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www.jswamerica.com 2 | PLASTICS ENGINEERING | JUNE 2019 | www.4spe.org | www.plasticsengineering.org
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CONTENTS VOLUME 75
NUMBER 6
JUNE 2019
SPME
6
Focus on: Kristina Queen Meet SPE’s Sales Support Associate, Kristina Queen.
SPE Podcast
8
New Plastics Podcast PlastChicks: The Voices of Resin
Adulting 101
12
8 Hosted by Lynzie Nebel and Mercedes Landazuri, the podcast will feature guest interviews, popular plastics topics, trends and the people that inspire our industry!
Adulting 101: Social Do’s and Don’ts at Professional Events By Lynzie Nebel
Medical 3D Printing
14
3D Printing the Future of Healthcare By Geoff Giordano Additive manufacturing, or 3D printing, is fast-tracking developments in the medical device industry.
14 A “smart” medication monitoring pill bottle made with Carbon’s MPU 100 medical polyurethane.
Design Notes
18
Adapting to Fast-Changing Product Sectors By Robert Grace Covestro is designing its materials portfolio to address needs in mobility, healthcare, energy storage, appliances, lighting, and other emerging markets. 18 As ride-sharing and self-driving cars become more prevalent, vehicle interiors will become increasingly like mobile living rooms, needing cleanable, durable materials and lighting that can be personalized.
Cover Story
24
Stabilizing Recyclables By Geoff Giordano Recycled plastics are subjected to chemical processes that weaken them over time. Some additives, however, can enhance the durability and strength of these sustainable goods time and time again. About the cover: Stabilizers help make recycled plastics more durable—process after process.
2 | PLASTICS ENGINEERING | JUNE 2019 | www.4spe.org | www.plasticsengineering.org
JUNE 2019
Building Greener Plastics Additives Produce More Durable Recycled Plastics
CONTENTS VOLUME 75
NUMBER 6
JUNE 2019
Sustainability
28
Almost Like New By Pat Toensmeier Recyclers rely on stabilizers to rebuild properties of reclaimed resins. If PCR demand accelerates, a new generation of additives could remake the market.
Sustainability
28 Baeropol stabilizers improve melt stability, color, and solubility of polyolefins in deck boards and other applications
32
Prepare for Round Three of the Plastic Waste Trade War By Doug Woodring & Trish Hyde After China closed its doors to scrap plastic imports and Westerners scrambled to find other export targets, diplomats chew on a proposal to add mixed plastic waste to a list of materials that require the receipt of a country’s informed acceptance of this type of trade under the Basel Convention.
As I See It 32 The heady mix of plastic waste, global damage, and national interest has already sparked two sparring matches, and another is set to begin.
36
Destination Düsseldorf By Pat Toensmeier The K Show in Germany will attract more than 3,000 exhibitors from 60 countries. Petra Cullmann, Messe Düsseldorf, talks about why K 2019 is so important to the industry.
42 Q & A with Petra Cullmann, global portfolio director for plastics and rubber at Messe Düsseldorf.
Departments
38 43
Industry News In this issue’s roundup of industry news, we explore developments from ExxonMobil, and more.
Energy-Saving Tip Extrusion Blow Molding – Insulation By Dr. Robin Kent
46
Patents
50
Events
Our regular roundup of notable patents. By Dr. Roger Corneliussen
SPE and Partnered Conferences, SPE Meetings, Non-SPE Events and Webinars
52 54 56
Market Place
Editorial Index
Advertiser Index
www.plasticsengineering.org | www.4spe.org | JUNE 2019 | PLASTICS ENGINEERING |
3
Editorial & Publishing Staff Sheri Kasprzak Editor-in-Chief (201) 748-8713 skasprzak@wiley.com Ryan Foster Art Director (203) 740-5410 rfoster@4spe.org Roland Espinosa Senior Account Manager Print & E-Media Advertising (201) 748-6891 respinosa@wiley.com Lisa Dionne Lento Publisher ldionnelen@wiley.com Sue Wojnicki Director of Communications (203) 740-5420 swojnicki@4spe.org
Contributing Editors Robert Grace bob@rcgrace.com Geoff Giordano geoffgio@verizon.net Patrick Toensmeier toensmeier@sbcglobal.net Dr. Roger Corneliussen Patents cornelrd@bee.net Matt Bechtel Industry News bechtel.matt@gmail.com Dr. Robin Kent Energy Saving Tips rkent@tangram.co.uk
sp e CRICKET PLAYER, RESEARCH ENGINEER... AND MY FAVORITE SPE BENEFIT IS...
NETWORKING!
“Being on several boards within SPE has helped me to stay in touch with a lot of people and given me a chance to learn from them.”
ABHISHEK AMBEKAR
member since 2007
SPE 2019-2020 Executive Board President Brian Landes CEO Patrick Farrey President-Elect Jaime Gómez Vice President – Business & Finance Jeremy Dworshak
Vice President – Marketing & Communications Conor Carlin Vice President – Sections Scott Eastman Vice President – Young Professionals Lynzie Nebel
Vice President – Divisions Jason Lyons
Vice President – Technology & Education Raymond Pearson
Vice President – Events Bruce Mulholland
Past-President Brian Grady
Want to connect with people like Abhishek? Join SPE! No matter where you work in the plastics industry value chain-a scientist, engineer, technical personnel or a senior executive-joining SPE can help you succeed. VISIT 4SPE.ORG TO JOIN TODAY!
4 | PLASTICS ENGINEERING | JUNE 2019 | www.4spe.org | www.plasticsengineering.org
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“WE HAVE MADE SOME GREAT CHANGES FOR ANTEC® 2020 THAT WILL OFFER EXHIBITORS MORE DEDICATED HOURS AND NEW FOOD & BEVERAGE EVENTS IN THE HALL. OUR GOAL IS TO INCREASE THE NETWORKING OPPORTUNITIES AT ANTEC® AND OFFER MORE TARGETED EXHIBIT HOURS.”
I was born in Denmark and spent my childhood as an Army brat, moving around from New England to North Carolina and two tours in Germany (which we loved—because we were close to Denmark). My degree is in International Trade/Communications and I studied at Vejle Commercial College in Denmark and Hammersmith & West London College in London, England. With that, I have traveled all over the world and settled in Annapolis, Md., with my partner Will. We have one child, one cat, and one dog. I began working for an association management company in 2008 and wore many hats within that organization.
WHY SALES AS A CAREER CHOICE?
I decided I wanted to make a job change to find something new and more flexible. When I read about the position at SPE and learned that they were growing their sales department, I was excited to take on a new challenge.
TELL US ABOUT YOUR ROLE AT SPE?
I am the sales support associate and came on board to work with the senior sales director, Stephanie Clark. SPE needed a person to handle exhibitor, advertising and sponsor servicing. I have been very lucky that the position has been a perfect fit, and I have had the opportunity to learn from Stephanie about sales strategies.
BEST ADVICE SOMEONE GAVE YOU ABOUT WORKING IN SALES?
Follow up. It may take some time to get people to respond, but don’t give up. Also, I have learned to view every interaction as a potential sale.
BEST ADVICE YOU COULD GIVE SOMEONE STARTING OUT IN SALES?
My mother once said that I could talk to the doorman as well as I can the CEO. I think that it is important that you treat people with respect—no matter what position they are in—we are all here to get the job done. Build personal connections with people. Don’t discriminate.
YOUR ALL-TIME FAVORITE FAMOUS SALES PERSON AND WHY?
I have a friend who sold Mary Kay, and she was very good at it. Mary Kay’s philosophy was “Pretend every person you meet has a sign on them that says—Make me feel important—and you will not only succeed in sales, but also in life.” I agree wholeheartedly with that philosophy.
SO, YOU JUST ATTENDED YOUR FIRST ANTEC®. WHAT DID YOU THINK? FAVORITE MEMORY?
I thought it was fantastic! I cannot even remotely begin to count how many trade shows I have worked in the last 10 years in association management, and this one was great! My favorite memory was a dinner I had at a local brew pub with the SPE staff. This was the first time I had met the SPE team. Everyone was fun and open, and I felt very comfortable.
WHAT ARE YOU LOOKING FORWARD TO MOST AT ANTEC® 2020?
Selling out the exhibit hall! I definitely feel more confident now that I have one ANTEC® behind me, and we have made some great changes for ANTEC® 2020 that will offer exhibitors more dedicated hours and new food & beverage events in the hall. Our goal is to increase the networking opportunities at ANTEC® and offer more targeted exhibit hours. I also look forward to getting together with the SPE staff.
FAVORITE PLASTICS PRODUCT?
My favorite plastics product, which I use all the time, is a bag that I have by a Danish company called Skagen. The bag is made of recycled plastic, and it has the Danish alphabet printed all over it. It just makes me happy.
6 | PLASTICS ENGINEERING | JUNE 2019 | www.4spe.org | www.plasticsengineering.org
MOM/DOG MOM, NEW AMATEUR CHEF, REALITY SHOW ENTHUSIAST, SALES SUPPORT ASSOCIATE...
sp e KRISTINA QUEEN Sales Support Associate
SPE PODCAST
New Plastics Podcast PlastChicks: The Voices of Resin
H
osted by Lynzie Nebel and Mercedes Landazuri, the podcast will feature guest interviews, popular plastics topics, trends, and the people that inspire our industry!
Was there a goal you had in mind for the podcast?
Their first live episode was launched at ANTEC® 2019 in Detroit. David Kusuma, vice president of research and innovation at Tupperware Brands was their first guest. He spoke to them about sustainable cutlery, and joint NASA projects.
M: Yes. #1, absolutely. #2, I just wanted to spend more time with you. I was like, “What project can we work together on?” #3, I know that you and I had been talking about the negative publicity that plastics get in the media and social media.
L: Well, yeah. We wanted to be cool and talk about plastics. Is that not what we’re doing?
L: That’s true. Because I go on those deep dives where I click those negative hashtags about plastic and then I get very upset.
We recently connected with Lynzie (L) and Mercedes (M) to find out more about their podcast.
How did the idea of starting a podcast together come up? Who’s idea?
M: You can’t stop yourself, and you just spiral. And then you just start texting me about how mad you are. L: Exactly. So, it’s for the best that we’re doing something positive because the alternative was very unhealthy.
L: I think it was my idea? I think I was thinking about it at the White Plains Executive Board (EB) meeting in December. M: We had already said we were going to do one and then you pitched it to Pat at the EB meeting. I know for me it was that you had already been on a podcast, so I had in the back of my head for a long time that I needed to get on a podcast. L: Fair enough. M: And then you got me hooked on the My Favorite Murder podcast, and it was like, “Oh, two girls who talk about murder. We could be two girls who talk about plastics.”
M: Right. And I was talking to Steve Russell from ACC (American Chemistry Council) about these images like the turtle with the plastic straw in its nose. A picture tells a thousand words; they tell a story. And stories are what stay with people—stories are what changes peoples’ minds. So why not replace those images and those stories with new stories that people will remember and which will change the narrative so that it encompasses the whole truth, and nothing but the truth. L: Yeah. That is a very nice way to look at it instead of it just being fueled by my anger.
8 | PLASTICS ENGINEERING | JUNE 2019 | www.4spe.org | www.plasticsengineering.org
And the cacophony of the thunderous laughter and applause might be distracting for some listeners. But I think that as we keep doing them, we’re going to have some exciting guests on, and we’re going to keep getting better, because that’s who we are. Right?
M: Yeah like, “I spiraled one day and I just wanted people to listen to me.”
M: I think that any publicity is good publicity. Give me some haters. Give me some mean ones.
L: Like, “I was just really mad and I needed people to understand that they are wrong.”
L: Alright, then let’s get ready, ‘cause I’m gonna start something.
How do you decide the subject matter of your podcast episodes?
How do you prepare for a podcast? Any special prep?
L: It was very much trial and error, because our original two episodes were not the same. It was trying to figure out what our audience would want to hear from us without making it just straight facts in your face. I think a lot of that had to do with the people we wanted to have speak.
M: Well, I for one like to get a full night’s sleep. Like a full 14 hours.
M: I think we’re still deciding what we want the subject matter to be. L: I’m sure we’ll evolve. M: Yes, on a case-by-case basis. On a “we need to do something now” basis. L: Exactly. My favorite way to operate.
L: Which starts with you not sleeping. M: Yeah. I dunno. Do you prepare for a podcast? L: I usually look at their LinkedIn to make sure I have the highlights, but I kind of prefer a little bit of surprise. M: Yeah. I mean I think our whole friendship has been preparation for this podcast. I feel good and confident about that. Like I don’t really need to do anything else as long as I know how to pronounce our guests’ names. Any preparation that we do, other than scheduling the guests, would be done day-of. If not a couple hours before, then a few minutes before.
Will the themes (other than plastics) be intertwined?
L: Certainly not our IT. We don’t prep our IT at all. Because that goes bananas every time.
L: Yeah.
What type of guests do you usually look for?
M: We’ll have callbacks to past episodes for sure. L: And if we’re at SPE events or conferences, that kind of drives the subject, and it could vary from what the speaker has to say.
M: Most of the people we’ve solicited to be guests we know through SPE.
M: Maybe if we get more feedback from our listeners, we could incorporate that.
L: Well, we have a pretty big pot to choose from right now. I could probably name you 10 more people from SPE that I want to talk to off the top of my head.
L: Maybe if we get some reviews. But just the nice ones. I don’t want the mean ones.
M: I think we’re looking for guests that have something new and interesting that they are allowed to talk about.
www.plasticsengineering.org | www.4spe.org | JUNE 2019 | PLASTICS ENGINEERING |
9
SPE PODCAST
You know, a lot of people in our industry aren’t allowed to talk about what they’re working on. L: So key. There’s a certain boy that works at a certain company that would be a very boring interview just based on how much we’d have to censor. M: Yeah. Aww, I hope we get to have him on someday.
Best advice you’ve gotten from someone on doing the podcast? M: Did we get any advice? L: I think most of the advice was, “You’re doing a podcast?”
L: That could get really mean, couldn’t it?
M: Well, Pat Farrey was the only one who told us that rather than diving into history we should take more of a forward look on things. Let’s talk about the new hot topics, which I think was great advice.
M: Depends who’s reading this. Gosh, I think Eric Larson because you were just so tired.
L: Although our history stories were quite fun. I mean, we were talking about whale bone corsets.
L: I was SO out of my element.
M: Well, hopefully we’ll be releasing the original two we did as specials.
Favorite guest so far?
