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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
TPE 成 为医 疗个人防护设备的优选材料
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In this issue
Volume 35, No 255
publlshed slnce 1985
A S l A’ S L E A D l N G m aga z l ne f o r the plastlcs and rubber lndustry
Features 焦 點 內 容 13 材料新聞: 個人防護裝備：尋求可生物降解/非塑料替代品 16 Front Cover – Against the back of the Covid-19 pandemic, the
use of Personal Protective Equipment (PPE) and product shelf-life of pharmaceutical packaging has become increasingly more important. TPE supplier KRAIBURG TPE covers both these sectors with its THERMOLAST compound series
19 Medical Sector – Medical tubing applications continue to evolve
while also playing a vital role in the delivery of quality healthcare worldwide. US extrusion machinery firm Davis-Standard addresses important ROI factors in the selection and care of equipment required for medical tubing
21 Building Industry – Smart materials are forming the building blocks in modern environmentally-friendly structures
Regulars 概 要
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 Chinese Editor Koh Bee Ling Circulation Stephanie Yuen Email: stephanie@taramedia.com.my
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Supplements 副 刊 IMA Automotive: In the automotive sector, less is more is quite a common phrase – with fewer component parts and a focus on lighter weight materials being used for improved fuel economy and lower CO2 emissions IMA Medical Devices Sector: The medical sector seems to have flourished in the Covid-19 pandemic, with injection moulding machine makers and medical devices producers successfully meeting the demand for critical medical equipment China is the largest tyre user and ultimately the largest polluter of scrap tyres. Thus, the country is on a mission to increase its tyre recycling with advanced technologies, more recycling plants, and new company partnerships DIGITAL EDITION www.plasticsandrubberasia.com
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On the Cover KRAIBURG TPE’s TPE compounds are meeting the needs of the healthcare sector
TPE 成 为 医 疗 个 人 防 护 设 备 的 优 选 材 料
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Industry News
M&As/Tie-ups/Investments • US speciality materials firm Celanese Corporation is selling its 45% equity investment in the Polyplastics joint venture to its partner Daicel Corporation for US$1.575 billion. Since 1964, Celanese and Daicel have operated Japanbased Polyplastics, a supplier of engineered materials including acetyl copolymer (POM), liquidcrystal polymer (LCP) and polyphenylene sulphide (PPS) polymer. Celanese will use part of the proceeds to fund a US$500 million share repurchase programme to its existing share repurchase authorisation. • Mitsubishi Chemicals has invested in France-based tech start-up Aveni to further develop its disruptive metallisation technologies for the 3D memory industry in the electronic materials sector. Aveni has also secured an investment in Series B financing from Diamond Edge Ventures (DEV). 2
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• Materials firm Arkema has acquired Fixatti, a Swiss company specialising in thermobonding adhesive powders, to enable Arkema subsidiary Bostik to strengthen its global offering of hotmelt adhesive solutions for niche industrial applications in the construction, technical coating, battery, automotive, and textile printing markets. Fixatti operates two sites in Europe and one in China, employs 180 people, and reports sales of some EUR55 million. Arkema is also investing in US-based Continuous Composites, the creator of Continuous Fiber 3D Printing technology (CF3D), to advance the development of 3D composite manufacturing. Meanwhile Arkema, with a focus on designing photocurable liquid resins through its Sartomer business, has a specific offering for additive
manufacturing and is now developing a new generation of solutions for CF3D. • US private equity firm SK Capital Partners is to acquire the specialty polymers business from Baker Hughes. Terms were not disclosed. The business, with manufacturing operations in the US, produces specialty low molecular weight olefin polymers, including a range of functional polymers and high melting point PE waxes. • Mitsubishi Chemical Advanced Materials has acquired the assets of two German carbon fibre recycling companies: CFK Valley Stade Recycling and carboNXT. With its own network to collect carbon fibre waste products, CFK caters to mobility-related industries. It also offers its proprietary technology that breaks down carbon fibre wa ste, and converts it into various usable forms of
carbon fibre. In turn, carboNXT sells the CFKrecycled products back to the market. • Thailandheadquartered integrated PET supplier Indorama Ventures Public Company is to acquire IMP Polowat, a Polish PET recycler. The acquisition consists of two assets with a combined capacity of 23,000 tonnes of recycled PET (rPET) flakes and 4,000 tonnes of rPET pellets. This acquisition is consistent with IVL’s target in scaling its recycling capacity to reach 750,000 tonnes by 2025. • US contract manufacturing and injection moulding company GW Plastics has been acquired by Swedenbased Nolato Group in a deal totalling US$230 million. Nolato specialises in manufacturing products in polymer materials such as plastic, silicone, and TPE within the healthcare, automotive, and consumer electronics industries.
INDUSTRY NEWS • Speciality chemicals firm Lubrizol Corporation has acquired Avid Product Development, which offers 3D printing capabilities, including design for additive manufacturing (DfAM), prototyping and production using powder bed fusion (MJF, SLS), fused filament fabrication (FFF) and stereolithography (SLA. Terms were not disclosed. • US-based private equity firm Arlington Capital Partners is to acquire the composites business of Triumph Group for an undisclosed sum. Included in the sale are the Triumph Aerospace Structures composites locations in Georgia, US, and Rayong, Thailand, of around 800,000 sq ft of factory space and 600 people. Key programmes supported by the sites include Boeing 787, 777 and V-22, Airbus A320, A330 and A350, Embraer E-2, Northrop Grumman Global Hawk, as well as the Gulfstream G650/700. • Japan Composite, owned 65% by Mitsui Chemicals and 35% by Nippon Shokubai, is to acquire the sheet moulding compound (SMC) and moulding operations of DIC Kako. The business acquired will change to JC Kako Co and is due to begin operating on 1 December 2020. The incorporation of DIC Kako’s SMC business will make for a dual-plant set-up between Shimizu and Narita, boosting Japan Composite’s SMC production capacity by 70% to 33,000 tonnes. • US silicones maker Momentive Performance Materials is selling its Consumer Sealants business to conglomerate Henkel. The sale includes the GE-branded consumer sealants, while the GE-branded construction sealants product line will remain a Momentive product. Momentive will continue to manufacture the consumer sealants through 2021 at its facility in Waterford, New York, under a transition supply agreement. The move away from consumer sealants will allow it to focus on its advanced silicones and specialty applications businesses. • Through the acquisition of the Solvay polyamide business, German chemicals firm BASF says it has enhanced its R&D capabilities in Asia Pacific with new technologies and part testing services.
DISCOVER KRAIBURG TPE Solutions with Thermoplastic Elastomers KRAIBURG TPE is one of the world’s leading manufacturers of soft, elastic thermoplastic elastomers. Our THERMOLAST®, COPEC® and For Tec E® range can be precisely custom-engineered to your every application – from automotive, consumer, industry, and medical. We deliver outstanding performance, quality and value across our specialized products and we have the know-how to develop individual compounds for new demands – all across the world.
+60 3 9545 6393 info-asia@kraiburg-tpe.com KRAIBURG TPE TECHNOLOGY (M) SDN. BHD.
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Industry News
BASF is planning to integrate the R&D centres from Solvay into its R&D existing facilities in Shanghai, China, and Seoul, Korea. BASF now has its first UL certified lab in Asia, adding to its existing labs, which have an ISO17025 accreditation. The new lab, located in Shanghai, will be part of the company’s global R&D network and complement BASF’s existing flame-retardant grade polyamide testing service, mainly for electronic and electrical solutions. • US flexible packaging firm Sealed Air Corporation has made an equity investment in UK-based Plastic Energy Global, the parent company
of Plastic Energy, to meet its target of 50% recycled content across all packaging solutions with 60% of that coming from postconsumer recycled content. Plastic Energy Global was established in 2012 with the goal of processing 300,000 tonnes of plastic by 2025. Headquartered in London, the company has two operations in Spain and has a vision for 50 new facilities over the next ten years in Western Europe and Asia.
the United Arab Emirates (UAE) and surrounding countries. Reifenhäuser India Marketing represents Buss in India. Reifenhäuser (MEA) is a joint venture between Germany-based machinery maker Reifenhäuser GmbH, Manish Mehta, Founder/ Managing Director of Reifenhäuser India Marketing, and Bharath Yalla, Managing Director of Reifenhäuser (MEA), which was founded in 2018.
• Swiss compounding machine maker Buss AG has entered into distribution partnerships in the Middle East and India. Machinery firm Reifenhäuser Middle East & Africa (MEA) represents Buss in
• German technology company Continental and system supplier aft automotive are setting up a 50:50 joint venture to manufacture couplings made of high-performance plastics for the
Plant Expansions/Openings/Set-ups • Austrian packaging company Greiner Packaging is partnering with Plastic Bank, a social enterprise that builds ethical recycling ecosystems in coastal communities, to open five collection centres in Manila, Philippines. 4
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Greiner says the Philippines is the world’s thirdlargest producer of plastic waste, after China and Indonesia, with an estimated 2 million tonnes of plastics ending up in the oceans each year; and the country’s Pasig River responsible for introducing
64,000 tonnes of plastic waste into the oceans every year. • Spanish petrochemical firm Repsol and recycler Acteco are joining forces to increase the capacity for production of recycled polyolefins at Acteco’s plant
for the future of mobility. The new company is planned to create more than 30 new jobs by 2025. • Styrenics maker Ineos Styrolution and UK recycler Recycling Technologies have tied up to further advance the development of recycling of PS in Europe. Recycling Technologies has already completed research and trial process with Ineos, including processing of PS on its Mark II test reactor, the RT7000, which turns hard-torecycle plastic such as films, bags, laminated plastics into an oil, called Plaxx, used as a feedstock for new plastic production. in Ibi, Alicante (Spain). The recycled product from this plant will be included in Repsol’s Reciclex range. The two companies have been collaborating since 2018, promoting the recovery of polymers and their re-introduction into the automotive, healthcare, construction and
INDUSTRY NEWS packaging sectors. Repsol’s aim is to recycle the equivalent of 20% of its polyolefin production by 2030. • The government of Jembrana Regency, in Northwest Bali, recently commemorated the groundbreaking for a new waste processing facility, the firstever solid waste management service that will benefit as many as 150,000 residents. The ground-breaking was carried out through a partnership between Project STOP, the Alliance to End Plastic Waste (the Alliance), and the Jembrana Regency. It is expected to be fully operational by the end of 2020. • BASF has opened its global Footwear Innovation Centre in Taiwan, a key footwear manufacturing hub in Asia. Located within the footwear manufacturing site of its strategic partner Longterm Concept (LTC) in Changhua, Taiwan, the 7,000
sq ft centre will bring footwear professionals, manufacturers, and designers together to co-create newgeneration footwear. BASF will also increase its alkoxylate capacity in Asia Pacific, with its latest investment in Jinshan, China. The company has acquired land, buildings and assets of Chinese firm SPC, related to alkoxylates production and adjoining the BASF Jinshan site, in order to fulfil the growing demand from customers across Asia.
