven blow moulder, with a three-cavity mould, is able to produce 5 l canisters. It is equipped with a 90 mm extruder with a forced feed zone and a triple head with 240 mm centre distance. Other features are the field bus architecture for the connection of various electronic components that allows digital transmission of signals; precise synchronisation of electric axes and a real-time diagnostics and supervisory system. The machine is also equipped with a module that enables the recovery of kinetic energy of the carriages during deceleration, converting it into electrical energy that is returned to the line. Meccanoplastica, meanwhile, will display its HL electric extrusion blow moulder, said to be noiseless. The 6tonne machine, with 350 and 400 mm carriage strokes, is able to produce 3 l containers. During the show, it will be equipped with a triple parison extrusion head (120 mm centre distance) to produce 350 ml HDPE oval-shape cosmetic bottles. The firm will also present its 18-cavity Jet55/L electric injection
Meccanoplastica will showcase its HL350 all-electric blow moulder
Italian Machinery and Technology blow moulder shown producing 5 g, 10 ml PE bottles and the Mipet1P two-step electric stretch blow moulder producing 750 ml PET bottles using PET preforms. The latter is manufactured at the firm’s facility in Barcelona. ST Soffiaggio Tecnica will showcase machines for producing automotive components. Using suction blow and 3D three-axis technology, its blow moulders can produce complex-shaped parts with minimal wastage. A 20-tonne machine with a 70-mm extruder and 2 l accumulator head will be shown. The area where the mould is mounted is completely free of any obstacles thus allowing for easier mould installation. Rotomoulding takes on a green theme Sustainability is being applied in all machinery facets including rotomoulding. Caccia Engineering has designed a machine with an exhaust gas modulation (EGM) system for the dispersion of gasses to help reduce the carbon footprint as well as cost and energy consumption. The EGM is realised through a variable speed extraction fan, which operates in line with the load percentage of the digital burner and is monitored through a software. In addition, a turbo fan system increases the total efficiency of the combustion
and heating equipment of the oven by up to 10%, with an overall savings of 38%, compared to competitors, says the firm. CNC machinery cuts into blade making, too Pagani, a specialist in aluminium moulds, will showcase its CNC machines for large moulds as well as three or five-axes machines. Other machines to be featured are for PU injection moulds as well as rotational, thermoforming and compression moulds. Granulator blade maker Povelato will present its new line of specially coated blades and high strength materials. It utilises CNC machines for blade milling and grinding, with treatments predominately carried out with furnaces in a controlled environment, giving the material a uniform structure that provides the blade with high resistance to wear and mechanical stress. Equipment for liquid refrigeration Frigofluid will exhibit equipment for the refrigeration and temperature regulation of process fluids. The firm says its equipment reduces power consumption and downtime. Products to be exhibited include air-condensed chillers with axial or centrifugal fans, 6 kW to 600 kW chilling power range; air-condensed chillers with inbuilt free-cooling system, 30 kW to 600 kW
chilling power range; compact watercondensed chillers, 6 kW to 600 kW chilling power and free coolers with axial or centrifugal fans, 45 kW to 600 kW. Staying cool will be highlight of Frigosystem’s exhibit with its new range of chillers. Raca Plus Energy are equipped with the R410 ecological gas for energy savings of up to 35% compared to the R407 conventional gas. The models come with multicircuit and multi-compressor systems and are available from 50 to 1,200 kW of nominal cooling power. The new line also comes with the i-Remote local and remote supervision system. Kite is another product highlight from Frigosystem. It is an air and water chiller for blown film extrusion. It is available with one, two, or three air outlets and water thermoregulated connections. Making industrial cooling processes more energy efficient is Castello d’ Agogna’s goal for its latest products. It will display its Adcooler that combines the heat efficiency of an adiabatic system with the energy savings of a dry cooler. It is suitable for all industrial processes that require water. Taking advantage of the evaporation of a small quantity of water, the Adcooler is able to achieve near wet bulb temperatures. During the show, the product will be presented in a self-draining version that empties automatically.