M: Not your area of expertise. L: NO. M: I was nerding out HARD. L: You guys were talking about language and origins of words, and I was just ready to take a nap. M: I think it’s hard to pick who our favorite guest is. They’ve all been so wonderful. Did we have a least favorite guest? L: Comin’ after you, Jeremy Dworshak! Ha. No, Jeremy’s was really good. I think we let the ratings decide.
A guest you can’t wait to have on? L: He didn’t agree to it yet, but I think John Beaumont will be pretty good. M: And of course, I have to say my plastics fairy godfather, Glenn Beall, a fellow Plastics Hall of Famer with John. And you know who I talked with yesterday that I was really impressed with was Ryan Howley, the president of Techmer PM. Talking to him about the future of the industry and the future of the company was really exciting, because he has a very different take on it than most people in our industry. I’m realizing he would be a great podcast guest. Now, I have not asked him at all, and I don’t think he even knows about the podcast, but I can’t wait to have him on. L: Again, surprising our guests with the fact that they are on a show is really the best. M: “Surprise, you’re on Candid Podcast!” L: “Did you know that right now we are doing a podcast? You didn’t? Well, now you do. Enjoy.” M: “Welcome to the pod!”
Best advice you could give someone if they wanted to start their own podcast? M: I mean, I don’t want to steal the slogan from a company that works with polymers … just do it, lowercase, so that it’s not their slogan. L: It’s just a colloquialism. Yeah, I mean, worst-case scenario, no one listens—which could be the boat we’re in
10 | PLASTICS ENGINEERING | JUNE 2019 | www.4spe.org | www.plasticsengineering.org
for all we know. M: Like a sinking ship … moving on!
Mercedes: rumor has it that you wrote and performed the musical introduction to PlastChicks podcast. Is this true? How much time did it take you to do this and how did you come up with the lyrics? M: It took me probably a couple minutes. There aren’t many lyrics. Initially, when we were brainstorming names for our podcast, “The Voices of Resin” was one of the many hilarious names we threw out there. And then we decided on PlastChicks day of. So, it wasn’t a lot of lyrics, and we kind of came up with them beforehand.
Lynzie: do you like it? L: Yes, especially because I didn’t have to do anything for it. M: Ha! L: Key element in my enjoyment. M: Originally, I wanted you to play viola backup on that track. That’d be a really hot track. L: Definitely. I don’t see why we didn’t do that. Look at me. Boy, do I have egg on my face.
L: Well, depends. Today I feel like I’m going the opposite direction. But yes, I’m sure at some point I’ll swing back around and get better. M: Something that I want to share is something that I heard about you, Lynzie. Something I heard you say to someone about our nemesis relationship. L: Mhm? I’m sorry, did I accidentally call you my friend instead of my nemesis? M: No, you ran into a mutual friend of ours, and you told them, “I miss the days before I had a nemesis because I miss being able to not do things.” L: It was A LOT easier. M: But I mean that’s what I’ve always loved about our relationship. We are very good friends. We’re competitive in a really fun way that enables us to achieve and take on projects like this podcast. L: Yeah. I mean, I think they’re always for the better. Anytime I’m tired I think, “Darnit! Mercedes would do this, and she would do it before me if she could, right? I better do it.” M: So that’s all I have to share—a quote from you. L: Perfect. See, there you go. One point for me. M: Darnit! New episodes streaming the first Friday of every month beginning May 1! Sponsored by SPE
When you first noticed the PlastChicks podcast on Spotify, how did you feel? L: I was so excited. If I was the one editing this and putting everything up, we would never have this podcast up, so I was really excited when I actually saw it as a final thing, and it wasn’t me just talking about it and people being like, “You’re insane.” It was real. M: Yeah, I was on a plane, waiting on the tarmac when I saw it up on iTunes, and I freaked out very quietly and screenshotted it. It was so cool to see our logo up there and us specifically in cartoon form.
Anything else you want share? L: Maybe these first couple episodes have a similar flow to them because they were at ANTEC® and they were all done in a few days, but our episodes are only gonna get better and cooler. M: Yeah. And especially the first one we released was the loudest one. It was done with a live audience. L: It was definitely weird to have people watching us. M: And the cacophony of the thunderous laughter and applause might be distracting for some listeners. But I think that as we keep doing them, we’re going to have some exciting guests on, and we’re going to keep getting better, because that’s who we are. Right?
www.plasticsengineering.org | www.4spe.org | JUNE 2019 | PLASTICS ENGINEERING |
11
ADULTING 101
Adulting 101: Social Do’s and Don’ts at Professional Events By Lynzie Nebel
Y
ou can’t swing a business card these days without hearing how important networking is to your career. Sure, that’s great in theory, but how does one actually “network?” There’s the awkward small talk, the uncomfortable questions, and the all too important question of what’s the drinking etiquette. We’ve gathered a few pieces of advice to walk you through your next networking event so that you can actually enjoy it for the fun opportunity that it is.
Another way to move the conversation into a topic you’re more comfortable with is to come prepared with a few generic questions. They can be industry specific or just general small talk questions. Relax. At the end of the day, unless you personally insult someone, the worst-case scenario is that your conversation is forgettable. That happens sometimes. Find another person and start up a new conversation. Rinse and repeat throughout the evening until you find a great conversation. Have a goal (or two) in mind. They can be lofty (like landing a new client) or as simple as meeting a few new contacts. Keeping in mind what you want to get out of the night can help drive your conversations in the right direction or guide you to the right people.
Feel free to get yourself a drink. Many of these events are open bar. Just remember this is absolutely the time to sip. Pick something delicious that takes you awhile to get through. If you don’t drink, that’s fine too; you can always grab a water because it gives you something to do with your hands. (Seriously, what are your hands supposed to do!?) As long as you always keep things professional, feel free to visit the bar! Make sure to keep your cards handy. Don’t just pass them out willy nilly or the very first second you meet someone, but cards do have a value. Personally, after a show/conference, I like to go through the cards and add those people to my LinkedIn. This way, I maintain the connection but can ditch the physical cards. There’s always going to be the awkward “So what do you do?” question. It just happens. The best plan for this is to have a strong defensive game. Have a quick sentence or two prepared about what your company does and what you do there. It doesn’t have to be the best bio of the year; your only goal here is to move the conversation into a more interesting territory.
Take notes. Not in a weird and creepy 1940s journalist way, but if you had a great conversation with someone or they mentioned any noun (person, place, or thing) that can help you, then make a note on the aforementioned business card. There’s no set formula on what you’re supposed to get out of a networking event, but keep in mind networking events are supposed to be the easy part of your day.
ABOUT THE AUTHOR Lynzie Nebel is SPE’s VP-Young Professionals and a Plastics Engineer at Tech Tank. She graduated from Penn State-Erie with a B.S. in Plastics & Polymer Engineering Technology/Technician. She lives in Pennsylvania with her husband, Daniel, son, Henry Ulysses, and 2 very fat ginger cats-Richard Dreypuss & Ralphie Templeton. She is expecting her second child in August.
12 | PLASTICS ENGINEERING | JUNE 2019 | www.4spe.org | www.plasticsengineering.org
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MEDICAL 3D PRINTING
3D Printing the Future of Healthcare Additive manufacturing, or 3D printing, is fast-tracking developments in the medical device industry By Geoff Giordano
T
he escalating adoption of 3D printing (3DP) is spurring increasing development of new plastics, some of them specifically for medical and dental applications. In its earlier days, 3D printing, also known as additive manufacturing, relied largely on generic resins developed for pre-3DP applications. But as 3DP gains a firmer foothold in manufacturing beyond the rapid generation of part prototypes, industry-leading companies are crafting plastics for specific medical uses. Plastics companies have begun pursuing collaborations with these 3DP leaders to invent materials that can be used throughout the entire product development cycle, according to John Kawola, president of Ultimaker North America.
conference in Anaheim, Calif., on Feb. 5. “Manufacturers who use plastic for production—molding, extrusion machining—are finding opportunities and demand to explore using 3D printing, and there is appeal to having the materials used for 3D printing match up with materials being used for conventional processes,” Kawola adds. Generally, he says, plastics for 3DP are quite similar at the chemical level to resins for traditional processes. In the case of filament used in the fused deposition modeling process Ultimaker employs, additives akin to lubricants, as well as others materials, are incorporated to improve flow during extrusion.
New Material for a New Part
“Numerous plastics/resin companies have entered the 3D printing space in the fast few years … due to demand from their customers and the fact that a portion of the equipment market is now open to third-party materials,” says Kawola, interviewed a few weeks before his scheduled discussion of these trends at the Medical Device and Manufacturing West
This hemocytometer adapter for Becton Dickinson’s Rhapsody single-cell genomic analysis system went through several design iterations to optimize it for 3D production using Carbon’s MPU 100 medical polyurethane. Courtesy of Carbon
When healthcare giant Becton, Dickinson and Co. of Franklin Lakes, N.J., needed an alternative to injection molding to make a critical component of a geneanalysis system, Carbon of Redwood City, Calif., had the answer. Carbon has pioneered a proprietary additive manufacturing method called Digital Light Synthesis (DLS). Unlike other common additive methods that build parts by depositing powder or filament layer by layer, DLS builds parts from a pool of resin that is subjected to projected light and saturated with oxygen to manipulate polymerization
14 | PLASTICS ENGINEERING | JUNE 2019 | www.4spe.org | www.plasticsengineering.org
A “smart” medication monitoring pill bottle made with Carbon’s MPU 100 medical polyurethane (above). A surgical tool handle, left, and ligating clip holder made with Carbon’s MPU 100, a medical polyurethane (left). Courtesy of Carbon
and create an overlapping continuum of material. In September, the company introduced a new material for life sciences applications called MPU 100, a medical polyurethane. One struggle in growing adoption of its resins for medical manufacturing was that they were black to facilitate Carbon’s photochemical process, explains Steven Pollack, Carbon’s senior staff research scientist. “When you use light as your chisel, you’d like to be able to control how deep the light gets into the part—and black is a great light-stopping pigment.” MPU 100 took about a year to develop and addressed concerns such as use in a surgical environment, where healthcare personnel would not know if a black-pigment device had been cleaned or not. Once this new white resin was developed, Carbon sent it to BD to see what they could achieve with it. More importantly, MPU 100 possesses the temperature and solvent resistance, smooth surface and non-porous properties ideal for a hospital setting, unlike other resins 3D printed with photochemistry. “In our dual cure concept, we use photochemistry to create the shape, then use a thermosetting chemistry to create the mechanical properties,” Pollack says. “After the part is built, you bake it—and that baking essentially turns on a thermosetting reaction. You can make a polyurethane, a polyepoxy, a silicon chemistry. MPU has a latent polyurethane chemistry; baking turns it on, and it goes from a material that is mechanically weak to a material with the mechanical properties of ABS or unfilled nylon.” BD has been one of Carbon’s earliest adopters since the latter’s founding in 2013. When the BD Life Sciences— Genomics group based in Menlo Park, Calif., began
working on the BD Rhapsody single-cell genomic analysis system, one of the toughest parts to produce was the hemocytometer adapter. The microfluidic holder is made up of numerous square recesses set at 90º angles and requires trapped negative space for the slide holder, undercut structures, and a window for optics. With this system, genomic sequencing can be done cell by cell. “You’re not just taking a tumor or other biopsy sample and averaging the genomics over all the cells of the sample,” Pollack explains. The BD system isolates cells in the hemocytometer adapter’s microwells, each of which is bar coded. The adapter then slides into the reader. Given the limited number of adapters that made to be made, 3D printing was the ideal process. And MPU 100 was the perfect material. “It’s got the right mechanical properties, surface feel and texture,” Pollack notes. BD and Carbon experts worked together to refine the part’s design to minimize resin use and maximize print speed. Rotating the honeycomb structure by 45º, for instance, made the walls self-supporting and reduced resin usage by 7 percent per build. A custom print script reduced print time by 55 percent. Ultimately, the project was successfully completed from development to part production using the same Carbon printers. Injection molding the part would have entailed prohibitive costs for complex molds to produce about 1,000 parts a year. MPU 100 has also been used by Biolase of Irvine, Calif., as a replacement material for cast urethane parts and reduced by 70 percent the time between design and final part.
Dental Discovery In recent months, dentistry-specific materials have also some to the fore. Dental applications have long been
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MEDICAL 3D PRINTING
suited for 3D printing to perfectly customize implants and surgical guides for patients. 3D Systems of Rock Hill, S.C., has bet big on demand for digital dentistry, launching the NextDent 5100 printer in 2018 to accompany its portfolio of 30 dental resins. Offered in a range of colors, the resins can be used by dental labs and clinics to closely match patients’ teeth and gums. “All of our NextDent materials are biocompatible as well as FDA listed and CE-certified, making them suitable for a wide range of prosthodontic and orthodontic applications,” says Rik Jacobs, vice president and general manager for 3D Systems dental operations. Several of the company’s dental resins have earned Class IIa certification, which Jacobs says means that “for the first time in dental history” multiple long-term applications such as splints, denture bases, crowns and bridges can now be manufactured for long-term use in the oral cavity using 3D printing technology. “NextDent Ortho Rigid material enables production of splints for long-term use in the patient’s mouth,” Jacobs explains. “NextDent Base material was specifically developed for the printing of denture bases.” Mostly recently, NextDent C&B MFH (Micro Filled Hybrid), developed to produce crowns and bridges with high strength and wear resistance, received the certification. Increased manufacturing speed and minimizing human error are key drivers in developing these new resins, Jacobs explains. For example, it can take 14 hours of lab work to go from an initial impression of a patient’s mouth to a final set of dentures. After that, models are shipped back and forth between the lab and dentist’s office. Patients make an average of five visits to be fitted for the device, Jacobs adds. “The process also results in significant material waste in the form of plaster and wax that is used in all iterations of the models
The NextDent 5100 high-speed 3D printer from 3D Systems is powered by Figure 4 technology combined with the broadest portfolio of dental materials. Courtesy of 3D Systems
working toward creation of the final product,” he notes. “With 3D printing—specifically the NextDent solution— the entire process can be accomplished up to four times faster than other available solutions while reducing material waste and capital equipment expenditure as well as reliance upon milling centers.” At press time, 3D Systems was planning to add NextDent Denture 3D+ to its dental repertoire by the first quarter of this year. The material, aimed at producing removable dental bases, could secure Class IIa certification by March. “This material has significantly lower shrinkage compared to standard denture base materials resulting in production of excellent-fitting denture bases,” Jacobs says. Continued development of dental-specific 3DP resins is not only a function of manufacturing efficiency but patient safety, Jacobs adds. Allergic reactions are a danger. “The biggest challenge experienced with traditional photopolymer resins are allergic reactions resulting from cytotoxicity,” he explains. “When a traditional dental photopolymer reacts with a patient’s saliva, the resin can begin to break down and release monomers (the individual molecules that create the photopolymer). These monomers can cause soreness and a burning sensation in the mouth.” 3D Systems’ new dental biocompatible photopolymers are monomer-free and being validated with testing institutions. “From early results, we anticipate almost no allergic reactions to the materials.” Carbon, too, has seen a surge in dental demands for new additive materials, Pollack notes. Dental applications have grown to such an extent that Carbon has broken out a growing team specifically to meet those needs. “We are seeing a huge uptick in adoption of our machines in dental laboratories by the people who fabricate things like dental models, surgical guides for patients who need implants, and more recently a huge growth in digitally fabricated dentures at lower cost than typical devices,” Pollack explains.