• US manufacturer of water-soluble and biodegradable films MonoSol, a division of Japanbased Kuraray, recently commemorated its US$72 million production facility in Lebanon, Indiana. Commercial production began at the US facility in February, just before shelterin-place orders took effect in March. After two years of construction, the 150,000-sqft facility will
employ up to 90 staff. It is the company’s fourth factory in the state and sixth globally. In late June, it also broke ground on a new manufacturing plant in southern Poland. • Indian conglomerate SRF has commissioned its EUR80 million bi-axially oriented polyethylene terephthalate (BOPET) film manufacturing plant in Jaszfenyszaru, located 50 km east of Budapest, Hungary. The plant will have a capacity of 40,000 tonnes/ year. SRF says its plants will have a combined capacity of 220,000 tones/ year of BOPP and BOPET films globally. • The Thai subsidiary of Japanese resin maker Japan Polypropylene (JPP) and 50:50 joint venture partner petrochemical firm IRPC Public Co Thailand have started up a 140,000tonne/year PP compounding plant in Chonburi Province. It will utilise raw material from a 300,000-
tonne/year PP polymerisation plant located upstream. JPP will also shut down a 70,000tonne/year PP polymerisation train located at Kashima, Japan, early next year. In March this year, Tokyo-based JPP, under Mitsubishi Chemical Corp., sold a 50% stake in Mytex Polymers (Thailand), its wholly owned subsidiary, to IRPC, a subsidiary of Thailand's state-backed oil firm PTT Public Co. • Chemical firm Nouryon has selected Green Bay, Wisconsin, US, as the location for a new facility to produce its Expancel expandable microspheres. The first step will be the start of initial production in Green Bay in October 2020; this will be followed by further increases over the next several years. Expandable microspheres are used as lightweight filler and blowing agents to make end products lighter and obtain different surface effects. AUGUST 2020
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Materials News
PPEs: biodegradable/nonplastic alternatives sought To contain the “other epidemic” of plastic materials, PPEs made of non-plastic and alternative materials are being developed as counter measures to the environmental impact of PPEs being discarded and littering the environment, says Angelica Buan in this report. Demand overtakes supply At fir st glance, it is merely a piece of a moisture repellent cloth with strings. The use of medical masks, commonly made of non-woven fabrics made f r o m p l a s t i c s l i k e P P, t o r e p e l , f i l t e r a n d p r o t e c t u s e r s , wa s m o s t l y c o n f i n e d t o h o s p i t a l s e tt i n g s d u r i n g t h e p r e - C ov i d - 19 e r a . B u t w h e n t h e n e w coronavirus pandemic broke out, demand for masks and other personal protective equipment (PPE) spiked tremendously causing demand to outpace supply and PPEs becoming priceless commodities. I n f a c t , t h e U S Fo o d a n d D ru g Ad m i n i s t ra t i o n ( F DA ) a n d t h e Wo rl d H e a l t h O rga n i s a t i o n ( W H O ) acknowledged the limited access of PPEs, with supply d e f i c i t s p r e a d i n g g l o b a l l y. I n e a r l y M a r ch , W H O sought for an increase in manufacturing by 40% to meet rising global demand. It had estimated that 89 million medical masks/month were required to meet the Covid-19 response. The situation has exposed the vulnerability of the PPE supply chain during the course of the pandemic.
An estimated 89 million medical masks/month were required for the Covid-19 response
The Pandemic Supply Chain Network (PSCN), a public-private collaboration formed by WHO and the WeForum aims at addressing supply security, as well as access to PPEs. In the earlier months into the pandemic, PPEs, specifically disposable face masks, had been advised by the WHO to be limited for use for medical and healthcare frontliners and essential workers to a u g m e n t t h e s u p p l y. B u t c o n t a i n m e n t m e a s u r e s
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around the world have eventually been readjusted as infection spread continues unabated in several countries globally. Scarcity breeds opportunities In the Philippines, where the number of morbidity and mortality cases from coronavirus infections is increasing, PPE use, specifically masks and face shields, has become mandatory, especially in public p l a c e s a n d t r a n s p o rt a t i o n . D e s p i t e t h e i n f l o w o f monetary and PPE donations from foreign countries, s u p p l y s e c u r i t y r e m a i n s a h i t ch i n t h e c o u n t r y ’s pandemic response. The Philippine Plastics Industry Association (PPIA), the country’s association of plastic fabricators with members engaged in moulding, extrusion, weaving, lamination and recycling, has taken up the challenge to produce the materials for PPEs locally to close the supply chain gap; and deli ver PPEs to front liner s rapidly. PPIA President Vicente Co and National Solid Waste Management Commissioner Crispian Lao said that localisation (of manufacturing) not only generates the much needed jobs, but also buffers the country against the impact of supply shortage. The locally produced non-woven PP materials can be made into disposable protective coveralls for healthcare workers as well as essential workers. The Philippine Plastics Industry Association along with Prima Plastic and ExxonMobil Chemical developed an alternative material using a PE-based solution for locally manufactured PPEs
Materials News Additionally, PPIA, collaborating with Prima Plastic Manufacturing Corporation and ExxonMobil Chemical, has developed an alternative material using a PE-based solution. Overcoming development glitches, such as the samples of the PE-based film being prone to tearing when sewn, Prima Plastics has added cellophane tape to reinforce the stitching. To make it durable, ExxonMobil supplied its metallocene PE compound as the basis for the primary formulation. PPIA said that it is further developing the material and starting to scaling the production of PE-based PPEs (coveralls and gowns) using the locally-produced material. PE and PP are highly recyclable post treatment materials, and can be recycled into trash bags, crates and pallets or utilised in waste-asphalt bitumen for road applications, though in the case of medical use PPE, the toxicity may not allow for recycling. Plastic-free solutions abound in the Philippines The assurance of a stable supply of PPEs, on the other hand, begets another worrisome situation for the Philippines that was ranked among the biggest plastic polluters in the world in a 2015 Ellen MacArthur Foundation ocean plastics report. The country, dealing with mounting waste plastics, mainly from single-use plastics, would have to wrestle with plastic waste that would be added on from discarded PPEs.
Abaca can be used in a variety of applications; and now for masks too
Environmental group Greenpeace cautions against the environmental implication of the increased use of PPEs, stating that this indeed would “add another level to an already severe global waste issue�. Shifting to biodegradable and biobased materials has always been the go-to solution, even with packaging or other applications that require plastics. The Philippines, where Covid-19 cases already crossed the 160,000 count in mid-July, has taken to introducing biobased masks not only to combat plastic waste but also to utilise its endemic raw materials.
Materials News Developing biodegradable or non-plastic materials has been a consistent initiative for the Philippines. Fo r e x a m p l e , t h e c o u n t r y ’s I n d u s t r i a l Te ch n o l o g y Institute under the Department of Science and Technology (DOST) has, in the past, developed agroindustrial waste-derived natural fibre thermoplastic composites for industrial applications; and abaca (Manila hemp) fibre-reinforced composites for boat applications. Abaca fibre has also been tapped as an alternative material to meet the demand for face masks suitable against infectious droplets. DOST, including different response teams (DOST-X), has evaluated materials for possible alternatives in making home-made face masks. One of the materials evaluated by DOST-X through its Regional Standards and Testing Laboratories (RSTL) is the abaca face mask from Northern Mindanaobased Salay Handmade Products Industries (SHPII). It utilised microscopy to evaluate fibre structures and measure pore sizes; as well as the abaca’s water repellency and absorbency through simple water drop tests and laboratory-modified water drop tests, respectively.
Further standard tests aside, abaca, as a material component for face masks, is locally available and environmentally friendly. Jute/chitosan polymers for PPEs in Bangladesh Bangladesh, which in mid-August, posted nearly 280,000 confirmed cases of Covid-19 (with a 57% recovery rate), is developing a cellulose-based biodegradable material to be applied in PPE production.
Bangladesh experts have utilised biodegradable and recyclable jute cellulose, coated with oligo-chitosan, to produce PPEs for the country's healthcare frontliners
This face mask produced by the Northern Mindanao-based enterprise SHPII is made from Manila hemp
These tests were done on the abaca-made face mask samples as well as on the commercial surgical face masks and N95 masks. While comparatively, the abacamade face masks showed advantages, such as lower absorbency (3-5%), compared to N95 masks (46%), but not as nearly as the surgical face mask, which absorbed only 0.17% of the total volume of water dispensed during the laboratory-modified water drop test. In the simple water drop test, the abaca masks showed no repellence compared to the surgical face mask, which yielded repellence. DOST-X stated that the findings from evaluations, which were done using its available resources, “do not reflect the filtering efficiency or the filter performance of the samples”. The agency said that it is still continually upgrading its capabilities to be able to conduct the standard tests as approved by regulatory bodies. The evaluation observations, however, may provide options as to the better choice from available materials.
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Inspired by the Sonali bag material developed by Dr Mubarak Ahmad Khan, a scientific adviser to Bangladesh Jute Mills Corporation, a team of experts led by Dr Mehjabin T ishan Mahfuz is utilising the material in developing single-use PPE. The team is utilising biodegradable and recyclable jute cellulose, which is coated with oligo-chitosan for added antiviral protection. It is locally produced and affordable for healthcare workers in Bangladesh. Chitosan has been found to provide natural and effective protection against viruses and bacteria; while the jute-polymer has been established to be nonporous, Mahfuz said. The biodegradable material for the PPE dissolves in water within seven days and in soapy water in three minutes. Additionally, it is durable since the tensile strength of the cellulose-chitosan polymer is 1.8 times higher than that of PP, which is a standard material component for surgical masks and other PPEs. Not only can the pile-up of plastic waste be prevented but also the problem in medical waste disposal can be addressed. Mahfuz said that the current waste management in Bangladesh and other low to middle income countries is often unregulated – the method of which includes incineration that contributes to air pollution or simply injudicious dumping.
Materials News Specifically, the lack of proper disposal of medical products is a constant and grave challenge, Mahfuz mentioned in a study published by the Massachusetts Institute of Technology (MIT). The PPE, targeted for healthcare providers who come in contact with infectious patients, will protect both the caregivers and prevent transmission of infections from one patient to another. Mahfuz added that the team is working with the International Centre for Diarrhoeal Disease Research, Bangladesh to develop the PPEs. Sustainably-sourced plastic-free shield in Ireland Apparently, the coronavirus is threatening humanity in ways that could be similar to how plastic waste wreaks havoc on the environment but through different routes. Nevertheless, both have the environment as a common denominator. Plastic-free PPEs may kill two birds with one stone. Ireland’s largest supplier of alternative to single-use plastic straws, EcoStraws, has put out what it calls the first plastic-free certified PPE in Ireland. The EcoShield visors can “help tackle both the demand for PPE and play an important role in the reduction of plastic pollution,” said the start-up company, which has diversified into sourcing new products that have eco values, since the pandemic began.