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NextDent C&B Micro Filled Hybrid is developed to produce crowns and bridges with high strength and wear resistance (left). 3dsystems-NextDent-Denture3D-Plus: NextDent Denture 3D+ is suitable for printing all types of removable denture bases and has significantly lower shrinkage versus standard PMMA denture base materials and is available in multiple colors (center). 3dsystems-NextDent-OrthoRigid: NextDent Ortho Rigid from 3D Systems is developed for digital manufacturing of splints (right). Courtesy of 3D Systems
Plastics in the dental space are “a very odd thing,” he says, because the FDA regulates the liquids or solids that become devices. Generally, the FDA regulates the final product. (Pollack came to Carbon after 10 years running the FDA’s Office of Science and Engineering Laboratories.) Carbon has partnered with a number of companies that have developed 3D-printable resins and has validated those resins to work on Carbon machines to produce dental models. Those companies includes Dentca of Torrance, Calif., and its denture resins; Germany’s Dreve and its gingiva guide; and Whip Mix of Louisville, Ky., and its surgical guide-compatible resin. “We’ve opened the resin store for third-party resins in the dental space,” Pollack concludes.
Future Applications While 3DP is gaining ground in numerous industries, traditional manufacturing processes dwarf its impact. But Ultimaker’s John Kawola foresees huge opportunity in the next five or more years. “If you take just take one segment—medical devices— including all the plastic components being used in probes or medical equipment or other such equipment, the percentage being produced using 3DP in the world today is much less than 1 percent in terms of end-use parts,” he explains. Injection molding output, by comparison, is worth “hundreds of billions of dollars of plastic parts… That’s why most of us are optimistic that there’s real opportunity (to grow 3DP) from 1 percent to 5 percent.” To that end, Ultimaker has started a Materials Alliance Program with a number of plastics companies. “We have a platform that allows quick development of the parameters and profiles that are needed for specific materials,” Kawola says. “The customer benefits by having an expanding choice of materials to use and equipment that has been
qualified and tested for these materials.” That collaboration is helping bring new investment and brain power from more established plastics and chemicals giants like BASF, Dupont, Clariant, and SABIC into the heretofore more insular world of 3DP startups. “3D printing has matured over the years without the participation of the large plastics companies,” Kawola explains. “The nature of closed hardware platforms meant that these companies were rarely part of the ecosystem. Now that the market is more open, we are starting to see much faster innovation and application development. In the past, the 3DP hardware companies had materials science capability and developed their own materials. These products were good, but the scope of investments and the collective people working on it in the industry was limited.” With 3DP, “simulation is evolving and processes are improving,” he says. “The goal is that engineers in the future will be able to accurately predict and design the (material) properties required.”
ABOUT THE AUTHOR Geoff Giordano has been a contributor to Plastics Engineering since 2009, covering a range of topics, including additives, infrastructure, flexible electronics, design software, 3D printing and nanotechnology. He has served as editorin-chief of numerous industry magazines and is founder and chief creative officer of content marketing firm Driven Inbound. He can be reached at geoff@ driveninbound.com.
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DESIGN NOTES
Adapting to Fast-Changing Product Sectors Covestro is designing its materials portfolio to address needs in mobility, healthcare, energy storage, appliances, lighting, and other emerging markets By Robert Grace
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s a supplier of advanced polymer materials, Covestro finds itself on the front lines of numerous emerging and evolving industries. Work must be done to stay one step ahead of both customer and consumer needs. Recent interviews with three of the group’s business leaders shed light on key industry trends and on where they see some of the best growth opportunities in the foreseeable future. Two of those executives—Shanghaibased David Hartmann and Leverkusen, Germanybased Phillip Polenz—were elevated into new roles just last September. The third—Shanghai-based Andreas Brandt—has held his position as vice president of marketing for electrical and electronics, and appliances for polycarbonates, for the past two-plus years. Hartmann, a New Zealand native, has assumed the recently created role of senior vice president for growth ventures, which represents a much broader portfolio than his previous focus on the firm’s Maezio™ brand for continuous fiber-reinforced, thermoplastic (CFRTP) composites. As such, he now oversees efforts across a diverse set of ventures and entrepreneurial activities where Covestro projects significant growth. These include CFRTP plus aspects of mobility, electric vehicles (EVs) and energy storage, global healthcare, nonautomotive LED lighting, business model innovation, and work on a brand-new polymer that Hartmann says is being developed as we speak.
“I now oversee seven different businesses around the world—each needs different types of tools, so it’s an interesting challenge. I also get a chance to work with core businesses at PCS (Covestro’s name for its polycarbonates business), for example, in mobility,” he says.
That said, he notes, the growth ventures portfolio functions like an incubator and helps the business in question grow till it reaches a critical mass.
Serving the ConnectedHealthcare Space “The largest [sector] for me is our global healthcare business and that’s really an exciting space,” Hartmann: steering Growth Ventures. All photos courtesy of he says. There is an exCovestro plosion of wearable devices that feature integration between electronics and digitalization and healthcare—for example, the Apple Watch with an ECG (electrocardiogram) function. “You see unbelievable opportunities for improving people’s lives, on a day-today basis.” Technology has always played a central role in healthcare, but today the soaring popularity of connected medical devices is transforming how healthcare is delivered. And these changes have huge implications for both product design and the materials used to make those devices. Connected health is a healthcare management and delivery system that relies on information and communications technology. Essentially, this technology is transforming care delivery by making it simpler, more collaborative, and more data-driven. Digital technologies included in
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the Internet of Medical Things (IoMT) universe that are the foundation of connected health include: »»
Sensors
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Voice recognition technology
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Wireless connectivity (to be advanced by the adoption of 5G wireless networking)
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Mobile devices and applications
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Videoconferencing platforms
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Big Data analytics, and
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Cloud computing
In its own assessment of this burgeoning sector, Covestro has noted that “developing and manufacturing the innovative technologies that enable connected health calls for versatile materials that can meet a broad list of requirements.” These materials should enable designers to create devices with: »»
Easy and intuitive user-friendly operation
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Attractive aesthetics and stylish designs that echo consumer preferences
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Ability to be miniaturized for portable or on-body use
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Ergonomics for comfort and safety
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Support for connectivity, including developments with 5G networks
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Support for power challenges, whether through use of battery or plug-in
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Practical performance, such as chemical and scratch resistance
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Biocompatibility for skin-adhered and subcutaneous devices (FDA Class I and II)
the
toughness
latest
and
Key factors for future medical devices will include aesthetics (color and finish); miniaturization (both thin wall and lightweight); and ergonomics (comfort and safety). Additionally, there will be growing demand for polymers that provide radiofrequency (RF) transparency (for antennas and 5G adoption); flame retardance (for devices with batteries Polenz: tracking future or connected to power); mobility and heat management (for thermally conductive materials that maximize design options to cool chips and sensors). And finally, medical devices also will require chemical and disinfectant resistance; practical performance (to include polymer additives that can boost properties such as UV resistance, toughness or antimicrobial action); and biocompatibility (especially for devices that will be worn against the skin).
The soaring popularity of wearables and connected medical devices is revolutionizing the healthcare sector, with major impacts on the materials used.
It’s clear that materials technology has a vital role to play in helping to ensure that proponents of the growing connected-healthcare revolution can deliver the products and services that are sure to be demanded in the coming years.
Keeping Pace with the New Mobility Polenz, meanwhile, also moved into his new, broader role with mobility last September as part of a global restructuring. Before that, he headed polycarbonates for the North American region. “My new role is truly global and is geared toward our mobility customers worldwide. Before, my focus was on many industries in a given region,” he says. The whole automotive industry is going through a huge change, he notes. It hasn’t experienced anything similar to this for decades. Some of mobility’s biggest themes involve electrification, autonomous driving, and connectivity. Other key trends in that sector include: »»
seamless integration of sensors and infotainment features;
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new ownership models beyond personal ownership, which changes things from a “one design fits multiple use cases” model to a “designing for single-use cases” model;
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ride sharing—itself a type of new ownership model, but one that for materials suppliers such as Covestro drives durability, modularity, multiuse features (aka electronics)
Mobility is rapidly beginning to realize a future where individuals will no longer need to drive themselves, but rather be transported via autonomous vehicles. “If you want to make it real, you have to make it real with materials,” Polenz says, noting that this offers huge new challenges for all material classes. “We do have very durable, weatherable, sustainable
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DESIGN NOTES
company’s booth get to strap on a VR headset and take a virtual journey through autonomous vehicles that highlight the key role the firm’s materials play in designing future vehicle interiors. This includes a wide selection of PC resins, thermoplastic polyurethanes (TPUs), and various coatings, sealants, and adhesives that contribute to numerous lightweight, durable applications, including both interior and exterior lighting, integrated electronics (in components such as touchscreens), seat cushions, sound-deadening foam, and more.
The rise of 5G wireless networks will help to enable the Industrial Internet of Things and overall connectivity within factories and throughout supply chains.
materials, and we continue to push the boundaries of these materials,” he says. With ride-sharing, for example, the demands for all materials will increase in the car. In the past, automakers sometimes could get by with using cheaper, less durable, lower-performing polymers. But shared vehicles will require hard-wearing, cleanable, high-performance polymers. “We do see a lot of opportunities there.” In addition to collaborating with partners up and down the value chain, the firm sees the possibility for new functional cooperation between, say, special coatings and other material classes to get at least as close as possible to the type of self-healing properties many in the industry would love to have. Polenz, meanwhile, envisions user experience as the key factor in future mobility. “Once the car becomes autonomous,” he notes, “the whole interior is going to change, and with that, the materials that will be used will be different. You want bigger displays. You don’t have to look at the street anymore, so you may want to play games, read a book, interact with other people who aren’t in the car.”
Virtual Reality Gets Real At various trade shows this this year, Covestro has been showcasing its new “Future of Mobility Virtual Reality Experience,” through which visitors to the
The ever-evolving automotive sector is creating new business possibilities in the area of electric vehicle batteries and energy storage. Strong growth in the fledgling, dynamic EV segment places it squarely in the growth ventures portfolio.
“We’ve seen the exponential takeoff of EVs over the last year, especially driven by the Tesla Model 3,” Hartmann says. “Tesla just did the groundbreaking of its Giga Factory 3 in Shanghai.” Additionally, he notes, Chinese battery maker Contemporary Amperex Technology Co. Ltd. (CATL) is actively signing deals in Europe. “There are just a lot of super-ambitious players in that field. We’re providing materials to many of them, and we’re talking to all of them.” The key point, according to Hartmann, is understanding the market’s needs and being able to define what that industry chooses as material standards. Doing so requires a global perspective. The Germans and the Japanese are doing a lot of EV research, “but the largest EV market in the world today is China—and they are super-committed to lithium ion,” he notes. As a result, Covestro for now is focusing on lithium ion energy storage in vehicles, as well as on home storage and EV charging stations.
Connectivity to Impact Vehicle Design Also, as regards the vehicle’s exterior, once it is driven autonomously, it will need to communicate more with things on the outside. Lighting and lenses will become even more important. The auto industry refers to this as vehicle-to-pedestrians (V2P), vehicle-to-vehicle (V2V),
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and vehicle to-everything (V2X) communications. For materials suppliers, this means more high-end sensors embedded both behind and inside their materials. It is also likely to stimulate the development of large, seamless, glasslike surfaces that may integrate sensors.
that is generated in tight spaces.” He touts Covestro’s Makrolon TC (thermally conductive) polycarbonate as an example of a product that can aid heat transfer, enable smaller packaging, and promote less active cooling strategies.
This opens up yet more opportunities related to exterior styling and illuminated branding features. Such aesthetics are increasingly important in mobility, as users strive to personalize their rides.
Mobility Beyond the Vehicle
“It’s all about integrating those obtrusive Lidar radar [cameras and lenses] that are sometimes sitting on top of the car, into the body panels,” Polenz says. “Then you also need materials that the Lidar radar can pass through and still fully function while also being scratchand impact-resistant. And you don’t need the front grille anymore, so again you can use different materials.”
Hartmann points out that other aspects of the future of mobility also hold promise. He says firms like his need to be asking, “What’s next? How will smart cities really integrate solutions? Where are some of the best practices in the world?”
And still, Polenz stresses, the growth of autonomous vehicles (AV) and advanced driver assistance systems (ADAS) means not only a need for more sensors but also for artificial intelligence (AI) to analyze the reams of data being captured.
Interestingly enough, he says, an automotive designer in China recently told him that his benchmark in this regard was Tokyo. The designer said, “China may have better rail systems, and Hong Kong may have fantastic small connectivities, but when you look at the timing of the public mobility in Tokyo, it’s impeccable. You arrive from a small bus and it gives you just enough time to go up to your rail platform to catch your train, then you go from a long-range train to a local subway, and it’s all timed perfectly. It’s this kind of integration that’s the next wave, and we’ve got a team studying that.”
“AI means dramatically higher computational power will be required. More computations mean more heat—heat
As for other parts of Hartmann’s portfolio, he notes the global LED lighting business is growing quickly.
Digital displays and touchscreens in vehicles are getting larger and more functional while driving advances in the integration of polymers and electronics.
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DESIGN NOTES
“There are really interesting luminaires being developed, as architects and designers start to realize that, wow, we don’t need to just retrofit fluorescent or incandescent. We can design completely new stuff. They’re starting to get that, so we’re beginning to see new solutions being rolled out. We want to participate in that wave and get the right materials for that.” Hartmann also is charged with exploring new organizational strategies, which he says includes seeking ways to pivot existing operations to new business models, or to brand entirely new businesses.