EcoStraws has collaborated with Transcend Packaging, Reelbrands and A Plastic Planet, to bring the plastic-free PPE EcoShield visors to Ireland
EcoStraws has collaborated with UK peers Transcend Packaging and Reelbrands, along with international campaign group A Plastic Planet, to bring the plastic-free PPE to Ireland. The compostable and lightweight EcoShield visors are made from FSC (Forest Stewardship Council) paper board and PEFC (Programme for the Endorsement of Forest Certification) cellulose from wood pulp for a clear, mistfree screen. It also features an adjustable headband. The partnership aims to manufacture more than 1 million pieces/week of visors. In the UK, The Very Group, 3 Oceans, and Yodel, which supply the national health service, are amongst the first customers to switch to the paper visor, the company informed.
Reusable, self-cleaning masks a reality in France Reusing PPEs has been suggested recently to cut the disposal rate significantly, but this suggestion seems unthinkable now that the virus has been found to mutate, and its behaviour remains unpredictable. How about a self-cleaning PPE, which is not only reusable but also hygienic, thus doubly bringing convenience to the user?
Ajelis's reusable Hygiafelt-Cu barrier patch works by destroying bacteria and viruses when passing through this additional filtration barrier
Supported by the EIT (European Institute of Innovation and Technology) RawMaterials, the largest consortium in the raw materials sector worldwide, French startup Ajelis has come up with a solution via its new selfdecontaminating masks. Ajelis’s self-decontaminating design is made of fabric and a reusable and sterilisable barrier patch that is covered with a copper-based solution, the self-decontaminating material with biocidal properties Hygiafelt-Cu. The reusable Hygiafelt-Cu barrier patch works by destroying bacteria and viruses when passing through this additional filtrating barrier. To augment the face mask shortage in France, Ajelis participated in the creation of a network of volunteer sewers to make masks for health personnel and law enforcers. Hygiafelt’s breathability is said to be six times higher than the standard NF EN149 protective device, and the aerosol protection (droplets) is close to 99%, while for a standard EN14683 protective device it is 95. Hygiafelt can be sterilised simply in boiling water, and incinerated like all textile waste. It, thus, does not require the establishment of a specific destruction process, Ajelis explained. The pandemic, at its worst, has brought about the best in material innovations to help the world recover from the health crisis and keep the environment safe for now from the other waste “pandemic” of discarded PPEs. AUGUST 2020
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Front Cover
TPEs find a niche in PPEs and pharma packaging Given the rise of pandemics like Covid19, the role of Personal Protective Equipment (PPE) in protecting the healthcare workforce has never been more important. Meanwhile, with product shelflife being a priority in the development of packaging materials, TPEs are finding a niche in this sector, too.
TPEs on an upward trajectory Packaging and personal protective equipment (PPE) share one thing in common: a judicious use of plastics. Plastics make for lightweight, flexible, and designversatile packaging, to name a few advantages. The efficiency of plastics for packaging makes it an economical and sustainable material solution. Likewise, these intrinsic properties of plastics make them also suited for PPEs. However, not just any standard plastic types can fit the bill for medical use. Innovative materials such as thermoplastic elastomers (TPEs) respond to the functional issues related to PPE designs and medical packaging, owing to their versatility and durability. TPEs continue to traction in the global supply chain, with a market that is projected to exceed US$19 million by 2022, according to a Grand View Research report. Thus, TPEs present advanced material benefits that make them a more suitable replacement for thermoplastics and standard elastomers. TPEs: a strong suit for safer PPEs PPEs provide protection against cross-infections and pathogenic transmissions and have the potential to block infections originating in blood, body fluids or respiratory secretions. Global organisations, among which include the World Health Organisation (WHO) and the UNICEF (United Nations Children's Fund), cannot emphasise enough on the safety and effectivity of PPEs, including disposable surgical masks and gowns, face shields, goggles, glasses, and shoe covers. According to the UNICEF, PPEs both for medical use and those specified only to protect the user, must ensure the safety performance as well as quality, among other criteria. The US Food and Drug Administration (FDA) has also laid out regulatory criteria for manufacturers to follow, which cover fluid resistance, leak protection, filtering capacity and tear resistance. PPEs also have to be durable, comfortable to wear, and to provide adequate barrier against contact with body fluids and respiratory secretions; plus able to withstand the rigours of patient care for healthcare workers and medical front liners. The advantages of mechanical properties coupled with biocompatibility, make TPEs well-suited for medical applications in parts sealing, strips, handles, and more. Cross-contamination and viral transmission are also significant issues PPE makers have to contend, most especially during this current Covid-19 situation. At best, PPEs offer ample protection for users, acting as barrier against pathogens and contagious bugs. As such, TPEs respond to the functional issues related to PPE designs, owing to their versatility and durability. For medical device applications, TPEs are sterilisable and offer advantages of mechanical properties as well as biocompatibility, making them well-suited in parts sealing, strips, handles, and more. Medically fit compounds KRAIBURG TPE, a global TPE manufacturer of a wide range of thermoplastic elastomer products and custom solutions for multiple industries, offers custommade TPE compounds, such as the THERMOLAST M materials for medical PPE applications.
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Front Cover Due to the use in of the compounds in a critical sector, KRAIBURG TPE says its THERMOLAST M TPE compounds are produced exclusively on a special medical unit. The compounds also meet the requirements of the VDI 2017 guideline for medical-grade plastics (MGPs), issued by the Association of German Engineers (VDI), as well as the Reach and RoHS standards and Regulation (EU) No 10/2011, for use in medical applications. The US DMFlisted compounds also conform to US CFR 21 FDA (raw material conformity), and are certified to ISO 10993-10 (Intracutaneous irritation), ISO 10993-4 (Hemolysis), USP <88> (Biological Reactivity, Class VI), ISO10993-11 (Acute systemic toxicity) and ISO 10993-5 (Cytotoxicity). In addition to the easy sterilisation properties, important features of the TPE compounds in THERMOLAST M are the elasticity and soft, flexible surface. Targeted at the medical sector, the THERMOLAST M compounds are free of allergens such as latex, as well as avoid potential environmental pollutants such as PVC, phthalates, and BPA (bisphenol A). Durability factor of compounds The THERMOLAST M includes the MC/LF series that can be applied in breathing masks, goggles, sealing for face shields and handles of glasses to protect users against viral and bacterial contaminants. Benefits of this series are the hardness level of 30-90 Shore A, low surface friction, abrasion and scratch resistance and the translucent colour. Furthermore, the MC/LF series of compounds can be easily processed through injection moulding and extrusion, with properties of adhesion to PP.
Meanwhile, the MC/AD/PA series in the THERMOLAST M TPE compounds are suitable for applications such as face shield head comfort pads and face mask seals that are used to protect users against infectious diseases. Properties of the injection mouldable compound are the hardness level of 60-70 Shore A, and its adhesion with nylons, such as PA6 and PA12. Available in a natural colour, it is also easily colourable in effect colours, to allow for customisation in medical PPE applications. THERMOLAST M MC/AD/PA series Compound Name
Hardness
Colour
TMxAPO
60-70 Shore A Natural
Adhesion PA6 & PA12
Material Advantages
• • • • • • • •
Colourable, also in effect colours Sterilisable (b-/y-radiation 2 x 35 kGy, ETO) Adhesion to PA6 and PA12 VDI 2017 US CFR 21 FDA (raw material conformity) Regulation (EU) No 10/2011 ISO 10993-5 (Cytotoxicity) ISO 10993-10 (Intracutaneous irritation)
All values published in this data sheet are rounded average values
THERMOLAST M MC/LF series Compound Name
Hardness
Colour
Adhesion
TMxLFT
30-90 Shore A
Translucent PP
Material Advantages • • • • • • • • • • • • • • • •
US DMF listed Adhesion to PP Low surface friction Abrasion resistance Scratch resistance Sterilisable (autoclave 134°C, b-/y-radiation 2 x 35 kGy, ETD) Optimised mechanical properties VDI 2017 Regulation (EU) No 10/2011 USP <88> (biological Reactivity, Class V) US CFR 21 FDA (raw material conformity) US FDA CFR 21 ISO 10993-4 (Hemolysis) ISO 10993-5 (Cytotoxicity) ISO 10993-10 (Intracutaneous irritation) ISO 10993-11 (Acute systemic toxicity)
All values published in this data sheet are rounded average values
TPEs respond to the functional issues related to PPE designs, owing to their versatility and durability
Pharmaceutical packaging with TPEs Materials used for pharmaceutical packaging must ensure the freshness, hygiene and shelf-life of the products, especially since spoilage and contamination can pose serious health risks to the user. Notwithstanding the fact that pharmaceutical packaging failures are also causing costly product recalls, thus extorting more trouble for manufacturers from penalties to regulatory compliance issues to brand reputation damage. Thus, maintaining the quality of the product until it reaches the consumer can be assured with the right material for the packaging. Essentially, the material has to meet quality standard requirements such as protection against light, heat, and moisture, and against chemical reaction with the packaged drug. It has to AUGUST 2020
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Front Cover allow for design flexibility and not add extra weight for the packaging for easy storage and handling. The use of polymer materials such as TPEs has been an important milestone in the development of pharmaceutical packaging as the compounds render the required properties, such as barrier protection against UV light as well as feature high impact strength and durability. With the pharmaceutical packaging market expected to amass a US$112 billion market by 2024, based on a Markets and Markets audit, polymers continue to be a leading material in this packaging segment, thus auguring demand for TPEs. Antimicrobial properties of THERMOLAST KRAIBURG TPE’s THERMOLAST M TPE compounds are specially developed for the medical and pharmaceutical industry and assure the specifications required for pharmaceutical packaging. The series meets the medical grade plastics international standards set in the USP Class VI, ISO 10993-4 (haemolysis), ISO 10993-5 (cytotoxicity), ISO10993-10 (intracutaneous irritations) and ISO 10993-11 (acute system toxicity). Biological contaminants are a major cause of spoilage of pharmaceutical products. The advantage with THERMOLAST M TPE compounds is that they can be sterilised using methods such as EtO gas, superheated steam (134°C), g-gamma ray treatment (2 x 35 kGy), b-ray (electron beam) treatment (2 x 35 kGy). Thus, these compounds are suited for applications like seals and valves in bottles for pharmaceutical storage, as well as for closures, septum, caps, infusion
caps and ampoules in pharmaceutical packaging. The compounds can also be used in applications related to the process of transfer and filling in pharmaceutical industries. Material performance for cost The THERMOLAST M TPE compounds are developed with optimum productivity and cost-effectiveness in mind. Aside from the materials’ ample range of application possibilities, other features are the costeffective moulding process and short cycle time advantage for injection and two-component injection moulding and extrusion processing, which allow manufacturers to boost their productivity. As well, the THERMOLAST M TPE compounds show excellent adhesion to various polymers such as PP, PE, COC, ABS, PS, PC, PET and PA. Optimum purity with the Medical Service Package KRAIBURG TPE provides a Medical Service Package that is orientated to delivering the highest quality standards of its TPE compounds, which are free of intentionally added heavy metals, latex, PVC and phthalates. As well, the production of the compounds is permanently assigned in a separate processing unit, with the constant manufacturing process recorded in US FDA Drug Master Files (DMF). Furthermore, the medical service package guarantees a 24-month supply of the compounds, allowing for supply security and long-term use by pharmaceutical packaging processors.