Developing a Whole New Polymer As for the new polymer that Covestro is developing, the executives were cagey. “It’s very exciting. We’ll be rolling it out in the next 18 to 24 months,” Hartmann said in January. Polenz adds: “This polymer is there, and David’s team’s task is to grow it and commercialize it.” Work on it is being done predominantly in Europe, but given that Asia will be a key target market, some work also is taking place now in China, he notes. Reflecting back on some of the cool stuff he saw at the CES 2019 consumer electronics show earlier this year, Polenz says, “Many of these concept vehicles ... are becoming real. A lot of them will be on the road, starting this or next year. That’s very exciting.” Hartmann, meanwhile, stresses the need for leading tech and consumer electronics companies to be more proactive when it comes to sustainability. While sustainability is a big focus within Covestro’s polycarbonates business, he says, it does not yet seem to be a priority with some others. “It’s an unbelievable challenge that humanity is facing, and if this [high-tech-focused] community of people is not seeing that at the top of their agenda, then what kind of chance do we have, because they’re at the forefront of what’s happening? From leading companies,” Hartmann continues, “I would expect more. I
expect bigger visions and bigger thought leadership. They can’t just follow the wisdom of the herd, that’s not a winning strategy. “That’s also why,” he adds, “when you look at our new setup, at Covestro we’re trying to build a really agile business, because we understand that things are changing super-fast, and we can make a positive contribution—but only if we have the capability to change quickly and help our customers drive new things forward, even before they know that they want it.”
Electronics Get a Housing Upgrade Andreas Brandt, based in China, is another Covestro official who is busy living with fast-paced change, steering marketing efforts for the company’s PCS business in the E&E and appliances sector. “An old paradigm,” Brandt recounts, “was that you have smart and expensive electronics on the inside, and you have a cheap box around it, and therefore you need plastics materials. I think this paradigm is changing.” Brand owners are shifting away from the concept of cheap housings to much higher-performance, more functional housings. “You still have the smart, expensive electronics inside, but everything gets smaller and dense and hot and high energy. Since there is not much space, the requirements for materials are increasing. What you will find in the housing is much more function than simply protection of the electronics inside.” The result is many more integrated housings, which may also include built-in antennas, for example, as well as other features—all with aesthetically attractive exteriors that not only look great, but also are pleasing to the touch.
As ride-sharing and selfdriving cars become more prevalent, vehicle interiors will become increasingly like mobile living rooms, needing cleanable, durable materials and lighting that can be personalized.
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Brandt comments that aspects of the “smart” and connected home can now be seen everywhere. The companies that excel in this sector, he contends, are those that emphasize high-quality design in their products and that consider ”smart” features to be almost a given. “Their products stand out for being aesthetically pleasing, and they become a piece of furniture. They’re not just the next gadget that you have in your household. Design is absolutely playing a more important role— as is integration of many devices into one.” Some, such as LG’s Brandt: addressing E&E needs stand-out Signature line of appliances, smartly integrate beautiful LED lighting to make the products easy to use, but also make them look to be high-end furniture with a function. Still, however, Brandt expresses some disappointment at the lack of major breakthroughs in the smart-home sector to date. “I didn’t see the revolutionary use case yet. The vision of the smart, connected home—we are not yet there.”
Leveraging Artificial Intelligence When it comes to artificial intelligence and consumerfocused robotics, Brandt says, “We are just at the beginning. As I look into AI ... I’m stunned by how many attempts there are on the market to come up with robots and all these nice little gadgets to have in your household with your children and your pets. Nice ideas, but they’re just a starting point. They’re still not good enough to have a major breakthrough.”
as likely to be driven by the AI movement, in consumer electronics first. “We have big, powerful players who are reshaping this quite dramatically, how it’s all connected and works. “The other aspect is the more industrial side of IoT [the Internet of Things]—the whole area of smart logistics, smart agriculture, smart cities. I’m not even talking about smart manufacturing, and how that will dramatically change.”
Making Robots Friendly Brandt sees Industry 4.0, for example, as helping to drive the development of autonomous devices and robotics. “The big change that I’ve seen is that the old robotics needed metal—oil, grease, etc. For polycarbonate,” he admits, “it was a very difficult play.” But now, he notes, in this social sphere, companies are striving to develop safe, friendly looking service robots that appear to be as human as possible, so as not to seem like an alien. That means these robots need to look nice, feel nice, be high quality, sturdy, and flame-retardant. “In that perspective, PC has a lot to offer to this social, logistics area of robotics. The task for us,” Brandt says, “is to identify the right player and the real needs behind this.” A host of major, polymer-intensive sectors are changing at the speed of light, and only agile, innovative firms will be positioned to make the most of their emerging opportunities. Covestro, with its revamped structure, aims to be one of those providers.
With so many big brands and clever entrepreneurs working tirelessly in this area, however, he expects to see some really cool things hit the market––likely sooner than later. He sees another big growth sector evolving in the adventure entertainment area—with the next generation of Go Pro-type cameras, as well as drones. The industry is really starting to mature now, he says. “These devices are getting very sophisticated now and have improved greatly in terms of noise, range, specialization, etc. This is not an embryonic industry anymore.” Drones need high-performing, lightweight, durable materials, meaning that composites (such as Covestro’s Maezio CFRTP materials) potentially have a big role to play, as do thermoplastic polyurethanes.
ABOUT THE AUTHOR Robert Grace is a writer, editor and marketing communications professional who has been active in B2B journalism since 1980. He was founding editor of and worked for 25 years at Plastics News, serving as editorial director, associate publisher and conference director. He was managing editor of Plastics Engineering from July 2016 through October 2017, and is now both editor of SPE’s Journal of Blow Molding and directing content strategy for SPE. He runs his own firm, RC Grace LLC, in Daytona Beach, FL., and can be contacted at bob@rcgrace.com.
As for major trends in his sectors, Brandt sees change
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COVER STORY
Stabilizing Recyclables Recycled plastics are subjected to chemical processes that weaken them over time. Some additives, however, can enhance the durability and strength of these sustainable goods time and time again By Geoff Giordano
I
n the emerging world of closed-loop plastics recycling, resins are going to have to perform double or triple duty—or more. Girding them to tackle such Herculean feats is a new generation of performance enhancers that provide strength and stability every step of the way. Not long after announcing the newest grades of its Baeropol Resin Stabilization Technology (RST) at NPE 2018, Technical Director Robert Sherman of Baerlocher’s Special Additives North America group addressed emerging trends in bolstering recycled polymers in a presentation at ANTEC® 2019 in Detroit in March. Reducing the number of additives required to achieve various mechanical and aesthetic properties is the goal of RST technology, Sherman explained at ANTEC®. RST additives are derived from palm oil-based stearate chemistry and emerged from Baerlocher’s investigation into blends of common additives that improve the function of antioxidants. Not only do certain blends improve the performance of commodity phenols and phosphites, but the process by which they are combined also boosts their effectiveness. Baeropol stabilizers inhibit the oxidative process to preserve a polymer’s structure. Furthermore, RST “is specifically composed of additives with the broadest global food contact approvals,” Sherman explained in his presentation. He detailed the history of the creation of RST, which has produced a range of stabilizing additives that maintain resin color, improve melt stability and long-term heat stability, as well as reduce blooming. RST is being used to stabilize polypropylene (PP), polyethylene (PE), styrenics, and polyamides, Sherman noted. RST “helps to boost commodity antioxidants and
other AOs in the system. (It) also acts as a lubricant as well as an antacid.” Baeropol DRS 6812 is the most recent RST additive. Like the full range of Baeropol products, it is meant as a dropin replacement for resin makers and compounders. While stabilizers are no mystery to those users, recyclers might need more guidance. For recyclers having problems incorporating high levels of reprocessed material into their conversion stream, increased stabilization can neutralize the acid found in postconsumer recycled (PCR) material and bolster resins that weren’t necessarily designed for multiple extrusions.
Unique Solutions “We work downstream with recycling companies, converters, and brand owners designing, specifying, and delivering stabilization that allows people to recycle,” says Roberto Nunez, business director for specialty additives. Consumers, particularly in the U.S., are requesting that brand owners avoid single-use plastics “at all costs.” Providing guidance to stakeholders across the processing spectrum is a key role Baerlocher plays in ensuring robust polymer performance over repeat uses, whether those repurposed plastics are industrial or postconsumer. A current priority is replacing phosphites. “Every solution is a little bit unique,” Nunez says, with Baerlocher offering “an infinite number” of custom stabilizers in up to three forms: compacted rod pellet, prill, or pastille. With the T-Blends stabilizers, “the choice of phenolic AO used in the blend is dependent upon the resin,” like low-
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Baerlocher Baeropol stabilizers, in granule and pastille form, include antioxidants to extend the longevity of a range of polymers— especially through multiple uses. Courtesy of Baerlocher
density, linear low-density, or high-density PE and PP, Sherman explains. DRS products are designed for users who require custom formulations and want to dose all their additives separately in their hoppers.
We work downstream with recycling companies, converters, and brand owners designing, specifying, and delivering stabilization that allows people to recycle,” says Roberto Nunez, business director for specialty additives. Consumers, particularly in the U.S., are requesting that brand owners avoid single-use plastics “at all costs.
Further Baeropol blends can incorporate nucleators and clarifying agents for PP, slip and anti-block agents for linear low-density PP (LLDPP), or UV stabilizers for highdensity PP (HDPP). Meanwhile, the “neat” RST can be dosed directly into an AO hopper, Sherman suggests. Recent successful users of Baeropol stabilizers include a global manufacturer of polyolefin resins “who has seen very good success for linear low film, specifically when it comes to being able to reduce additives and the number of gels as well as improve gloss and clarity in the resin,” Sherman notes. For pipe, “we’ve had excellent acceptance among several customers when it comes to using RST as a great way of boosting the oxidation induction time (OIT).” When it comes to pipe, one of the main test methods, especially in the U.S., is OIT. “We’re able to very easily increase OIT at lower loadings than normal AOs would allow.” This results in better processability for products like drainage pipe. When working with customers, “we will typically receive samples of resins, and in our lab, we will go through multi-pass extrusion and other processes to try to determine how we can meet the customer’s requirements for stability,” Sherman explains. “We will take that data
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COVER STORY
back to the customer, and from there we work with them to sampling additives they can incorporate into their resin either in their labor, occasionally, straight into production trials.”
Stabilizers in Recycling A significant part of Baerlocher’s role in the recycling revolution is educating recyclers about how to extend the longevity of various polymers with stabilizers. When Baerlocher gets involved in upstream processing with masterbatchers and converters, that education might take the form of presentations similar to the one Sherman gave at ANTEC® 2019, detailing the performance enhancements RST provides as a dropin replacement for other commercially available additives. The various antioxidants in the many grades of Baeropol prevent changes in rheology and color, as well the formation of gels, Sherman explains. Gels—crosslinked polymers—will give a product like top bags “a texture somewhat like sandpaper instead of being perfectly smooth and transparent.” While of course many products are “a one-and-done molding process”—like many pipe resins and injection molded plastics—thermoforming and blow molding produces a lot of waste. “On a normal basis, about 30 percent of that molded part is sent for regrinding. If you are a resin manufacturer, you typically will have a more robust stabilization package.” In a case where RST is used as a partial phosphite replacement in high-density polyethylene (HDPE), Baerlocher can provide data on stabilizer-improved performance through five passes through an extruder— the equivalent of being recycled four times. With a group of samples containing contain 500 ppm of phenolic antioxidant, 500 ppm phosphite antioxidant and 500 ppm antacid or RST, Sherman notes the complex rheology of stabilized HDPE run through an extruder at various frequencies, either “extremely slowly or very, very fast.” Preventing crosslinking through five extrusions, RST ultimately performed nearly identically to three high-order phosphites. When RST is used in cast linear low-density polyethylene film (LLDPE), it can allow lower phosphite dosage, reduce blooming by reducing additive use, provide better melt stability compared to standard formulations, and dramatically boost OIT while using less antioxidant. For instance, 500 ppm of RST can offset the use of 1,000 ppm of the stabilizing phosphite TNPP and 1,000 ppm of antacid.
LLDPE film is “very commonly put back into recycling,” Sherman explains, although post-industrial film is still far easier to reuse given how clean it remains in controlled conditions, as opposed to postconsumer film that is subject to multiple unknown contaminants. If postconsumer film “is not properly cleaned, or if there is contamination from cleaning surfactants, that can be very detrimental for the antioxidants when you extrude it. That’s part of where RST works very well, because many of those contaminants are acidic, and RST is a very good antacid.” When RST T-blends are added to post-consumer polyolefins, the initial properties of the resin are retained to such a degree they are similar to prime resin—allowing for stable rheology and improved longterm stability. That can be particularly important in cases where manufacturers are trying to “upcycle” a resin for a demanding use than its initial function—for instance, using a recycled milk jug resin for plastic pipe. “In that case, you would want a much more robust additive package. If you’re down cycling by taking some recycled part and turning it into lawn edging, you’re typically less interested in long-term stability.” RST greatly improves two key performance parameters when stabilizing PCR: melt index and OIT. RST added to PCR HDPE flake produces nearly the same rheology through three extrusions while resulting in better initial OIT and retention of OIT through three extrusions. OIT is extended from about seven to 11 minutes in flaked repro to between about 34 to 36 minutes to oxidation with 2,500 ppm of RST T-blend T-1214.
ABOUT THE AUTHOR Geoff Giordano has been a contributor to Plastics Engineering since 2009, covering a range of topics, including additives, infrastructure, flexible electronics, design software, 3D printing and nanotechnology. He has served as editorin-chief of numerous industry magazines and is founder and chief creative officer of content marketing firm Driven Inbound. He can be reached at geoff@ driveninbound.com.