TPE compounds are suited for applications like seals and valves in bottles for pharmaceutical storage
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Medical Sector
Cost-efficient equipment for medical tubing Medical tubing applications continue to evolve while also playing a vital role in the delivery of quality healthcare worldwide. US extrusion machinery firm DavisStandard addresses important ROI factors in the selection and care of equipment required for medical tubing
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ith Covid-19, single-use plastics have been important to every industry, but have become even more critical for medical applications. Tubing equipment options are vast and costefficiency is essential, requiring processors to plan ahead to achieve maximum ROI.
• • • • •
The following factors are vital: Product versatility Options for expanded capabilities Precise and consistent product development Cleanroom factors Space limitations
Product versatility and being able to expand capabilities is essential in a high-growth market such as medical tubing. Equipment that supports efficiency, maximum line speeds, consistent and measurable quality, and the ability to process a wide variety of materials is typically worth the investment. For medical tubing manufacturers, materials can range from FPVC, polyurethane (PU) and nylons to PEEK and FEP. Tubing lines can be customised based on customer applications. Typical line speeds range anywhere from 100 ft/minute to more than 800 ft/minute depending on the materials, tubing application and requirements. Types of tubing applications include: • Microbore • Alternate polymer • • • • • •
Davis-Standard can customise a tubing line based on customer applications
Multi-lumen catheter Endotracheal and tracheotomy Radio-opaque striped Cannula tube Pipettes and Multi-layer tubing compositions
Selection of equipment Choosing the right equipment from the onset, including extruder design, control systems and feedscrews, is the best way to ensure a faster ROI. Timely upgrades can also offer a costeffective option when needed. As with any precision process where technology advances are made on a regular basis, it is important to have access to an R&D line. Testing new resins, AUGUST 2020
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Medical Sector making parts for proof-of-concept and conducting trials is paramount to maintaining a competitive advantage. It also helps validate processes before making equipment investments or going into large-scale production. While some companies have their own R&D capabilities, for those that do not, Davis-Standard has a dedicated medical tubing lab in a climate-controlled, cleanroom environment in their Pawcatuck, Connecticut facility. Customers can access the latest technology, extruder through downstream, to assist with R&D trails at a minimal expense. Cleanroom and space factors Cleanroom factors and space limitations should also be considered to maximise ROI. Machine construction, machine surfaces and treatments, extrusion drive and control systems are all part of creating a hygienic environment. For example, Davis-Standard’s MEDD extruder is a direct drive design eliminating the need for a gearbox and oil for cleanroom applications. It also allows for flexibility to change between a ¾ and 1-in. machine sizes using the quick-change barrel feature. For tight spaces or where co-extrusion capabilities are necessary, smaller machine designs that do not sacrifice torque and processing versatility are the way to go. In this area, Davis-Standard’s HPE models provide high-torque and direct couple motors in a compact design. The HPE-A model has height adjustments and swivels and tilts on a column to be positioned at any angle, while the HPE-H is a fixed height horizontal extruder. For resins that are especially challenging to process, Davis-Standard can integrate a melt pump into the control system to be coordinated with extruder pressure and speed, which provides a more stable output. In some cases, melt pumps can provide greater process control and can be sold and integrated on a line new or added at a later date if the customer changes materials or adds new material to be processed. Best practices to achieve strict cleanroom standards Best practices relate to equipment construction, surface treatments and extruder design features. These suggestions also promote effective and efficient disinfection and sterilisation procedures, while supporting regulatory standards set forth by the ISO certification system. Machine Construction • Use stainless steel or rust corrosion-proof materials where coatings are not practical • Ensure wipe-down zones are accessible • Minimise potential collection areas for dust and debris stagnation • Design containment options for possible fluid or residual lubricant leaks • Employ compact designs to minimise floor space
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Machine Surfaces/Treatments • Apply water-based or epoxy-based paint in areas not constructed with rust or corrosion-resistant materials • Polish surfaces and design with smooth, tapered or round edges for effective wipe-down • Use stainless steel surfaces to avoid contamination in product “contact” areas; stainless steel hoods and guards included for ease of cleaning Extruder Design Features • Utilise direct drive systems where applicable • Water-cooled motors (eliminate turbulent air movement from cooling blowers) • Permanent magent synchronous motors (eliminate the need for gearbox/oils/mechanical drive train; less noise and more energy efficient) • Include barrel cooling blower designs that minimise dust generation • Route control cabling and wiring to simplify cleaning measures • Affix polyurethane casters for ease of equipment movement and cleaning while also protecting the cleanroom floor Right coiling/reeling technology Meanwhile, selecting the right coiling and reeling technology for extrusion tubing application is essential. It is also imperative to ensure operator safety during unloading.
Automatic dual coiler KWA
Use the latest drive and control technology • The winding pitch should be automatically calculated using pre-programmed tube sizes while allowing fine-tuning during production • The dancer should have modern sensing technology for an extra-light touch on the tube. This is especially important for medical tubing where a contactless dancer is recommended to ensure product quality
Medical Sector • The end limits for reversing winding direction should be given by adjustable sensors, allowing for full edge-to-edge lays. This includes defining how a full reel is completed, either at its exact length or just a bit more to finish the lay-up to the edge Always ensure operator safety • Dual coiling, safe fully-automated transfers, and ergonomic handling all play a role in operator safety, and in ensuring the quality of finished coils or reels • Cut-off, strapping and coil unloading should be done automatically and safely within an operator-free enclosure • Reels that unload from the front side should be at a convenient height for the operator. The unloading door should be positioned to protect the operator from the winding side of the machine when opened • Reels that unload from the backside should be at a convenient height for the operator. Use a reel-lift for large reels. As with front side machines, the unloading door should be positioned to protect the operator from the winding side of the machine when opened
Consider the application • Automotive, heating and plumbing, irrigation, micro-duct and special tubing are typically wound on strapped coils. Tubing should be run at a constant speed without interruption or ramping during coil transfers. Optional automatic coil ejection onto a trolley or reception table is recommended • Medical tubing is typically wound onto a stainless steel fixed bobbin. The line speed in relation to rotational speed should be synchronised with traversing and switchback capabilities in order to achieve perfect lays. The goal is to have a smooth and clean finished coil, without gaps, overlaps and tube compression (ovality) • For irrigation tubing, automatic reelers are typically used to wind flat irrigation laterals onto cardboard reels. Consistent speed without interruption or ramping during coil transfers is important. Davis-Standard sister company Maillefer supplies several coiling and reeling machines based on application, tube diameter range, maximum coil diameter and linear speed. These options can be viewed at https://www.maillefer.net/en/components/ coilers-and-reelers/
Building Industry
Smart materials hit home Advanced material technology builds the foundation for the new era of smart building and home structures, says Angelica Buan in this report.
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he building and construction sector accounted for 36% of final energy use and 39% of energy and process-related CO2 emissions in 2018, 11% of which resulted from manufacturing building materials and products such as steel, cement and glass, according to a 2019 report by the Integrated Environmental Assessment (IEA) of the UN Environment Programme. That is why, energy efficiency in buildings can help in emissions reduction that is necessary for mitigating climate change. Not only does an energy efficient environment save up on energy costs, it can also promote comfort and health of users and dwellers. Materials used in structures can also help in increasing the energy efficiency in buildings. It is for this reason that the smart materials market is poised to advance in the coming years, in view of the changing global safety, efficiency and sustainability standards. Smart materials are like living parts of a smart structure – they can sense their environment and respond accordingly to such conditions or stimuli as pressure, temperature, electric/magnetic field, mechanical/physical stress, pH, and so on. Smart materials have mechanisms that defy the limitations that conventional materials, such as concrete, metal or wood , and help optimise energy use of the space. AUGUST 2020
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Building Industry Supercapacitor with bricks Energy savings in homes can be as simple as unplugging electric appliances or switching off lighting fixtures to reduce electricity consumption. But what if we can harness electricity directly from the wall? In today’s material technology advancement, it is no longer a far-fetched idea. Researchers at Washington University in St. Louis, Missouri, have developed smart bricks that can store energy. According to the paper presented by the team , led by Julio M. D’Arcy, Assistant Professor of Chemistry, and published in Nature Communications, the smart brick can store enough energy to power emergency lighting or sensors that could be embedded inside the walls of a house. For starters, bricks offer a porous network and a very strong material. In their study, the team filled the maze-like pores inside the brick with chemical vapour. The reaction was a plastic nanofibre coating, known as Pedot, as well as causing the bricks to turn from reddish orange to a dark blue. Due to the multitude of pores, more of the brick’s interior surface was coated. That enhanced the brick’s ability to store energy and turned it into a supercapacitor, which isn’t able to store as much energy but can more powerfully and quickly discharge electricity.
PEDOT-based smart bricks can store energy for purposes such as lighting bulbs and, potentially, powering personal gadgets
In their research, the team stacked about 60 bricks, which were able to store enough energy to power a 3W light bulb for nearly one hour; and they recharged within 15 minutes. While more research is needed, the team believes this proof of concept may one day result in walls that are able to store energy, enough to power bigger devices like laptops. Meanwhile, sustainable bricks were the focus of the study of a team of Australian scientists from Flinders University. They experimented on a rubber polymer to develop a type of green brick that is made from recycled PVC, waste plant fibres or sand.
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Canola oil
Elemental sulfur Copolymerize 180 ℃
Renewable triglyceride
Surplus feedstock
Friable rubber for heavy metal remediation, oil sorption, and fertilizer The rubber polymer is made from sulfur and canola oil, and can be compressed and heated with fillers to create sustainable construction materials
The rubber polymer is made from sulphur and canola oil, and can be compressed and heated with fillers to create construction materials that is deemed to replace non-recyclable construction materials, says a new paper published in ChemEurJ. The powdered rubber can be potentially used for tubing, rubber coatings or bumpers; or compressed, heated then mixed with other fillers to form entirely new composites, including more sustainable building blocks, concrete replacement or insulation. The team, led by Flinders PhD Nic Lundquist, said that adding that the rubber particles also can be first used to purify water and then repurposed into a rubber mat or tubing. The novel recycling method (called reactive compression moulding), as well as the new composites, according to Lundquist, are an important step forward in making sustainable construction materials, and an additional method of recycling PVC or carbon fibre. Smart opportunity for future window technology Windows are one of the most important parts of a dwelling space, and at the same time, a key factor in preserving its energy efficiency. Being that windows are responsible for heat loss or maintaining the coolness of the house, incorrect orientation or design can affect the comfort of the dweller. Glass in windows, being a conductor of heat, can contribute to the amount of sunlight coming through the home and can even significantly increase its cooling load. A smart window developed by researchers from Korea Institute of Energy Research (KIER) can automatically adjust the amount of sunlight entering the room by changing the colour of window depends on the intensity of sunlight. It does this without the use of an external power supply.