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SUSTAINABILITY
Almost Like New Recyclers rely on stabilizers to rebuild properties of reclaimed resins. If PCR demand accelerates, a new generation of additives could remake the market By Pat Toensmeier
E
fforts to improve the level and quality of plastics recycling are growing in many parts of the world as consumers, business, and regulators seek common ground in addressing litter, waste disposal practices, marine pollution, and the need to promote sustainable lifestyles as effective ways of reducing society’s carbon footprint and environmental impact. Recycling plays a major role in this debate. It is the cornerstone of the “circular economy,” in which the consumption of mostly commodity plastics (and other materials) doesn’t end after a product’s use. Advocates want effective collection and recycling channels developed for high-volume, single-use plastics like packaging, bottles, jugs and containers, cups, food utensils, and especially shopping bags, to guarantee that these materials will be reclaimed, reused, and removed from the waste stream for as long as possible, and ideally, for good. Most postconsumer recyclate (PCR), however, lacks the properties and performance that can broaden its reuse potential. And this is where additives suppliers see an opportunity, both for business and for the circular economy. The ability to maintain and possibly upgrade the properties of select materials within the PCR stream— primarily polyolefins, PET, polystyrene, and some polyamides—through use of stabilizers could result in growing demand for the additives and for the PCR they enhance. Suppliers are promoting this approach to recycling through recent product developments and at conference and trade show presentations.
Performance Enablers “Additives have to play a role in sustainability, especially if efforts call for reusing plastics as they were originally
Stabilizers raise PCR properties which suit materials for longterm uses like blow molded HDPE stadium seats. Courtesy of Alibaba
intended or upcycling them into applications with value,” says Robert Sherman, technical director for special additives, North America, at Baerlocher USA. The current PCR stream in the U.S. and elsewhere often results in potentially high-value materials like HDPE in milk jugs being commingled with other plastics and recycled into low-value products such as lawn and garden trim. HDPE could, if properly cleaned and processed in a pristine mono-material stream, retain most of its original properties with the addition of stabilizers during subsequent compounding and find long-term applications in products like non-pressure pipe, stadium seating, deck boards, and storage containers. “A drain pipe made of recycled HDPE can last for 50 years,” Sherman notes.
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Baeropol stabilizers improve melt stability, color, and solubility of polyolefins in deck boards and other applications (above). Baeropol DRS 6812 antioxidant, shown in prill form, can replace phosphites or reduce their loading (right). Courtesy of Baerlocher USA
Baerlocher is among the companies that actively promote stabilizer use as a way to improve recycling. Products include Baeropol T-Blends, which boost the stabilization of recyclate by combining multiple stabilizers to capture free radicals, eliminate hydroperoxides, and neutralize acidic species, all of which, if untreated, would reduce the properties of PCR. The T-Blends retain PCR’s initial aggregated properties, said Sherman in an ANTEC presentation earlier this year, and maintain stability similar to that of prime resin, as well as long-term control over properties. During the presentation, he noted that while HDPE flake has poor OIT (oxidation induction time), the addition of a T-Blend stabilizer improved initial OIT in tests and retained it during three extruder passes. The company also supplies Baeropol RST (resin stabilization technology) grades, which blend additives in a balanced formulation that contains multiple antioxidant as well as antacid chemistries for polyethylene, polypropylene, polystyrene, and low-temperature polyamides. RST chemistry is generally recognized as safe for indirect food contact. Recent additions to the RST line include Baeropol DRS 6812, an antioxidant that is formulated to improve melt stability, color, and solubility in polyolefin PCR. The stabilizer replaces phosphite on a 1:1 drop-in basis, acts as a synergist to reduce phosphite loading, and allows the use of lower-cost phosphite without affecting properties. These stabilizers demonstrate some of what’s available for recycling. They also represent the types of additive
formulations that could become more common as regulatory pressures grow on resin producers and product brandholders to improve the efficiency and effectiveness of recycling. “As customers require more and more recycled content, additives will be needed to allow resins to retain their properties,” Sherman says. Recycling could evolve into big business, though not in all regions. Europe appears to have the broadest programs in the world, experts say, primarily because of regulations and laws that increasingly focus on product redesign to optimize PCR content. Recycling in the U.S. lags the European model. As a result, “It is generally rare in the U.S. to find someone that uses stabilizers when recycling resins,” Sherman remarks.
Finding Markets One analyst explains that the U.S. recycling rate is declining after the overseas market for post-consumer plastics collapsed following the 2018 ban by China on imports of plastics waste. In 2016, China took 51 percent of global plastics waste shipments, most of which were from the U.S. China’s ban on imports led to many collection and recycling programs being abandoned in the U.S. and offsetting demand for PCR has yet to develop. Recycling is a more profitable business in Europe due to regulations that cover European Union members. Automotive is an important outlet for PCR, which is used in blends or as core layers in parts. Even so, the European Commission reports that only 6 percent of new plastics in
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to concentrate production on a handful of grades in order to streamline inventories and lower manufacturing costs. Analysts say that under these conditions it’s not unusual for PCR grades to cost more than prime polyolefins, with the result being that most buyers opt for virgin resins. Many analysts believe that in the future, resin producers, compounders, and of course recyclers will move aggressively into PCR supply if demand warrants it. Recycling could be a major business opportunity, one that spurs developments in stabilizer chemistry. Right now, the consensus is that markets are getting by with existing chemistries. But if PCR demand ramps up, materials producers, compounders, recyclers, and end-users will identify evolving performance needs and expect suppliers to meet them. Biodegradable ecovio polymer from BASF is a dual-use retail and compostable bag. Courtesy of BASF
Europe currently comes from recycled material, a number the EC wants to increase. Another factor affecting recycling in the U.S. is the lack of a broad and effective system of collection, sortation, and processing. America needs to increase investments in infrastructure to support recycling, analysts say, so that PCR is not only collected and processed, but the system generates viable products for many markets. One approach that may become common is to reduce the types and amounts of plastics collected. By focusing on products with high-demand resins such as HDPE, PET, and polyamides, and establishing mono-material processing streams, quality recyclate could be produced that would, with stabilization, attract users. This will likely happen as more brandholders demand PCR content in their products. A third factor, at least for now, is the low price of virgin resins, notably polyolefins. Analysts attribute part of this to fracking, which is increasing U.S. oil and natural gas production and consequently depressing these prices. A related price influence is an effort by some large resin suppliers
PP battery cases are recycled in mono-material streams and used in high-value recycling applications. Courtesy of Scrap Mart Metals
Restoring Properties Examples of how existing products have been formulated to meet current needs were discussed at the Plasticon Sustainable Plastics Innovation conference in Dubai last year. Talke Schaffrannek, director of applied sustainability at BASF, spoke about additive approaches to restoring PCR properties in order to create viable post-use resins. One technique involves BASF’s Joncryl ADR functional additives which, when used in reactive extrusion, restore mechanical properties by rebuilding molecular weight and chain branching in thermoplastic polyesters (PET and PBT), polycarbonate, polyamide, thermoplastic polyurethane, and polylactid acid (PLA) resins. Schaffrannek also cited Recycloblend 660 and Recyclostab 451 additives, both from Byk, which repair and upgrade the properties of recycled plastics. Loadings of 0.7 to 1.2 percent of Recycloblend 660 neutralizes solid impurities and retains mechanical properties in polyolefins and TPOs. Typical applications include vehicle bumpers, filled PP systems, and rotomolded parts. Recyclostab 451, in 0.2 to 0.5 percent loadings, improves the long-term stability of recycled PP from automotive battery cases and minimizes the effects of acidic residue. Stabilizing PCR from PP battery cases is especially important because the application comprises a model for future recycling: a relatively pristine, mono-material stream. In the U.S., estimates are that 90 percent of all automotive battery
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Plastic marine waste fouls oceans and coastlines like this beach in Tanzania. Courtesy of Loranchet
cases are recycled, with the PP reused in new cases and other high-end applications, Schaffrannek says. BASF supplies additional stabilizers for recycling. These include Irganox, an antioxidant; Irgafos, a highperformance organo-phosphite that acts as an antioxidant in some versions; and Chimasorb and Tinuvin, hindered amine light stabilizers that prevent UV degradation and maintain the chemistry, physical properties, and appearance of polymers.
Image and Reality The success rate of recycling will be decided as much by consumer opinion and regulation as by product development. One issue that provokes controversy is marine litter, notably the amount of plastics waste in global waterways and oceans and washed up on beaches. Estimates put the amount of plastics dumped in oceans yearly at 8.8 million metric tons. China alone accounts for 2.4 million metric tons of plastics ocean waste every year. As a result, marine litter is a powerful image and incentive for recycling. European countries, the U.S., and other nations are working to reduce this pollution, most of which originates in Asia. The European Parliament (EP) seeks aggressive rules that limit the amount of single-use plastics for sale and increase the collection rate of PET bottles as one way of keeping these products from becoming marine litter. By 2029, the EP wants a 90 percent collection rate for plastic bottles in Europe. By 2030 it seeks a 30 percent recyclecontent rate for PET and other bottles.
well, in Europe and lately the U.S. While it’s unlikely that the bags will be effectively collected and recycled, alternative approaches are appearing. BASF, for example, offers a compostable, bio-based polymer called ecovio FS, which can be used as a retail bag and then for organic waste. The product runs on LDPE blown film lines, is moisture and tear-resistant, and designed for effective composting. For the foreseeable future, stabilizers will be an important, if underused, means of increasing PCR performance. If the market for PCR is to develop in the U.S., or expand in Europe, resin producers, recyclers, and product brandholders will need an infrastructure that guarantees the collection of specific materials for cleaning, compounding, and reuse in high-volume, high-value applications. Commingled waste streams and low-performance PCR will not build a viable recycling business. Current stabilizers are necessary for immediate recycling needs. In the future, growing performance demands and application options will likely generate entirely new classes of stabilizers.
ABOUT THE AUTHOR Pat Toensmeier is a Hamden, Conn.-based freelance writer and reporter with more than 35 years of business journalism experience, much of it with Modern Plastics and Aviation Week. Over the years he has specialized in writing about manufacturing, plastics and chemicals, technology development and applications, defense, and other technical topics.
The ubiquitous LDPE retail bag is a target of regulation as
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Prepare for Round Three of the Plastic Waste Trade War After China closed its doors to scrap plastic imports in 2017 and Westerners scrambled to find other export targets, diplomats chew on a proposal to add mixed plastic waste to a list of materials that require the receipt of a country’s informed acceptance of this type of trade under the Basel Convention By Doug Woodring & Trish Hyde
T
he heady mix of plastic waste, global damage, and national interest has already sparked two sparring matches, and another is set to begin. At the heart of the issue is that much of the planet relies heavily on global trade––exporting and importing what we value. The trading of plastic waste can fit these criteria. However, the exported value often comes with a toxic cost. Finding the value in circular economy trading can help negate the need for some of these plastic waste trade wars. The increased inability to easily move commodities, which properly processed plastic resources are, is part of the reason for the world’s plastic pollution problem. The other significant issue is the lack of local capacity for proper collection, sorting, and basic processing for material recovery, across communities of all levels of economic advancement, including both Hong Kong and Singapore, which are two of the wealthiest cities in the world. In Round 1 of the plastic pollution fight, China announced its intention to cease the acceptance of scrap plastic imports in early 2017. Western industry insiders said it would never happen. They trusted market forces, expecting that such a ban would be viewed as an economic trade barrier.
This was a grave miscalculation. We now know China’s application to the World Trade Organization also opened the door to human and environmental damage. This created the need to manage and limit the importation of plastic waste, where up to 40 percent of a bale shipped to China was unrecoverable, due to contamination and poor material quality.
In 2018, China formalized its plan, and ceased importing a number of materials, for recycling, including all unprocessed plastic––leaving plastic exporting nations with enormous volumes of waste on their own front doors and declaring a plastic waste crisis. China’s border closure was the modern day “shot heard around the world” in terms of Western countries and their abilities to easily offshore their domestic plastic waste liabilities. Lack of homegrown capacities and high labor costs helped to shut the door on value-adding opportunities for many developed markets, while “commodity traders” often grabbed the resources from domestic processors as the buyers in China paid more, for lower quality material. With China’s borders closed, Round 2 of the plastics challenge resulted in Western countries turning quickly to find new export markets. Malaysia, Thailand, Vietnam, and Indonesia became the targets. Joining legitimate and responsible processors of these resources was a groundswell of illegal and irresponsible businesses. Like China, these countries felt, and feared, the harsh impacts of poor quality, contaminated imported plastics which had nowhere to go except into the environment. Their relatively quick actions to slow plastic imports for recycling, following China’s lead, means most exporters did not find quick solutions for re-routing their previously China-bound exports. Round 3 is on the way, as diplomats have been considering a proposal to add mixed plastic waste to a list of materials that require the receipt of a country’s informed acceptance of this type of trade under the Basel Convention. If successful, trading mixed plastic waste resources will
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change from being business-led buying and selling to one of government determination. Plastic waste exporting countries will need the informed consent from recipient countries (like Malaysia, Thailand, Indonesia, or China) in order for importation to be approved.
A Shifting Problem: Sustainable Trade These topics were among some of those addressed across the world both in Nairobi at the United Nations Environmental Assembly (UNEA) and at Plasticity Pacific in Fiji. Cutting across the localized need for solutions include the macro questions of whether recycling is really about sustainability, or if it’s a means for richer nations to shift a problem? Today, the trade of plastic waste hides under the banner of doing environmental good at home without having to consider the impacts on recipient nations. With the high publicity and visibility of plastic waste issues today, we all face much tougher questions than trying to decide which recycling bin to use for which type of material. We need plastic to maintain our modern lifestyles (think mobile phones, credit cards, auto parts, and medical equipment, among others), and the original concept behind recycling is still valid––to continually reuse materials for the ongoing benefit of all. However, the mechanics of recycling are trapped in the Industrial Age where production was optimized with little thought for future consequence, while
waste recovery facilities are frequently outdated and built for paper, glass, and metal. Far from shunning the complexity of the issues, many businesses recognize the implications of pleading ignorance and instead have committed to being leaders in the solution, even if that solution has yet to be defined. Recycling for resource reuse is of paramount importance. Given that no single company or nation can possibly reuse all consumed resources, trade is essential. Trade, however, needs to be responsible, and it needs to be the trading of resources that will be completely used and managed. The challenge we face is not whether plastic waste resources should be moved between countries for economies of scale and reuse, but instead, it is the question of how do we shift from thought to action, from principle to practical, and from me to we?
From Me to We: Shifting the Focus Over the past eight years we have held the Plasticity Forum around the world on the topic of plastic circular economies. We have engaged thousands of people from all parts of the value chain for industry-led, fit-for-purpose solutions. From this diverse and deep exploration, we offer some thoughts on solving the key question: How do we optimize value for plastic in its second life with localized processing while allowing the transfer of materials only if needed for creating
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SUSTAINABILITY
economies of scale from smaller markets to larger ones and transferring only value, instead of burden (waste).
resources through collection, sorting, and processing should take priority over downcycling the materials.