Building Industry The research team, led by Han Chi-Hwan, inserted a light absorbing layer that can generate electromotive force into an electrochromic device. It can control the intensity of sunlight and dramatically reduce the energy used for lighting by 30% to 40% or more. Additionally, this new smart window technology can lower the price by 30% to 50% or more comparing to existing electrochromic products, the researchers said. Han added that this photosensitive automatic colour conversion smart window technology has the effect of blocking heat when sunlight is strong, so it can improve the energy efficiency when applied to a zero-energy building. It is also expected to contribute to the construction of a future smart city by combining solar cell technology and electrochromic technology into one. This technology development was carried out as a part of the future leading technology development project supported by KIER. Meanwhile, solar power is a key advantage of another smart window breakthrough developed by scientists from the US Department of Energyâ&#x20AC;&#x2122;s Argonne National Laboratory, Northwestern University, the University of Chicago, and University of Wisconsin-Milwaukee. The solar smart window prototype utilises solar cell technology, harnesses solar power to increase energy efficiency and cuts energy costs. Incorporating solar cells into windows while balancing the other complex, and often conflicting, roles of windows proves challenging, they said.
The scientists combined solar cell technology with a novel multicriteria optimisation process. It adjusts thicknesses of solar cell layers in window designs to meet the needs of the user. For example, to reduce the energy required to cool a building in the summer, the optimal window design might minimise the amount and type of light passing through while maintaining the desired luminosity inside. On the other hand, when winter savings are a priority, the design might maximise the amount of sunlight that passes through, thereby reducing the energy required for heating the building. Additionally, the sunlight that doesnâ&#x20AC;&#x2122;t pass through is captured by the solar cell in the smart window and converted into electricity The design framework is customisable and can be applied to virtually any building around the world, according to Prof Junhong Chen of Argonne and the University of Chicago. The demonstration prototype consists of dozens of layers of varying materials that control the amount and frequency of light passing through, as well as the amount of solar energy converted into electricity. One group of layers, made of perovskite, comprises the windowâ&#x20AC;&#x2122;s solar cell, which harvests sunlight for energy conversion. Another set of layers, a nanophotonic coating, tunes the frequencies of light that can pass through the window. Each layer, measuring tens of microns thick, varies in thickness. The study, published in the Cell Reports, Physical ScienceFuture, demonstrates the feasibility of the smart window prototype for industrial scale. As well, future considerations include developing the same technology in a flexible form so that the smart window materials can be retrofitted to cover preexisting windows.
The solar smart window prototype utilises solar cell technology, harnesses solar power to increase energy efficiency and cuts energy costs
Walls that breathe Structures that seem to blend in the environment are not only a modern architectural fad but sustainable, too. For a non-claustrophobic, green living appeal, smart skins can very well rival conventional wall materials. In this rationale, researchers from the Texas A&M College of Architecture have developed smart skins that allow structures to respond to heat, making them more energy efficient. The National Science Foundation-funded study aims to make a building not only attractive and functional, but also more energy efficient. AUGUST 2020
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Building Industry The team used a “shape-memory polymer,” in creating the smart skin. The team explained that the smart skin wall can self-regulate temperature: it can be “opened” to absorb air when it is hot, and “closed” when it is cold, without using external mechanical devices or electrical devices.
The smart skin, which utilises “shape-memory polymer", allows buildings to self-regulate temperatures
The researchers are using materials including alloys and stimuli-responsive polymers to enable a building that has a smart skin applied to it to function almost as a living thing in its own environment. High-tech 3D printers are also used to aid in the design and construction of the polymers. With further research, the team sees the potential of the smart skin as not only limited to self-regulating building temperature but also help in ensuring air quality and water conversion. Road concrete that drives away pollution Taking a joy ride may soon get a new definition with this new road concrete that can bar
pollution. Take it from the British Cementitious Paving Association (Britpave) that raises the potential of using a new concrete technology with photocatalytic material to reduce the elevated levels of traffic exhaust emissions on UK’s highways. Highway England, the government-owned company charged with operating, maintaining and improving England's motorways and major A roads made a review, following increased concerns about the elevated levels of nitrogen dioxide (NO2) from increased traffic levels. Solutions being eyed include installing a network of 9 m high pollution barriers at key locations across the strategic road network or the use of temporary 60 mph speed limits at peak times. Britpave suggested another less intrusive solution: the use of concrete roads with the addition of titanium dioxide (TiO2) to eradicate pollution. TiO2 is a photocatalytic material that reacts in sunlight to absorb nitrate oxides and convert them into harmless nitrates. It is increasingly available as a pavement spray or as an additive to concrete and adds 5-10% to the cost of a concrete road. A research done by the Eindhoven University of Technology (TU/e ) in 2011 found that the application of TiO2-applied concrete in urban streets is a method to improve the air quality in highly polluted areas. Using this technology can potentially degrade a wide range of air contaminants, including nitric oxide (NO) and NO2, mainly emitted by automobiles, it said. Britpave says concrete roads promote longevity, reliability, minimum maintenance, less road works, better whole-life costs and, therefore, a better return on capital investment . The potential of photocatalytic materials has been the focus of several studies in view of stunting the increasing outdoor and indoor pollution. The Netherland’s TU/e also did a study in 2015 on the efficiency of photocatalytic materials on indoor air quality. The study featured a functional wallcovering with layers of the coating and nanosilica. It found that the best performing coatings, able to degrade 69% of NO2, are those containing nanosilica applied in two layers. Meanwhile, similar studies, such as the air-purification effects of photocatalytic materials, are needed to maximise the full potential of smart materials to create environmentally-sound living spaces.
Photocatalytic materials in construction application are found to significantly reduce outdoor and indoor pollution
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Injection Moulding Asia Automotive In the automotive sector, less is more is quite
Commodity vs engineering plastics for parts US firm ExxonMobil has introduced a new foamable PP grade as an easily and affordably processed sustainable solution for high volume applications, including food and beverage packaging, industrial packaging, building products and automotive parts. Achieve Advanced PP6302E1 is a high melt strength (HMS) grade that is said to improve product stiffness by up to 30%, compared to standard HMS PP foam, for significant cost reduction opportunities.
a common phrase – with fewer component parts and a focus on lighter weight materials being used. As well, engineering plastics are also
taking the realm of electric vehicles charging equipment.
Lightweighting a factor in seating Automotive makers are replacing metal parts with lighter weight plastic parts for improved fuel economy and lower CO2 emissions. German materials firm BASF and Toyota Motor North America Research & Development have achieved lightweighting success with the new 2021 Toyota Sienna. The vehicle, scheduled to launch later this year, features a reduced mass of the third row seat, with a 30% weight reduction and 15% cost savings vs the prior generation, where the third-row seat was comprised of 15 different steel components making it very heavy. Traditionally, resin components for seating have had metal reinforcement, which can add more cost to the process. Toyota also wanted an injection moulded part that was a shoot-and-ship part – meaning it was made in one piece, without complex and costly post-processing. BASF used its 35% glass-reinforced and impact-modified PA6 grade Ultramid B3ZG7 CR, and its proprietary computer aided engineering (CAE) tool Ultrasim for development efforts.
ExxonMobil’s new foamable PP grade is said to be an affordably processed sustainable solution for high volume applications
While foam applications have been dominated by amorphous polymers such as PS, PU and PVC, foamed PP is a relatively recent advancement having been introduced only about 20 years ago. Now, the commercial potential of foamable PP can be pursued and fully realised, says ExxonMobil. Achieve Advanced PP6302E1 is said to be a viable alternative to PS foam (with accompanying VOC and monomer concerns), and can reportedly eliminate tradeoffs and set new standards for sustainable foamed PP parts by delivering value-in-use in a number of ways. For example, it is processable on existing PS foam lines with various blowing agents, reduces material use while delivering product integrity, and is recyclable where appropriate collection and recycling facilities exist. In automotive parts (such as headliners, ducts, floor liners), the PP foamable grade delivers the stiffness that allows vehicle manufacturers to maintain performance properties while reducing weight and increasing fuel efficiency. The foam structure can also provide benefits such as heat insulation and sound dissipation.
The new Sienna generation features first-of-its-kind third row free-standing seatbacks
Said Matt Parkinson, Manager Applications Development Engineering and Composite Technologies, BASF Performance Materials, of the seat design, “It is the first of its kind in the way it is designed without inserts as a fully injected seat back. One of the challenges was to ensure a high elongation and impact qualities for the crash requirements. At the same time, we focused on strength and stiffness because the seat also serves as a load floor.”
Materials focusing on battery charging in EVs With electric vehicles (EVs) a growing market, German speciality chemicals company Lanxess says it sees great potential for its technical thermoplastics in the charging infrastructure for electric mobility: for components of charging plugs and sockets, charging stations and wallboxes – in garages and carports, for example – as well as for components in inductive, wireless charging systems for high-voltage batteries. Even though the level of standardisation in the field of electric mobility is currently still in progress in many 1
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Injection Moulding Asia Automotive areas, polyamides and polyesters offer a wide range used for floor plates is the glass-fibre and glass-ballof possibilities for applications in the area of battery reinforced PA6 Durethan BG30XFN01. It displays charging with direct or alternating current. flow properties and is also strong and resistant to Unreinforced materials are mainly used for warpage. charging plugs because they offer a high level In interiors: comfort and performance of dimensional stability There is no doubt the automotive industry is in and surface quality, are transition: with trends such as in-vehicle infotainment impact resistant, and thus (IVI) set high standards for long-lasting aesthetics, mechanically robust, and colour fastness, durability and cleanability of visible are also available as flamesurfaces. At the same time, materials used for interior retardant compounds vehicle components not only have to meet increasingly whenever they come into strict and partly regional standards and specifications contact with live electronic in terms of odour and emissions, but preferences parts. As an example, depending on the manufacturer also play a crucial Lanxess’ halogen-free role. flame-retardant PA6 German materials supplier KRAIBURG TPE Durethan B30SFN30, has extended its compound portfolio for soft-touch in flammability tests surfaces for automotive interior applications with the conducted in accordance FG/SF (Fogging/Surface-Finish) series. Benefits are with the US standard UL the flowability that allow stress-relieved filling with 94, achieves a classification complex component geometries, low wall thicknesses of V-0 with a test body or large variations in wall thickness. It also allows for thickness of 0.75 mm. perfect surfaces even at low processing temperatures Given the ever-higher Wallbox for charging electric and with reduced pressure peaks, the risk of distortion charging voltages and cars with alternating current or waviness is reduced. up to 22 kW battery capacity currents, heat-conductive In the odour assessment: consistent results in thermoplastics for accordance with VDA 270 B3, with a score of 3.0 for removing the heat that is generated are also becoming all hardnesses from 50 to 80 Shore A, are confirmed. increasingly important. Mineral-based PA6 compounds All of these properties make compounds from the FG/ Durethan BTC965FM30 and BTC77ZH3.0EF, which SF series an ideal material for all insert mats and shelf have high filler content, can be used in the vicinity of mats for centre consoles, instrument panels, glove charging plugs. And despite the high filler content, boxes, door pockets, and roof liners. the materials display elongation and processing KRAIBURG TPE has also launched its new GP/HF characteristics. compound series that combines optimum flowability Potential new applications for charging wallboxes with an attractive cost-performance ratio, in the usual include covers and structural components. As visible consistent quality. The firm says it is, thus, making parts, covers have to be not only easily paintable and a major effort to support the automotive industry in weathering- as well as UV-resistant, but also have a coping with high cost pressures. low tendency to warp. This requirements profile is met by Pocan C1203, for example, an unreinforced blend of PC/PBT. Another current development trend is inductive and wireless charging of vehicle batteries. The flat floor and vehicle pads that are required here and accommodate – among other things – the inductive charging coils have to be constructed from materials that are not only fire-resistant and mechanically strong, but also have a low tendency to warp and exhibit high dielectric strength. The materials also have to be light and weathering-resistant, with their properties remaining highly stable across a temperature range of -45 to To be able to supply customers from a single source, KRAIBURG TPE has extended its compound portfolio for soft-touch surfaces for automotive interior applications +125°C. One material that can be 2 AUGUST 2020
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Injection Moulding Asia Medical Devices Sector
Medical equipment manufacturing shows symptoms of growth Despite the adverse impact of the Covid-19
During the first six months, the value of incoming orders for machines produced in Germany and China rose by almost 25%, the Japanese-German manufacturer said, adding that the packaging and medical technology sectors account for most of the orders. Likewise, demand for all-electric machines is also rising sharply, so the company has to increase its production capacities in its IntElect series. As a result of stable sales, SHI Demag expects to post a 17% increase year-onyear, in overall incoming orders for 2020.
crisis on many industries, it has failed to
flatten the growth curve for medical devices producers who are successfully meeting
the demand for critical medical equipment, says Angelica Buan in this report.
Healthcare sector pumps up machine demand The healthcare system has witnessed a major disruption since the onset of the coronavirus pandemic. For one, demand for personal protective equipment (PPE) and medical devices during this period has outpaced supply. Health resources are channelled towards securing medical equipment supply and in reinforcing the Covid-19 response. At the same time, the medical technology industry is counted upon to fill in the demand for PPEs, ventilators, test kits, respirators, and other critical medical supplies. For the plastic injection moulding industry, it is clear that it has an important role to play in bridging the demand-supply gap, and in producing top of the line PPEs to effectively contain virus spread. At this time, demand for injection moulding machines has risen. Indeed, demand for injection moulding machines are at its peak. One such machine maker Sumitomo (SHI) Demag has recently reported machine order increases. It said that it has maintained a healthy order book in the first half of 2020, compared to the first half of 2019.
Stocking up the market with high-tech masks The World Health Organisation (WHO) has specified the types of masks to be worn to obtain the optimum protection as worldwide demand for masks surge. German machine manufacturer Arburg has begun making high-tech masks, following its production of protective glasses on its Allrounder machines at its Lossburg headquarters in mid-April.
Arburgâ&#x20AC;&#x2122;s sterilisable high-tech masks are moulded from liquid silicone rubber and PP, and are designed for multiple uses
The face masks, which Arburg has been producing since May, are moulded from LSR (liquid silicone rubber) and PP. About 3,500 of these multifunctional high-tech masks are expected to be produced daily under series production conditions, Arburg said. Gerhard BĂśhm, Arburg Managing Director Sales, said that they have since been getting specific requests for the masks from hospitals and nursing homes from all over the region.
SHI Demag has reported a spike in machine orders in the first half of the year; and increased its production capacities in its IntElect series
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Injection Moulding Asia Medical Devices Sector Arburg additively manufactured the first prototypes with its Freeformers. The LSR component and mould simulation was carried out using Sigma Engineering’s Sigmasoft software. In a record time of only around five weeks, its partners Polar-Form and Foboha built the corresponding injection moulds for the LSR and PP components, signalling that Arburg can start series production in Lossburg. The companies Ewikon (cold runner) and Männer (hot runner) were also involved in the implementation of the mould technology; other partners involved are Barth Mechanik (gripper) and Packmat (packaging technology), while the raw material for several 10,000 masks was sponsored by chemicals groups Wacker and Borealis. The multifunctional product consists of a soft LSR mask and a firm PP shield with eyelets for attaching elastic bands. In the middle there is a standardised connection with a hole. The opening is sealed with a flow gate to protect against infection when doing regular daily activities. In the next expansion stage, filter housing can be fitted on the opening.
Also for the pandemic, Arburg implemented the safety goggle project with Swiss speciality chemicals group Ems-Chemie and German protective glass maker Uvex. Since April, safety glasses have been produced at Arburg’s facility in Lossburg on an allelectric Allrounder 570A in a cycle time of about 50 seconds
operation. Two electric machines are being used for this purpose. An Allrounder 570A with a clamping force of 2,000 kN produces the LSR masks at the Arburg Training Centre using a four-cavity mould from Polar-Form, while an Allrounder 470 E Golden Electric with a clamping force of 1,000 kN and a two-cavity mould from Foboha simultaneously produces the associated PP shields at the Customer Centre. The larger machine operates with an LSR dosing system from Elmet and a six-axis demoulding robot from Kuka, which removes the flexible masks from the mould and places them on a conveyor belt. In the second machine, the PP shields are handled more easily by a linear Multilift Select robotic system. Finally, the PP shield is manually placed on the silicone mask with interlocking. This is completed with the corresponding elastic bands and packed. By using a temper-free LSR, this step can be carried out without disruptive production stops caused by the time-consuming and energyintensive tempering of the component, Arburg said. Sustaining the global need for respirators Like surgical masks, respirators are critical protective item at this time. But unlike surgical masks, N95 respirators have greater filtering efficiency, with the capability to block as much as 95% of airborne particles. Demand for N95 increased not only among medical front liners but also among the general public who wanted extra protection when outdoors. 3M, a Minnesota-headquartered company, has responded to the growing need for respirators by ramping up production of respirators globally. In the first half of 2020, it has delivered over 800 million respirators around the world, with 400 million in the US. It is on track to deliver 2 billion respirators globally by the end of the year.
The masks are designed for multiple uses and can be easily sterilised. The temper-free LSR material of type Elastosil LR 5040 is suitable for food contact applications, and has been tested for biocompatibility. In addition, the LSR has good sealing properties, a high tear resistance and can be easily sterilised. Arburg expects to produce at least 15,000 or more of these masks per week in a two-shift
3M is boosting production of its respirators, targeting to deliver 2 billion respirators globally by year end; Cummins manufactured the filters for 3M’s Powered Air Purifying Respirators
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Injection Moulding Asia Medical Devices Sector Minnesota teams in March and provided to M Health Fairview and other Minneapolis-based healthcare systems.
3M, which worked with medical devices company Nissha Medical Technologies to create anti-fogging Latitude Plus protective face shields, has also recently collaborated with power solutions provider Cummins to manufacture particulate filters for 3M’s Powered Air Purifying Respirators, or PAPRs. Cummins will utilise labour and existing equipment at its Neillsville, Wisconsin facility, which is typically used for producing diesel engine filters, to produce the filters.
Coupling ensures adequate access to test kits Diagnostic testing has proven to be effective in stemming the spread of infection at an early stage. Globally, test kits are indispensable devices to help flatten the infection curve. Quality specimen collection supplies are a crucial component in ensuring that access to testing is available, according to Kevin Murdock, Founder of CPT Medical, a South Carolina-based surgical pack and kit manufacturing firm that specialises in viral transport media (VTM).
Nissha Technologies’s collaboration with 3M produced anti-fogging Latitude Plus protective face shields
Cummins worked with Flambeau on the respirator component. Flambeau makes the injection-moulded two-part housing – the main TPE housing – and a snap-on vented cover made of ABS, to secure the inserted filter. PAPRs are an important piece of equipment for frontline healthcare workers responding to the Covid-19 pandemic, Cummins said. PAPRs use a battery-powered blower that sends filtered air into a hood or head top that covers the wearer’s head or face; and can provide increased levels of respiratory protection, especially for critical healthcare situations such as aerosol generating procedures. PAPRs may also be more comfortable to wear for those who need respiratory protection for long periods of time. The partnership has the potential to more than double the current production of filters for 3M’s PAPRs. The additional filters are needed as 3M has ramped up production of PAPRs to meet a surge in demand due to the Covid-19 pandemic. Meanwhile, Cummins also partnered with US materials supplier DuPont to supply critical material for N95 respirator masks. Cummins’s NanoNet and NanoForce Media technology, which uses DuPont’s Hybrid Membrane Technology (HMT), can typically be found in air, fuel and lube filtration products used in heavy-duty diesel engines to prevent long-term engine wear. Now, it is being used in the N95 masks to protect user against Covid-19. The first mask prototypes using Cummins’s donated media were assembled by University of
CPT Medical and Hoowaki collaborated to produce testing kits in the US
CPT Medical has teamed up with Hoowaki, the developer of a first-of-its-kind injection moulded nasopharyngeal swab with large-scale production capability, also located in South Carolina, to produce testing kits in the US. Hoowaki is providing its NP collection swab with Microgrip technology to CPT Medical to be packaged along with CPT’s VTM. The partnership started with producing 20,000 kits/day and pumped this up to 200,000 kits/week. Hoowaki adapted its existing technologies to develop the NP swab, which has the advantage of being produced on existing injection moulding equipment, enabling production on a scale not currently available with other swabs. Enabling high volume production of test swabs Swab testing is a standard protocol to determining infections. The widespread use of medical swabs, especially during the Covid-19 outbreak, has boosted the market, which is projected to reach US$4 billion by end of 2027 and growing at a CAGR of 6.9% from 2020, according to Fortune Business Insights. 5
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Injection Moulding Asia Medical Devices Sector Portable, economical ventilator Medical ventilators are critical medical devices for patients with serious respiratory conditions to assist in their breathing. The prevalence of the coronavirus infection has driven the demand for ventilators. PMC Smart Solutions, a US-based company specialising in moulding and contract assembly, has helped in producing the Venti-Now portable emergency ventilator. PMC worked with Venti-Now Non-Profit Corp that has the concept, design and early prototype of the ventilator but lacked the medical device manufacturing and regulatory experience (which PMC could provide), according to Lisa Jennings, President/CEO of PMC. The Venti-Now ventilator is a pneumatic mechanical device. Small and portable, it is designed for quick production and maximum affordability for medical professionals who use it. Venti-Now is also easy to operate and utilises standard, disposable BVM bags so that it is ideal for use in emergency situations in both hospital and field locations. PMC worked to standardise components and make the product at the lowest possible cost, and most efficiently to assemble with as many as 1,000 units/week said Alan Sundheimer, PMCâ&#x20AC;&#x2122;s VP of Engineering and Technology. Thus, it can be seen that both equipment manufacturers and machine makers have rallied around to produce technology that can cater to the latest pandemic needs.