1. Continue the pressure: With the disruptive forces already in play, countries that have been a dumping ground should continue putting pressure on wasteexporting nations so that only recovered plastic feedstock is exported. In other words, only highquality, fit-for-purpose material that has a second life in the recipient country.
Yet, the greater challenge is what to do with the rest–– the dirty mixed plastics where it is hard to derive value. These materials can be converted from waste to energy, but increasingly entrepreneurs, scientists, and researchers are looking beyond the calorific value and using dirty plastic’s embedded characteristics; for example, extracting the aluminium from chip packets and using a processed form to create a higherperforming building aggregate. Chemical recycling is also a new opportunity which can yield a pure, high-quality polymer as a byproduct, without the contamination burdens with which some mechanical recycling processes contend.
2. Business focus on sustainable market opportunities: One Plasticity alumnus recently said that, despite the fact that his business collects and processes used materials and then manufactures new goods for sale, his business is not that of a recycler. Rather, he says his business is a plastics engineering, design, and product manufacturer that happens to specialize in using recovered plastic. Like many entrepreneurs in this space, he starts with his customers, combining their needs with his strategic strengths to determine which profitable products to make and sell within the specialty market he serves (in this case, agricultural and aquaculture products where there is good market turnover and margin for profit). It is only after this analysis that he turns his mind to where he can source suitable waste plastic, its costs, and the processes needed to transform it. Interestingly, he found that his customers are a great source of the very waste plastic he needs. 3. Collaborating for competitive advantage markets: The market disruption currently being experienced globally is an opportunity for industries, countries, and regions to apply this thinking from above. Each group knows its manufacturing strengths and weaknesses and where it has strategic opportunity. The only part missing is determining where there are viable opportunities to replace virgin plastic with recovered plastic, in order to ensure clear pathways for plastic waste to be transformed into feedstock for reuse. 4. Walking the talk: Governments and businesses wield huge buying power through their own procurement. Adopting policies favouring recovered content, is a powerful demand catalyst to stimulate product development using recovered plastic. 5. Extract value from all plastic: There are some plastics (such as clean, clear PET) that are highly valuable as recovered plastic, yet there are many that, either through lack of volume or high contamination, are perceived as worthless.
6. Innovative substitutes for non-recoverable hazardous plastics: There are more than 43,000 types and combinations of plastics. While all are technically recoverable and reusable, it is simply not viable to do so for many of them with today’s technologies and economies of scale in sorting and collection. Where there is no value, and not even energy, the innovation challenge should be set globally to identify substitutes or recovery solutions. Over time, the “too-hard basket” of plastics will diminish. 7. Engage in the conversation: It is easy to want to blame others for the global plastic waste problem–– should governments have done more, are community attitudes the cause, or are corporates ones at fault? The problem with the blame game is that, once started, the finger pointing rarely ends. Above all else, new collaborations and shared responsibility created across business sectors can help shift thought to action, embed principle to practice, and help change the focus from me to we.
ABOUT THE AUTHORS Douglas Woodring is founder of Plasticity Forum (the global forum bringing about applied plastic circular economies) and founder of Ocean Recovery Alliance (a solutions-focused non-governmental organization dedicated to better oceans). He is a sustainability economist with more than 20 years of experience in business, finance, and circular economy across the globe but with deep roots in Asia where he is based. Trish Hyde is founder of The Plastics Circle (a circular economy innovation and application firm) and founder of PlastX (a tech startup for businesses to buy the specific recovered plastics they need, direct from a community of paid collectors). She is an accomplished business leader and adviser with global knowledge and expertise in circular economies and operational performance. Douglas and Trish invite readers to join industry leaders and influencers at the next world-leading action-based plastic circular economy forum––Plasticity Amsterdam, on June 19, 2019, in The Netherlands (www.plasticityforum.com).
It is obvious that extracting valuable used plastic
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19TH ANNUAL
COMPOSITES: Forming the Future of Transportation Worldwide
SEPT 4-6, 2019
CALL FOR PAPERS ATTEND THE WORLD’S LEADING AUTOMOTIVE COMPOSITES FORUM You’re invited to attend the 19th Annual SPE Automotive Composites Conference and Exhibition (ACCE), September 4-6, 2019 at the Suburban Collection Showplace in Novi, MI. The show features technical sessions, panel discussions, keynotes, receptions, and exhibits highlighting advances in materials, processes, and equipment for both thermoset and thermoplastic composites in a wide variety of transportation applications. PRESENT BEFORE A GLOBAL AUDIENCE The SPE ACCE draws over 900 attendees from 15 countries on 5 continents who are interested in learning about the latest composites technologies. Few conferences of any size offer such an engaged, global audience vitally interested in hearing the latest composites advances. Interested in presenting your latest research? Abstracts are due ASAP and papers on June15, 2019 to allow time for peer review. Submit abstracts viawww.SubmitACCEPapers.com. EXHIBIT / SPONSORSHIP OPPORTUNITIES A variety of sponsorship packages are available. Companies interested in showcasing their products and / or services should contact Teri Chouinard of Intuit Group at teri@intuitgroup.com. FOR MORE INFORMATION
SPEautomotive.com/acce-conference +1.248.701.8003
49TH ANNUAL
PLASTICS –> Advancing Mobility NOVEMBER 6 2019
CALL FOR NOMINATIONS
–> HALL OF FAME AWARD –> MOST INNOVATIVE USE OF PLASTICS AWARDS
The Automotive Division of the Society of Plastics Engineers (SPE®) is announcing a “Call for Nominations” for its 49th-annual Automotive Innovation Awards Gala, the oldest and largest recognition event in the automotive and plastics industries. This year’s Awards Gala will be held Wednesday, November 6, 2019 at the Burton Manor in Livonia, Mich. Winning part nominations (due by September, 15, 2019) in 10 different categories, and the teams that developed them, will be honored with a Most Innovative Use of Plastics award. A Grand Award will be presented to the winning team from all category award winners. An application that has been in continuous use for 15 years or more, and has made a significant and lasting contribution to the application of plastics in automotive vehicles, (nominations due by May 31, 2019) will be honored with a Hall of Fame award.
SPONSORSHIP OPPORTUNITIES This annual event currently draws over 800 OEM engineers, automotive and plastics industry executives, and media. A variety of sponsorship packages - including tables at the banquet, networking receptions, advertising in the program book, signage at the event and more are available. Contact Teri Chouinard of Intuit Group at teri@intuitgroup.com. For more info and to submit nominations, go to: www.speautomotive.com/innovation-awards-gala.
IAG19_CFN_Hlf_PE_May.indd 1
INNOVATIVE PART COMPETITION CATEGORIES: • Additive Manufacturing • Aftermarket • Body Exterior • Body Interior • Chassis/Hardware • Environmental • Materials • Process, Assembly & Enabling Technologies • Powertrain • Safety & Hall of Fame
4/10/19 12:24 PM
AS I SEE IT
Destination Düsseldorf The K Show in Germany will attract more than 3,000 exhibitors from 60 countries. Petra Cullmann, global portfolio director for plastics and rubber at Messe Düsseldorf, talks about why K 2019 is so important to the industry By Pat Toensmeier
T
he triennial K Show will be the center of the global plastics industry for eight days this fall. More than 3,000 exhibitors from over 60 countries will fill the massive fairgrounds (175,000 square meters) of organizer Messe Düsseldorf in Germany between Oct. 16 and 23, presenting the latest technology, machinery, materials, and applications to attendees from 161 countries. Petra Cullmann is the global portfolio director for plastics and rubber at Messe Düsseldorf. She discusses why K 2019 is so meaningful for business and what attendees will see there.
Why should plastics professionals attend K 2019? K has been the most important meeting place of the international plastics industry for 67 years. For eight days, the “Who’s Who” of the plastics world will meet in Düsseldorf to demonstrate the industry’s capabilities, discuss trends, and set the course for the future. Only at K will visitors have a complete overview of where the industry is heading because they can experience innovations throughout the value chain.
What new areas of technology and manufacturing will be highlighted? Our core strength is putting on a service-oriented event, so for technology input, it is important to get the right partners onboard. We work closely with groups like the German Association of Plastics Converters and the German Plastics and Rubber Machinery Association. The trade fair is also under the patronage of Euromap, the European Committee of Manufacturers for the Plastics and Rubber Industry. Another key association that we rely on is the Scientific Council, a group of professors of polymer science and plastics technology at scientific institutions.
Petra Cullmann, global portfolio director for plastics and rubber at Messe Düsseldorf
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Together with our German and European association partners, we have developed four key topics for presentation: 1. Plastics for sustainable development and the circular economy. 2. Digitalization of the value-added chain/Plastics Industry 4.0, which includes platform economy and valueadded networks. 3. System integration, which covers functionality through material, process, and design, and covers new materials and additives, additive manufacturing, lightweight engineering, mobility and e-mobility, and bioplastics. 4. Promotion of young professionals for the industry. In addition, the following trends will be highlighted: modification, additive manufacturing, and functionalization of polymer raw materials; resource efficiency; material efficiency and availability; reduced mold changeover times; and zero-waste production.
Courtesy Messe Düsseldorf/ctillmann
A special show, “Plastics Shape the Future,” a project of the German plastics industry spearheaded by PlasticsEurope Deutschland and Messe Düsseldorf, will include keynote speeches and discussions of relevant topics. A joint presentation of the VDMA (German Engineering Federation) and its member companies will focus on sustainability and the circular economy. And the Science Campus will encourage dialogue between research and industry and provide exhibitors and visitors with a comprehensive view of scientific activities and results in plastics research.
What types of developments will K display? K is structured in three main categories: machines and equipment; raw materials and auxiliaries; and semifinished products, technical parts, and reinforced plastics products. K 2019 represents the industry’s complete production chain in unparalleled depth and breadth. Exhibitors of all categories will present world premieres during the show. Only K features such a high density of international product launches.
How will K highlight the impact of plastics on global societies? Polymer materials deliver impressive results in almost all areas of application. Plastics are indispensable for many applications. While the questions of proper disposal and reuse pose significant challenges for global societies, plastics are valuable materials which ought to be produced in a sustainable manner and reused to create high-quality products. K 2019 will show an overview of the possibilities and insight into the industry’s cooperation with different institutions.
Will there be outreach to regulatory and political bodies at K? This year again, government and institutional representatives from all over the world will come and see where the industry stands and how it is facing challenges. Especially against the background of discussions about plastics and the environment, which can only be addressed and resolved globally, the meeting of representatives from politics and industry at K is very important. The key is circular economy. The devastating effects of littering in the oceans must lead to a process of change in society and industry. Plastics are too valuable to be carelessly thrown away. The EU is setting an example with its new plastics recycling strategy. Exhibitors will highlight these issues at their booths, and “Plastics Shape the Future” will address marine litter, packaging waste, and climate change as well as resource conservation, energy efficiency, and recycling.
ABOUT THE AUTHOR Pat Toensmeier is a Hamden, Conn.-based freelance writer and reporter with more than 35 years of business journalism experience, much of it with Modern Plastics and Aviation Week. Over the years he has specialized in writing about manufacturing, plastics and chemicals, technology development and applications, defense, and other technical topics.
www.plasticsengineering.org | www.4spe.org | JUNE 2019 | PLASTICS ENGINEERING |
37
INDUSTRY NEWS
ExxonMobil Completes Elastomers Expansion in Wales, Announces Expansion in Texas
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xxonMobil, the largest publicly traded international oil and gas company, has completed an expansion of its specialty elastomers manufacturing plant in Newport, Wales, doubling the plant’s manufacturing capacity and increasing global manufacturing capacity of Santoprene™ thermoplastic elastomers by 25 percent. The company also announced a $2 billion investment to expand its Baytown, Texas, chemical plant, which will create approximately 2,000 jobs during construction and contribute to the approximate 15 percent return the company expects from its chemical investments. Regarding the Welsh plant expansion, Karen McKee, president of ExxonMobil Chemical Co. says, “ExxonMobil’s high-performance plastics help make automotive and consumer products lighter, resulting in improved fuel efficiency and higher performance, compared with products made with traditional materials. This Newport investment doubles the site’s manufacturing capacity of higher-value products.” Santoprene thermoplastic elastomers are engineered to perform like vulcanized rubber and can be reused and re-engineered, leading to reduced shipping weights, improved recycling capabilities, and moresustainable manufacturing. The Newport project created approximately 35 full-time production jobs and supported 130 jobs during construction. The announcement of its completion followed ExxonMobil’s recently announced plans to expand its Fawley refinery in the United Kingdom to increase production of ultralow sulfur diesel by almost 45 percent, or 38,000 barrels per day. The Baytown expansion is in addition to the company’s 2017 Growing the Gulf initiative, which outlined plans to build and expand manufacturing facilities along the U.S. Gulf Coast, creating more than 45,000 jobs across the region.
“Our substantial investments in the United States support ExxonMobil’s long-term growth plans and will result in thousands more high-paying jobs,” says Darren W. Woods, ExxonMobil chairman and chief executive officer. “Through the billions of dollars that we’re investing in the Permian Basin to increase oil production and the expansion at our operations along the Gulf Coast, our company is making significant, lasting contributions to the U.S. economy and the many communities where we operate.” ExxonMobil’s Baytown facility is the largest integrated petrochemical complex in the U.S. Founded in 1919, the complex is located on approximately 3,400 acres along the Houston Ship Channel, about 25 miles east of the city. The facility includes a refinery, chemical plant, olefins plant, plastics plant, and global technology center. Its expansion, expected to begin in 2022, includes a new Vistamaxx™ performance polymer unit, which produces products that offer higher levels of elasticity, softness, and flexibility. These attributes contribute to a reduction in materials used and increased performance, and the new unit will produce about 400,000 tons of Vistamaxx polymers a year. The Baytown project will also enable ExxonMobil to enter the linear alpha olefins market. Linear alpha olefins are used in numerous applications, including high-performing engine and industrial oils, waxes and building blocks for surfactants, polyethylene plastic for packaging, and other specialty chemicals. The new unit will produce about 350,000 tons of linear alpha olefins a year. “Our Baytown chemical expansion will put us in a solid position to maximize the value of increased Permian Basin production and will deliver higher-demand, highervalue products produced at our Gulf Coast refining and chemical facilities,” says Woods. “Global demand for chemicals is expected to be greater than energy demand growth and GDP growth over the next 20 years.”
38 | PLASTICS ENGINEERING | JUNE 2019 | www.4spe.org | www.plasticsengineering.org
Tupperware Brands to Introduce Circular Material Made from Mixed Plastic Waste
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upperware Brands Corp., a global marketer of food preparation, storage, and serving solutions, announced its collaboration with SABIC, a petrochemical company and one of its long-term suppliers, for the introduction of certified circular polymers into its products. This collaboration highlights both companies’ commitment to advance a circular economy where plastic waste and materials are used, reused, and repurposed. “Tupperware Brands is committed to meeting the needs of today’s consumers, who are increasingly asking for solutions that mitigate waste and advance a more circular economy. The introduction of this new material, and the products in which they will be used, reflect our continued dedication to further reduce our environmental footprint at all levels of the product lifecycle—from design, production, and distribution to products’ use and reusability—and also reflects our heritage of innovation and sustainable design,” says Bill Wright, Tupperware’s executive vice president, product innovation, and supply chain. For more than 70 years, Tupperware has provided
reusable, safe, and environmentally responsible products that help consumers store, prepare, and cook food. Introducing polymers from recycled material reflects Tupperware’s commitment to sustainability. Starting in the summer of 2019, Tupperware will begin introducing the certified circular polymers in new products that aid in the reduction of single-use plastics, including a portable reusable straw and an on-the-go coffee cup. “We are pleased to extend our collaboration with Tupperware Brands, as we are unified in our goal to deliver high-quality solutions made from advanced, recycled materials that address consumer needs and safety standards,” says Sergi Monros, vice president, performance polymers and industry solutions at SABIC. “We continue to innovate with materials and look to create more sustainable and environmentally responsible solutions to support a circular economy. Our material is made through a process that takes mixed plastic waste destined for disposal, breaks it down to its original raw state, and recreates high-quality plastic that maintains the purity and quality that are the hallmark of Tupperware products.”
David Stasse Named Executive Vice President and Chief Financial Officer of Trinseo
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rinseo, a global manufacturer of plastics, latex binders, and synthetic rubber, named David Stasse its executive vice president and chief financial officer effective July 1. He will replace Barry Niziolek, who earlier this year announced his plans to retire. Stasse, the company’s current vice president, treasury and investor relations, will also join its executive leadership team. “We are extremely pleased to name an executive the caliber of Dave Stasse as CFO,” says Frank A. Bozich, president and chief executive officer of Trinseo. “His track record at Trinseo, his strategic and financial acumen, and his credibility with investors make him ideally suited to take on this role. Dave has worked closely with Barry Niziolek throughout his tenure, which will enable a smooth and seamless transition. On behalf of the board, I want to thank Barry Niziolek for his leadership in strengthening the company’s financial performance,
compliance programs, and operational discipline during his tenure as Trinseo’s CFO. We will miss his counsel and we wish him all the best in his well-deserved retirement.” Stasse joined Trinseo in 2013 from Freescale Semiconductor Inc., where he served as vice president and treasurer from 2008 to 2013 and as assistant treasurer from 2006. He previously served as first vice president, debt capital markets, at MBNA Corp., as treasury manager of SPX Corp., and held numerous financial leadership positions at Honeywell International from 1998 to 2004, last serving as director of corporate finance. Stasse, who holds a master’s degree in business administration in finance from the University of Maryland and a bachelor of science degree in business logistics from Penn State University, will continue to be located at Trinseo’s global operating center in Berwyn, Pa.
www.plasticsengineering.org | www.4spe.org | JUNE 2019 | PLASTICS ENGINEERING |
39
INDUSTRY NEWS
Jerry MacCleary to Retire from Covestro
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ovestro LLC announced that Jerry MacCleary will retire from his current position as chief executive officer and chairman of the board, effective Dec. 31, 2019. “I’ve had a long, fulfilling career with this company, and I’m incredibly proud of what we’ve accomplished over the years,” says MacCleary. “Covestro has a vibrant new culture, a strong, diverse leadership team, and a promising future here in the region—I can’t think of a better time to retire. Saying goodbye to my Covestro family won’t be easy, but I’m looking forward to starting this next chapter of my life.” MacCleary’s retirement caps a 40-year career at Covestro. He first joined the company in November 1979 as an accountant, and he has held roles in sales, marketing, general management, and strategic leadership. In 2004, MacCleary was named head of the North American Polyurethanes business, a responsibility he maintained even after taking the helm at Covestro LLC in 2012. He led the North American organization through a number of transformative changes, including Covestro’s separation
from Bayer AG and establishment as an independent company in 2015, and was named to his current position as chief executive officer and chairman in 2018. MacCleary’s leadership extends into the chemical industry as well, where he serves as chairman of the American Chemistry Council’s board of directors and chairs its sustainability committee. He also serves on the board of directors for the National Association of Manufacturers and the executive committee for the Society of Chemical Industry. Both inside and outside Covestro, MacCleary is known for championing initiatives that help to advance sustainability, innovation, and diversity and inclusion. “Our team, our business, and our reputation in North America have thrived under Jerry’s leadership, and we’re grateful for his many contributions over the years,” says Dr. Markus Steilemann, chief executive officer of Covestro AG. “While Jerry will retire at the end of 2019, the impact he’s had on our culture, community and industry will be felt for years to come.” Covestro’s North American polyurethanes division produces high-performance polymers as part of the global Covestro business.
Kraton Appoints Atanas Atanasov Chief Financial Officer
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raton Corp. announced that its board of directors appointed Atanas H. Atanasov senior vice president and chief financial officer, effective May 6, 2019. Atanasov will assume the role from Christopher H. Russell, the company’s chief accounting officer, who has also served as interim chief financial officer since November 2018.
Partners. Atanasov also spent nine years with GE Capital in various finance roles of increasing responsibility. He holds a master’s degree in business administration from the Collins College of Business at the University of Tulsa and a bachelor of science in accounting, summa cum laude, from Oral Roberts University.
“We are extremely pleased to welcome Atanas to Kraton. We believe his background, experience, and leadership approach will be instrumental as Kraton continues to execute on its innovation-led growth strategy to deliver exceptional value for our shareholders, customers, and employees,” says Kevin M. Fogarty, the company’s president and chief executive officer. “Atanas brings to Kraton over 20 years of disciplined financial leadership experience, with proven expertise in accounting, tax, financial planning and analysis, banking, and capital market transactions.”
Fogarty also noted the contributions Russell made in his capacity as interim chief financial officer. “On behalf of our board of directors, I want to thank Chris Russell for his commitment and significant contributions during the past six months. His leadership ensured continuity in all critical activities our CFO organization supports. Moreover, Chris was a willing and able thought partner to our leadership team, our board of directors, and me, personally, as we closed 2018, built our plans for 2019, and evaluated a number of strategic considerations. As chief accounting officer, Chris remains a valued Kraton senior leader.”
Atanasov most recently served as a chief financial officer of Empire Petroleum Partners, LLC. Prior to joining Empire in 2016, he served as executive vice president, chief financial officer, and treasurer of NGL Energy
Kraton produces styrenic block copolymers, specialty polymers, and high-value performance products derived from pine wood pulping co-products.
40 | PLASTICS ENGINEERING | JUNE 2019 | www.4spe.org | www.plasticsengineering.org
Robert Langer Wins 2019 Dreyfus Prize for Chemistry in Support of Human Health
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he Camille and Henry Dreyfus Foundation announced that Robert Langer, institute professor at Massachusetts Institute of Technology, won the 2019 Dreyfus Prize in the Chemical Sciences. The biennial prize, which includes a $250,000 award, is being conferred this year in Chemistry in Support of Human Health. The award ceremony will be held at MIT on Sept. 26 and will include a lecture by Langer. “It’s always been a dream for me to be able to use my scientific background to help prolong life and relieve human suffering,” says Langer. “When I look at the remarkable individuals in chemistry and chemical engineering around the world, including the people who have won the Dreyfus Prize previously, receiving this award is truly humbling,”
Robert Langer, winner of the 2019 Dreyfus Prize in the Chemical Sciences. Courtesy of Science History Institute/Wikimedia Commons
Langer is being honored for discoveries and inventions of materials for drug delivery systems and tissue engineering that have had a transformative impact on human health through chemistry. His work on drug delivery is at the interface of biotechnology and materials chemistry, with a strong focus on the study and development of polymers to deliver drugs continuously and at controlled rates for prolonged periods. His innovations have been lauded as the cornerstone of that industry and translated into commercial products used in the treatment of brain and prostate cancer, macular degeneration, and a variety of mental health disorders, including schizophrenia and opioid addiction. His pioneering work with Joseph Vacanti in tissue engineering has led to the creation of new skin, cartilage, bone, corneas, and blood vessels in humans. Langer is further renowned as a mentor, with nearly 1,000 former students and postdocs becoming established leaders in academia, industry, and government. His papers have been cited in scientific publications more than any other engineer in history, and his leadership in both the underlying science and its applications have given rise to entirely new fields of the chemical sciences and engineering. “There is no greater benefit that the chemical sciences
provide to society than the many profound contributions to the science and technology of human health,” says Matthew Tirrell, chair of the Dreyfus Foundation Scientific Affairs Committee and director of the Institute for Molecular Engineering at the University of Chicago. “Bob Langer created two rich fields at the intersection of chemistry and medicine: controlled release materials for delivery of therapeutic macromolecules and tissue engineering. His discoveries have been translated, often by Langer himself, to many products that profoundly impact human health. In a diverse field of chemists and chemical engineers with many powerful contributors, the enormous body and influence of Bob Langer’s work stands out in a singular way.” Initiated in 2009, the Dreyfus Prize in the Chemical Sciences is conferred in a specific area of chemistry in each cycle and is the highest honor of the Camille and Henry Dreyfus Foundation. Based in New York and established in 1946 by chemist, inventor, and businessman Camille Dreyfus, the foundation is a leading non-profit organization devoted to the advancement of the chemical sciences. Its mission is to advance the science of chemistry, chemical engineering, and related sciences as a means of improving human relations and circumstances throughout the world.
www.plasticsengineering.org | www.4spe.org | JUNE 2019 | PLASTICS ENGINEERING |
41
INDUSTRY NEWS
Westfall Technik Acquires Delta Pacific Products and Its Subsidiaries
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estfall Technik, Inc., a global holding company that provides plastics manufacturing solutions to the medical, packaging, and consumer goods industries, acquired Delta Pacific Products and its wholly owned subsidiaries, Prism Plastics Products and NxTBio Technologies, each of which operate on a standalone basis. This acquisition marks a significant investment in the medical/healthcare space for Westfall. As an injection molding company with over thirty years of operating experience in the San Francisco Bay Area, Delta serves the large and growing medical device startup community in that region, working with med-tech research and development professionals from the prototyping phase through FDA approval and full production. Prism, located outside Minneapolis, also marks a strategic investment for Westfall as the company looks to expand its presence and provide additional capacity and capabilities to its customers in the Midwest. On a combined basis, the additions of Prism and Delta add over 50,000 square feet of production space to Westfall’s capacity, and the
company plans to expand Delta’s current footprint to allow the business to scale alongside its customers. “We chose to join Westfall Technik because we knew Westfall would expand the services and production capacity we offer to the medical device community in the Bay area and greater Minneapolis. We can now offer our customers high-volume production, device assembly, and rapid precision toolmaking throughout the United States and, through Westfall’s extensive sales team, can offer our services to customers we could never previously reach,” says Yuan Tian, Delta’s president and chief executive officer. Westfall also acquired NxTBio Technologies, a developer, marketer, and distributor of branded bioscience laboratory consumables including pipette tips, filter tips, tubes and strip tubes, vials, multi-well plates, and related racking systems. Westfall’s ability to engineer and build highvolume production systems will accelerate the growth of NxTBio’s product portfolio.
SC Johnson Expands Offerings of Concentrate Products to Combat Plastic Waste
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C Johnson is continuing to address the plastic waste crisis by expanding and widening access to its concentrate offerings.
“Plastic waste is becoming a bigger and bigger environmental problem,” says Fisk Johnson, chairman and chief executive officer of SC Johnson. “We hope more people can give concentrates a try, as every single time you use a concentrate bottle you [create] nearly 80 percent less plastic waste.” Since the unveiling of Windex® concentrates in 2011, SC Johnson has expanded its refill options to other popular cleaning brands, including Pledge®, Scrubbing Bubbles®, Shout® and fantastik®. The new line of SC Johnson concentrates will begin rolling out in the U.S. and Canada, when Scrubbing Bubbles, Windex, and fantastik bottles, and two-count refill sets hit e-commerce retailers. The next wave of concentrate
refills, including Scrubbing Bubbles, Windex, and Mr Muscle®, will be available for purchase online in Mexico this July, in the United Kingdom starting in August, and in China and Japan beginning this September. The benefits of concentrate refills are primarily environmental and in line with the steps SC Johnson has taken regarding waste reduction and the circularity of its products. For example, the company’s trigger bottles deliver more than 10,000 sprays and can be refilled dozens of times; by purchasing bottles with a long lifespan, millions of pounds of plastic waste can be stopped from ending up in landfills. “Refilling with a concentrate is a small change that could make a real difference in minimizing plastic waste,” Johnson says. “Together, we can reduce plastic waste and work towards a cleaner planet.”
42 | PLASTICS ENGINEERING | JUNE 2019 | www.4spe.org | www.plasticsengineering.org
SOCMA: Increase in China Tariffs to Place Disproportionate Burden on Specialty Chemical Manufacturers
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he Society of Chemical Manufacturers and Affiliates (SOCMA) says the Trump administration’s decision to raise tariff rates from 10 to 25 percent on $200 billion in Chinese imports will disproportionately burden specialty chemical manufacturers. The U.S. Trade Representative (USTR) notice of the tariff increase was published in the Federal Register on May 9 and went into effect at 12:01 a.m. May 10. Specialty chemical supply chains are particularly dependent on China because, in many cases, China is the sole supplier of raw materials and building block chemicals. The fact that chemical tariff lines made up nearly half of the delistings for List 3 (the products effected by the tariff increase) speaks volumes regarding the degree to which certain inputs are simply unavailable outside of China at reasonable costs and in sufficient quantities, if at all. “While SOCMA supports the administration’s end goal of zero tariffs and improved IP protection in China, a 25 percent tariff on $250 billion in Chinese imports will place a significant burden on our members and the industry,” says Jennifer Abril, president and chief
executive officer of SOCMA. “Whether it is pigments, agrochemicals, or pharmaceuticals, specialty chemicals are vital inputs to critical sectors of American industry. These sectors are thriving, but cannot continue to sustain the volatility introduced by these actions. We have illustrated the interdependency of these supply chains to USTR at every opportunity and have stressed the need for a product exclusion request process for List 3. The promised exclusion process in today’s Federal Register notice acknowledges this, and SOCMA looks forward to working with the administration towards an expeditious and transparent process for evaluating List 3 exclusion requests.” To date, the U.S. has levied tariffs on 1,517 Chineseorigin chemical products valued at roughly $15.4 billion. China has levied retaliatory tariffs on more than 1,000 chemical and plastics products valued at roughly $10.8 billion. As the U.S. and China negotiate the sequencing of tariff removal, SOCMA is proactively monitoring and advocating on behalf of the specialty chemical industry, particularly advocating for the USTR to roll back tariffs on chemical products in Harmonized Tariff Schedule chapters 28, 29, 32, and 38, as soon as possible.