At the thick of this growing demand for test swabs for nasal and throat swab tests, Austrian machine maker Engel and German mould making company Hack Formenbau partnered to ensure the global supply of test swabs. By providing an integrated system solution and process technology consulting, they are helping plastics processors to launch high-volume production of two-component test swabs with a short lead time. Engel and Hack Formenbauâ&#x20AC;&#x2122;s tie up yielded an integrated system solution and process technology consulting to enable plastics processors to launch high-volume production of two-component test swabs with a short lead time
The test swabs have a thermoplastic handle and a head made of a thermoplastic elastomer (TPE) to make the examination less uncomfortable for the patient. Hack Formenbau developed this twocomponent design, initially with three different head design proposals. With a 32-cavity mould and a cycle time of 6 to 8 seconds, processors can achieve an output of up to 320 test swabs/ minute and 460,000 test swabs/day with a single production unit. Engel has adapted the integrated production process to the mould solution developed by Hack Formenbau. The process is undertaken on a tiebar-less, hydraulic, two-component Engel Victory machine with an integrated Engel viper linear robot for fully automated removal and depositing of the swabs. The Victory machine is equipped with iQ weight control for process consistency. This smart assistance system from Engelâ&#x20AC;&#x2122;s inject 4.0 programme detects fluctuations in the raw material and ambient conditions, and automatically compensates for them shot-byshot by adapting the quality-relevant process parameters.
PMC assisted in the manufacture of Venti-Now ventilator, a portable pneumatic mechanical device ideal in emergency situations in both hospital and field locations
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Rubber Journal Asia Industry News • With Malaysia’s glove market in a boom phase, various companies are investing to set up joint ventures or enter the market. Investing holding company MQ Technology (MQTech) is partnering with Hong Kongbased JD Resources International in a 30:70 joint venture to buy a company involved in the manufacturing of medical rubber gloves. Property developer Titijaya Land is partnering glove producer Rubberex Corp. to set up glove production. Titijaya had previously already inked an agreement with China’s Sinopharm on the sale of medical-related equipment; and with Sinomach Heavy Industry to set up a personal protective equipment (PPE) fabric facility. Penang-based property developer Aspen Group Holdings, which is listed on Singapore’s Catalist board, is also entering the market with a joint venture with investment holding company CMY Capital. In its first phase, it will have an investment of RM105 million to produce 1.1 billion pieces of gloves/year in Kulim, from the third quarter of 2021. IT solutions provider Inix Technologies Holdings is investing RM22 million to form a 65:35 rubber glove joint venture with Lyglan Properties. The partners will acquire a factory in Negeri Sembilan. Others include precision engineering and automation systems firm AT Systematization Bhd and HLT Global, a maker of ceramic hand moulds for glove companies that has a 55% stake in HL Rubber Industries. Kanger International has also had a nudge from Dubai-based Constellation Holdings (a procurement agent for PPE and medical equipment to the UAE Ministry of Health and Prevention), to set up a joint venture.
• Maxxis Rubber India plans to set up five manufacturing units in India, in addition to the expansion of current units that cater to the two and four-wheeler markets. The manufacturer is an OEM supplier for automotive companies including Honda, Yamaha, and Maruti Suzuki. It has also established a retail partnership with Yamaha with Maxxis’ tyres made available for sale at Yamaha dealerships throughout India. • Technology company Continental plans to invest US$4 million to expand its ContiTech Vibration Control business unit in Indiana, US. Aside from increasing efficiencies at its anti-vibration systems at the 100-sq ft facility, Continental plans to move existing technical centres in Canada and Michigan to the facility by end 2024. It will phase out operations at its suspension and vibration control products manufacturing site in Ontario, Canada, by March 2021. In addition, Continental will also expand its R&D operations to reduce noise vibrations for the automotive and commercial sectors. It is expected to create more than 45 new jobs by the end of 2023. Continental acquired its Auburn facility in 2019 from another major automotive manufacturer but continues to develop products and systems for in-car vibration and noise technology. • Yokohama India, a whollyowned subsidiary of Yokohama Rubber Co, is to double capacity at one of its plants located in Haryana to 1.6 million tyres/year from 0.7 million tyres/year and increase from 500-700 employees. Yokohama India has been supplying passenger car and SUV tyres since 2007. • A new partnership between multinational mining company BHP and Novum Energy will
see used earth moving tyres from all seven BHP Mitsubishi Alliance (BMA) and BHP Mitsui Coal (BMC) facilities recycled. The partnership will create up to 30 new jobs at Queensland’s Bowen Basin in Australia. BHP is expected to feed some 2,000 tyres/ year to Novum, with 19,000 tonnes of rubber producing 9 million l of oil, 4,500 tonnes of pyrolysis black and 2,500 tonnes of steel. • Indian tyre major Mahansaria Tyres Private (MTPL) has acquired a controlling stake in the European Agriculture Tyre Distributor (EATD), to build a distribution network in Europe. Based in Germany and the Netherlands, EATD will distribute MTPL’s Ascenso tyres in European countries including Germany, Austria, Switzerland, Belgium, Netherlands, Czech Republic, Slovakia and Poland. Set up six years ago, EATD also will distribute Tianli tyres manufactured by China-based manufacturer of agriculture, forestry and earthmover tyres Tianjin United Tire & Rubber International. MTPL also plans to build a US$115.8-million tyre manufacturing facility in Gujarat, due for completion by end-2020. • Scandinavian tyre recycler Enviro Systems and French global tyre manufacturer Michelin have prolonged the letter of intent regarding a strategic partnership, which was announced in April 2020, to October, partly due to the ongoing pandemic. Enviro had finalised a directed share issue (private placement) of approximately SEK32.5 million to Michelin, corresponding to ownership of 20% after the completed issue, which Michelin subscribed for through its wholly owned subsidiary Michelin Ventures SAS. Following the completion of the issue, Michelin became the largest owner of Enviro.
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Rubber Journal Asia Industry News • Chinese tyre maker Linglong Tire is setting up a global R&D and technology base in Jinan, Shandong province. Linglong says it will make full use of Jinan’s economic advantages, convenient transportation advantages and talent concentration advantages. • The Serbian subsidiary of Cooper Tire is investing US$8 million to increase production capacity at its Kruševac tyre manufacturing plant and increasing it to more than 882,000 sq ft, with equipment upgrades and 118 new jobs to Cooper Tire Serbia. It will manufacture light truck tyres, including 4 x 4 tyres, and large diameter tyres up to 22 in. • German chemicals firm Evonik’s multi-purpose silicones manufacturing facility in Geesthacht, Germany, is now fully operational after completing final commissioning tests and gaining the necessary authority approvals. It is now producing the silicones and silyl-terminated polymers (SMP’s) used in parquet adhesive flooring, liquid membranes for roofing or electronical potting applications. • Carbon black supplier Orion Engineered Carbons has upgraded its emissions controls at its Texas, US, plant, to comply with strengthened environmental standards and reduce emission permits for NOx and SO2 by 2,300 tonnes/year of air pollutant emissions. • India’s Apollo Tyres has virtually inaugurated a new manufacturing facility housed within its plant in Vadodara, Gujarat. The modular 10,000 sq m facility will produce 30,000 two-wheeler radial tyres/month and 60,000 cross ply tyres/ month for the two-wheeler industry. Already commanding a
double-digit market share in the premium two-wheeler segment in India, Apollo is aiming to secure leadership in the segment and service the global markets with high-end bias and steel radial tyres. • Malaysian condom manufacturer Karex Bhd is planning to build a new facility for rubberbased medical gloves at its Innotex (Thailand) Ltd. (ITL) base in Hatyai. ITL currently manufactures condoms, personal lubricants and other rubber products including catheters but intends to produce at least 2.5 billion gloves/year made from nitrile, natural rubber and any other new materials. The new glove manufacturing business will first have a production capacity of up to 500 million gloves/year from two production lines, while the remainder will be gradually set up over the course of the next 48 months. The company estimated that the initial production phase will require a capital expenditure of around RM40 million. • Danish wind energy and green tech development company WindSpace has signed an agreement with Canada’s Environmental Waste International Inc. (EWS) for the use of its patented reverse polymerisation technology and proprietary microwave delivery system for its first plant in Nyborg, Denmark. The agreement also includes a long-term partnership between the companies and a mutual exclusivity agreement for the development and installation of waste tyre recycling plants across Europe. WindSpace has been working on the establishment of Elysium Nordic, a tyre recycling project in Nyborg, Denmark since 2018. It will be capable of
processing 30,000 tonnes of endof-life tyres/year, with planned start of construction during Q1 2021 EWS’s proprietary system for processing rubber tyres via a unique microwave technology recovers highly valuable commodities, including reclaimed carbon black (rCB), steel, syn gas and oil. • US speciality tyre maker Maxam Tire has opened a new advanced and automated solid tyre production facility, with compound advancement and automated technology. Danvers, Massachusetts-based tyre maker says it has established a strong reputation throughout the world, selling products across all specialty tyre segments in North America, Europe, Latin America, Asia and Africa. It adds that its new production facility will serve the industries core solid tyre segments including material handling, skid steer, telehandler and loader. Phase one production has officially launched with considerations for future production expansion. • Malaysia’s Petronas Chemicals Group Bhd (PCG) and South Korea’s LG Chem have tied up to build a nitrile butadiene (NBR) latex manufacturing plant at the Pengerang Integrated Complex (PIC) in the southern state of Johor, targeting the growing nitrile glove market and further strengthening Malaysia’s position as the largest exporter of gloves globally. PCG said construction of the plant will begin in 2021 while production is scheduled to start in 2023. It will have a production capacity of 200,000 tonnes/year when completed. PCG and LG Chem will also work together to offer various grades and new applications of NBR as well as develop high-value added products through continuous R&D and investments, according to PCG.
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Rubber Journal Asia Recycling
China’s green moves drive up tyre recycling China is beating the odds from rising scrap tyres and air-polluting recycling methods
with advanced technologies, more recycling plants, and new company partnerships, says Angelica Buan in this report.
China leads in waste tyre output Yearly, over 1.5 billion units of tyres are produced and 1 billion waste tyres are generated, but only 10% are recycled. Increasing the recycling of waste tyres translates to increasing investments into new technologies and expanding capacities. China, the world’s largest tyre consumer and producer, accounting for 30% of the world’s tyre market, reportedly generated over 15 million tonnes of waste tyres in 2019, with waste tyres scrapping increasing from 8-10% per year according to the China Tyre Recycling Association (CTRA).
Shandong Linglong Tire’s new manufacturing base in Changchun
Nevertheless, the market is expected to pick up over the next few years. According to a report by Research and Markets, vehicle ownership is projected to rise to over 380 million units by 2025, auguring demand for tyres.
Tyre production on a roll Even with the Covid-19 restrictions still in effect, tyre businesses have started to rebound. Zhaoyuan-headquartered Shandong Linglong Tire has recently launched its fifth manufacturing base in Changchun automotive economic zone, with a total investment of US$700 million and capacity of 12 million passenger and 2 million truck/ bus tyres/year and 200,000 truck/bus retreads/year when it reaches full completion. Its other four plants in China are in Zhaoyuan, Dezhou, Liuzhou, Jinmen; and it has two international ones in Thailand and Serbia. Hubei Linglong in Jinmen, the fourth manufacturing plant, commenced only in late 2019. It is targeted to generate a capacity of 12 million passenger tyres/year; 2.4 million truck and bus tyres/year; and 60,000 offChina was reported to have generated over 15 million tonnes of waste tyres in 2019 the-road tyres/year. Similarly, Hangzhou-headquartered Zhongce During the Covid-19 pandemic, China’s Rubber Group (ZC Rubber) has recently resumed automobile market waned, and as a result the full tyre production. ZC Rubber is one of the world’s country’s tyre output is projected to dip by largest tyre makers, with subsidiaries in Europe, the 15-25%, depending on the local and foreign US, Brazil and Thailand. market situation, according to a report from the Elsewhere, Sailun Group, early this year, China Rubber Industry Association (CRIA). inaugurated two projects: the Dongying factory for In 2019, CRIA estimates the total car tyre semi-steel radial tyres, a project that is listed in the output was at 652 million and this year the 2020 Key Engineering Projects of Guangrao County, overall tyre production is expected to drop by Shandong Province, with an investment of about 15%.
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Rubber Journal Asia Recycling Furthermore, China is boosting its tyre recycling business, by improving recycling technologies like thermal cracking, and increasing tyre retreading rates. The guideline also encourages the recycling of tyres into rubber powder. Material recovery from ELTs can be carried out through various methods such as pyrolysis, devulcanisation, chemical recycling and various other modalities to obtain secondary materials such as rubber granules, carbon black, fuel, fibres, etc, for many industrial applications. In addition, China has set up recycling initiatives such as utilising rubber asphalt for road applications and waste rubber-derived fuels for cement kilns.
Sailun recently launched the Dongying factory for semi-steel radial tyres, and Shenyang plant for all-steel load meridian tyres
RMB1 billion. It also started construction on the Shenyang plant for all-steel load meridian tyres. With the completion of the project, the Shenyang plant will have a production capacity of 5 million tyres/year, making it one of the largest all-steel meridian tyre monolith factories in the world.
Recycling facilities on the rise Underscoring the country’s objective to improve rubber recycling is a watershed project, the Central China Rubber Resources Recycling Industrial Park in Xiangyang, Hubei province. The US$340 million 7.5 million-sq ft area is so far the country’s largest rubber recycling park. The facility aims to process 400,000 tonnes/year of ELTs, including a capacity of 300,000/year for rubber modified asphalt, and 100,000 tonnes/ year for recycled rubber. The park has sections for manufacturing, processing, trading, storage and research. Along the same line, China’s Hongtai Holding is building a scrap tyre recycling facility in Hefei’s Lujiang High-tech Industrial Development Zone. The 1.2 million-sq ft plant is capable to process 300,000 tonnes of scrap tyres/year, using Hongtai’s liquid phase pulverisation technology. The US$154 million project comes in two phases. The first phase, expected to go onstream this year, will have a capacity of approximately 100,000 tonnes and is expected to generate US$81 million in annual revenue once operational. The second phase will have a capacity of 200,000 tonnes/year when completed by 2023. The Guangzhou-headquartered company is also planning to build a 100,000-tonne/year facility in Jieyang.
More tyres means more waste The sector’s brisk activities anticipate furthering tyre production, and as a result would have increased the amount of end-of-life (ELT) tyres. In China, more than 300 million used tyres are not recycled, and the amount could reach 13 million/ year of ELTs, according to data from CRIA. Now, the country is taking bold steps to raise recycling rates of rubber scraps, including drafting guidelines for the reuse and recycling of waste rubber tyres. The Ministry of Industry and Information Technology, in 2011, developed the Opinions on the Guidance of Comprehensive Utilisation of Waste Tyres, the first industrial policy for the comprehensive utilisation of waste tyres specifically issued by the Chinese Government. In 2012, the Conditions for the Access to Tyre Retreading Industry and the Conditions for the Access to Comprehensive Utilisation Industry of Waste Tyres were also issued. Industrial policies provide the framework for the development of comprehensive utilisation of waste tyres, while encouraging tyre recycling by providing incentives to relevant enterprises, such as those engaged in retreading tyres or producing rubber powder from waste tyres.
Converting waste to resources with technologies China’s air quality has rebounded to the pre-Covid-19 levels, reports say, or simply put it has once more degraded as pandemic lockdowns eased and economic activities restarted.
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Rubber Journal Asia Recycling Furthermore, in the same year, a smart factory for recycling waste tyres that is non-polluting was built in Central China’s Henan Province by homegrown tyre maker Doublestar Group along with ten universities and led by Southeast University. The group has innovated green recycling technologies, including pyrolysis and carbon black generation to make the factory pollution-free. The 13-ha factory, with an investment US$49.3 million in the first phase, can process 100,000 tonnes/year of waste tyres and produce 45,000 tonnes/year of pyrolysis oil and 35,000 tonnes of carbon black/year; with annual sales expected to reach RMB360 million.
China’s black carbon emissions was claimed to have accounted for 20-24% of the total global emissions from 1990-2007
As an industrial power house, the country has been besieged with poor air quality. Arctic Institute, in its report, mentioned that China’s black carbon emissions, mainly coming from using biomass, coal or oil, transport diesel, and open agricultural burning, accounted for 20-24% of the total global emissions from 1990-2007. Efforts have been exerted to reduce carbon emissions and improve air quality in the years thereafter. Other contributors to air pollution are used tyres that are sent to oil refineries for recycling, as well as the recycling of trucks/buses ELTs by retreading using crude technologies. To curb tyre recycling-induced air pollution, China crafted a comprehensive regulation for the utilisation of waste tyres. It covers the aspects of technical equipment and process, ecological environmental protection, product quality control and safety management. Zhu Jun, President of CTRA, has stated that waste gas discharged from refining facilities for waste tyres have caused serious damage to the environment. Advanced technologies in tyre recycling, such as pyrolysis, which is considered as a viable thermochemical process to recycle waste tyres, are being tapped to achieve the comprehensive tyre utilisation targets without causing air pollution. In 2019, approximately 1,500 comprehensive utilisation enterprises and approximately 200 million waste tyres were recovered and reused, according to CTRA.
Partnerships kick-off recycling Locally-based companies are engaging in rubber recycling project s and partnerships, as well. ZC Rubber and Nanjing Lvjinren Rubber have partnered to expand the capacity of recycled rubber to 20,000 tonnes/year. The project, which will be fully operational in September this year, is set to become China’s leading Industrial 4.0 recycled rubber demonstration plant in the tyre industry, the partners said.
ZC Rubber recently resumed full tyre production
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Rubber Journal Asia Recycling ZC Rubber is the only experimental unit designated by China’s Ministry of Commerce, the Ministry of Finance, the Ministry of Industry and Information Technology and the CTRA. The company’s development model is based on sustainable resources, it said, adding that it carries out pilot projects for the recovery and comprehensive utilisation of waste tyres. ZC Rubber reports that it has been actively cooperating with universities and scientific research units in China and abroad to seek the most advanced comprehensive utilisation technology for ELTs. ZC Rubber ordered the first set of tyre recycling equipment from Nanjing Lvjinren Rubber. The equipment has been developed in as a part of a project of National High Technology Research and Development Program of China by Professor Zhang Liqun’s team of Beijing University of Chemical Technology. In the same pursuit for waste tyre utilisation, Switzerland-headquartered scrap tyre recycling solutions provider Tyre Recycling Solutions (TRS) and manufacturer of steel fibre for concrete reinforcement Tengzhou SDS Star Smith Metal Products (SDS) have formed a joint venture for ELT recycling to address China’s growing demand for performance recycled rubber powder.
The venture will also commercialise the performance recycled rubber powder produced not only by its own recycling factory, but also produced from any other tyre recycling factory licensed by TRS to produce TyreXol in China, say the partners. Rubberised asphalt roads on the way The country is also working on paving roads with rubberised asphalt made out of scrap tyres. One such project is in the south of China’s Beijing. This development is the biggest application of scrap tyre paving in the country. This latest application comes after almost five years ago of a 600-m long road in southern Beijing made with scrap tyres. This road is still used by motorists and still remains in great condition. After that, over 70 key roads in that area were developed with rubberised asphalt. To produce the asphalt, some 2.7 million scrap tyres were used. This sustainable method both gives second life to scrap tyres and improves the durability of roads. Meanwhile, Chinese companies are seeking new markets for rubber reclaim. For example, Tianyu (Shandong) Rubber and Plastic Products is exporting its crucial tyre component to the Indian market, even though the country has a large domestic reclaim rubber industry. Tianyu produces on average 200 tonnes/day of reclaim rubber and already runs two sites in Tianjin and Shandong. Currently, Tianyu also exports its products to the Philippines, Europe and Southeast Asia, and it is searching for new markets as it looks forward to boost exports. Thus, it can be seen that China’s taking its environmental concern arising from waste tyres seriously, with all the projects at hand.
TRS and SDS teams announcing the joint venture for ELT recycling in China
The 67% (TRS)-33% (SDS) joint venture, Tyre Recycling Solutions China Jointco (TRS China), a consolidated subsidiary of TRS Switzerland, will be located at the Tengzhou Economic Development Zone, Shandong Province, one of the nation’s clusters for the production of tyres. The TRS China subsidiary will develop a production facility for recycling car and truck ELTs starting in the last quarter of 2020, with a target to produce 60,000 tonnes of TyreXol rubber powder by end of 2023.
The lure of new markets is encouraging companies to enter the rubber reclaim market
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8 - 9 DECEMBER Thermoplastic Elastomers World Summit Venue: Frankfurt, Germany Tel: + 44 (0) 1372 802 202 Email: phaggerty@smithers.com Internet: www.elastomer-forum.com/tpe-elastomers-worldsummit-2020
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