#92
Extrusion Blow Molding – Insulation Heating
Action:
As with conventional extruders, shear heat will be negligible downstream of the screw tips, and almost all of the material flow components downstream of the screw tips will benefit from insulation. The area downstream of the screw tips is often crowded and insulation is difficult to fix and retain.
»»
Only attempt insulation where it is easy and practical to apply.
»»
Check the thermal isolation of the parison heads from the main machine and improve.
»»
Insulate cooling water hoses.
»»
Insulate flat surfaces of the mold block with flat insulation board to reduce parasitic heat gain to the chilled water system.
»»
Use insulation between the mold and the machine platens to prevent heat transfer between the cold mold and the machine.
»»
Increase the demolding temperature until the maximum for good product is reached––with good parison control there will be limited differential shrinkage and de-molding is possible at higher temperatures.
»»
It is possible to demold quickly from the main mold and use post-cooling with water-cooled contour clamps in critical areas.
Cooling Parasitic heat gain in EBMMs is often significant. Cooling water hoses are rarely insulated and will suffer from parasitic heat gain, but the major cold surface area is the mold itself. Molds are rarely insulated, even though they are mainly flat surfaces and can be fitted with simple, flat insulation on the outer faces to dramatically decrease the amount of parasitic heat gain to the cooling water system. The mold will not only gain heat from the atmosphere but also from the main machine if it is not insulated from the rear platen.
Dr. Robin Kent - ©Tangram Technology Ltd. (www.tangram.co.uk)
www.plasticsengineering.org | www.4spe.org | JUNE 2019 | PLASTICS ENGINEERING |
43
SOCMA: Increase in China Tariffs to Place Disproportionate Burden on Specialty Chemical Manufacturers
T
he Society of Chemical Manufacturers and Affiliates (SOCMA) says the Trump administration’s decision to raise tariff rates from 10 to 25 percent on $200 billion in Chinese imports will disproportionately burden specialty chemical manufacturers. The U.S. Trade Representative (USTR) notice of the tariff increase was published in the Federal Register on May 9 and went into effect at 12:01 a.m. May 10. Specialty chemical supply chains are particularly dependent on China because, in many cases, China is the sole supplier of raw materials and building block chemicals. The fact that chemical tariff lines made up nearly half of the delistings for List 3 (the products effected by the tariff increase) speaks volumes regarding the degree to which certain inputs are simply unavailable outside of China at reasonable costs and in sufficient quantities, if at all. “While SOCMA supports the administration’s end goal of zero tariffs and improved IP protection in China, a 25 percent tariff on $250 billion in Chinese imports will place a significant burden on our members and the industry,” says Jennifer Abril, president and chief
executive officer of SOCMA. “Whether it is pigments, agrochemicals, or pharmaceuticals, specialty chemicals are vital inputs to critical sectors of American industry. These sectors are thriving, but cannot continue to sustain the volatility introduced by these actions. We have illustrated the interdependency of these supply chains to USTR at every opportunity and have stressed the need for a product exclusion request process for List 3. The promised exclusion process in today’s Federal Register notice acknowledges this, and SOCMA looks forward to working with the administration towards an expeditious and transparent process for evaluating List 3 exclusion requests.” To date, the U.S. has levied tariffs on 1,517 Chineseorigin chemical products valued at roughly $15.4 billion. China has levied retaliatory tariffs on more than 1,000 chemical and plastics products valued at roughly $10.8 billion. As the U.S. and China negotiate the sequencing of tariff removal, SOCMA is proactively monitoring and advocating on behalf of the specialty chemical industry, particularly advocating for the USTR to roll back tariffs on chemical products in Harmonized Tariff Schedule chapters 28, 29, 32, and 38, as soon as possible.
#92
Extrusion Blow Molding – Insulation Heating
Action:
As with conventional extruders, shear heat will be negligible downstream of the screw tips, and almost all of the material flow components downstream of the screw tips will benefit from insulation. The area downstream of the screw tips is often crowded and insulation is difficult to fix and retain.
»»
Only attempt insulation where it is easy and practical to apply.
»»
Check the thermal isolation of the parison heads from the main machine and improve.
»»
Insulate cooling water hoses.
»»
Insulate flat surfaces of the mold block with flat insulation board to reduce parasitic heat gain to the chilled water system.
»»
Use insulation between the mold and the machine platens to prevent heat transfer between the cold mold and the machine.
»»
Increase the demolding temperature until the maximum for good product is reached––with good parison control there will be limited differential shrinkage and de-molding is possible at higher temperatures.
»»
It is possible to demold quickly from the main mold and use post-cooling with water-cooled contour clamps in critical areas.
Cooling Parasitic heat gain in EBMMs is often significant. Cooling water hoses are rarely insulated and will suffer from parasitic heat gain, but the major cold surface area is the mold itself. Molds are rarely insulated, even though they are mainly flat surfaces and can be fitted with simple, flat insulation on the outer faces to dramatically decrease the amount of parasitic heat gain to the cooling water system. The mold will not only gain heat from the atmosphere but also from the main machine if it is not insulated from the rear platen.
Dr. Robin Kent - ©Tangram Technology Ltd. (www.tangram.co.uk)
www.plasticsengineering.org | www.4spe.org | JUNE 2019 | PLASTICS ENGINEERING |
43
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PATENTS
Our Regular Roundup of Notable Patents By Roger Corneliussen
Water Purfication U.S. Patent 10,231,458 (March 19, 2019), “Nanocomposite and a Method of Making the Same,” Mohamed Abdel Salam; Mohamed Abdel, Abdullah Yousef Obaid, Reda Mohamed El-Shishtawy, and Saleh Ahmed Mohamed (King Abdulaziz University, Jeddah, Saudi Arabia) Pathogenic bacteria, the main cause for life-threatening human diseases, have become more resistant to antibiotics. Research is focused on finding effective alternatives for antibiotics, and recent studies have revealed that nanomaterials can be effective antimicrobial agents. Mohamed et al. developed a nanocomposite that includes a silver nanoparticle core surrounded by a polypyrrole shell with carbon nanotubes. The polypyrrole covers at least a portion of the carbon nanotubes and a portion of the core. The high affinity of silver nanoparticles towards sulfur-containing amino acids and the phosphor atoms in the bacterial DNA causes death or inactivation of the bacteria.
Extruded Composites U.S. Patent 10,232,540 (March 19, 2019), “Extrudable Oriented Polymer Composites,” Richard Guillemette, Robert Peters, and Christopher Hummel (Guill Tool & Engineering Co. Inc., West Warwick, R.I.) Nanostructured materials have internal structures on the order of 1 to 100 nanometers. Metals, ceramics, polymers, and composites may be processed in a variety of ways to form nanosized features with many improved properties. Co-extruded multilayer polymers may contain tens to thousands of micro- to nano-polymer layers. These methods are based internal dies splitting and reforming melt streams. Guillemette, Peters, and Hummel developed novel tubular or profile shapes of coextruded multilayer polymers. These materials contain tens to thousands of layers of milli-, micro- to nanopolymer layers. These new shapes contain contiguous layers of milli- to nano-polymer layers in three dimensions and these contiguous layers may be twisted or turned
to further expand the potential microlayer geometries. Examples include beams, fiber composites, wood plastic composites, clay composites, and nanocellulose composites.
Surface Porosity U.S. Patent 10,226,883 (March 12, 2019), “Mold and Process for Producing Porous Devices.” Wei-Hsiang Chang, Stephen Lee Laffoon, and Christopher S. D. Lee (Vertera, Inc., Atlanta) Polymers have been shown to have many advantages such as water resistance, low toxicity, and chemical and heat resistance, as well as shape-memory properties. Adding pores to one or more surfaces of a polymeric implant may increase friction and promote adjacent tissue growth. Chang, Laffoon, and Lee produced a porous surface from a solid piece of polymer using track, mold, and press assemblies. The polymer is processed below the melting point of the polymer to produce a solid with an integrated porous surface without damaging mechanical properties.
Virus Adsorbents U.S. Patent 10,226,752 (March 12, 2019), “Adsorbent for Adsorbing Virus and Bacterium, Carbon/Polymer Composite and Adsorbent Sheet.” Hironori Iida, Shun Yamanoi, Machiko Minatoya, Seiichiro Tabata, and Shinichiro Yamada (Sony Corp., Tokyo) Activated carbon made from traditional coconut husks and petroleum pitches are used as filters with some ability to adsorb a virus. An adsorbent for a virus or a bacterium must have a specific surface area of 10 m 2/g or more and a pore volume of 0.1 cm 3/g or more. Iida et al. developed an adsorbent from carbon/polymer composites with improved virus adsorption from plantbased material such as rice chaff and straw, barley, wheat, rye, Japanese or foxtail millet, coffee beans, or tea leaves. These candidate materials after processing are
46 | PLASTICS ENGINEERING | JUNE 2019 | www.4spe.org | www.plasticsengineering.org
available in large amounts from agricultural cooperatives, alcoholic beverage makers, food companies, or food processing companies.
Anti-Cancer Agents U.S. Patent 10,231,996 (March 19, 2019), “Biocompatible Polymer Coated Silver Prussian Blue Nanoparticles (SPBNPs: Ag3[Fe(CN)6]) Sudip Mukherjee and Chitta Ranjan Patra (Council of Scientific & Industrial Research, New Delhi, India) Metal nanoparticles have been explored for the treatment of several diseases such as cancer, cardiovascularrelated diseases, diabetes, Parkinson’s, arthritis, HIV, hepatitis, tuberculosis, Alzheimer’s, and cirrhosis due to their unique properties. Recently, scientists have discovered new classes of nanoparticles. Metal complex nanoparticles such as Prussian blue nanoparticles have been tested for heavy metal toxicity, coating medium, drug delivery vehicles, MRI substance, luminescent materials, and sensors. Mukherjee and Patra developed highly biocompatible and nontoxic PVP (poly(n-vinyl-2pyrrolidone) coated silver Prussian blue nanoparticles (SPB-NPS: Ag3[Fe(CN)6] where PVP acts as stabilizing or capping agent. These particles are highly stable for more than two weeks towards different physiological buffers or solutions with different pH and are compatible with normal cells but inhibit different cancer cells in vitro and tumor growth in mice. Additionally, they show excellent antibacterial activity towards gram-negative E. coli and gram-positive bacteria.
Electrically Responsive Hydrogels U.S. Patent 10,232,144 (March 19, 2019), “Electrically Responsive Hydrogels,” Ross Tsukashima and Heath Bowman (MicroVention, Inc., Aliso Viejo, Calif.) Blocking blood vessels for the treatment of aneurysms as well as other conditions is a useful medical tool. One treatment involves the insertion of an expansile material, such as hydrogel, for occlusion. Tsukashima and Bowman developed implants based on electrically responsive hydrogels. Systems that provide electricity to induce a response in hydrogel-containing implants are described. They contract when exposed to a positive charge and expand to a negative charge. Thus, they expand when exposed to blood and shrink when exposed to a positive charge induced by a battery.
Removing Carbon Monoxide U.S. Patent 10,232,347 (March 19, 2019), “Hollow Mesoporous Carbon Banosphere Composite Material Loaded with Gold Nanoparticles, and Preparation Method thereof and Application in Continuous Processing of CO,” Jianmei Lu, Dongyun Chen, and Jun Jiang (Soochow University, Suzhou, China) The
rapid
development
of
technology
and
industrialization is increasing the emission of toxic gases such as CO, SO2 and NO2 which damages the environment and human health. CO is the most common and harmful toxic gas. CO emissions mainly come from car exhaust and inadequate coal combustion. It is colorless and tasteless, quickly combining with human hemoglobin, excluding oxygen, resulting in human hypoxia. Removal of CO from the atmosphere is critical for the health of humanity. Lu, Chen, and Jiang developed mesoporous carbon nanosphere composites loaded with gold nanoparticles for removing CO. In the presence of an initiator, aniline and pyrrole are polymerized in deionized water containing a surfactant to form hollow carbon precursors. This is, then, calcined to obtain hollow mesoporous carbon nanospheres. These hollow mesoporous carbon nanospheres are immersed in a chloroauric acid solution, stirred, and centrifuged to remove the liquid. Finally, hollow mesoporous carbon nanospheres, loaded with gold nanoparticles for CO removal, are formed by reduction.
Making Composites by Additive Processing U.S. Patent 10,232,550 (March 19, 2019), “Systems for Additively Manufacturing Composite Parts,” Nick S. Evans, Faraon Torres, Ryan G. Ziegler, Samuel F. Harrison, Ciro J. Grijalva, III, and Hayden S. Osborn (The Boeing Co., Chicago) Additive formation of composites relies on sequential layering of multiple composite plies with each ply containing fibers. This limitation prevents application to advanced composites. Evans et al. developed a system for additively manufacturing advanced composites consisting of a delivery assembly, a feed mechanism, and a source of curing energy. The delivery assembly is based on a delivery guide delivering continuous flexible lines along a print path. This delivery assembly further consists of a first inlet receiving a non-resin component and a second inlet receiving a photopolymer. The delivery assembly applies the photopolymer to the non-resin component. The feed mechanism pushes the continuous flexible line out of the delivery guide. The energy source delivers the curing energy to the continuous flexible line after it exits the delivery guide.
Vinylidene Chloride Sieves U.S. Patent 10,239,043 (March 26, 2019), “Vinylidene Chloride Copolymer-based Carbon Molecular Sieve Adsorbent Compositions and Processes therefor,” Junqiang Liu, Douglas E. Beyer, Edward M. Calverley, and Chan Han (Dow Global Technologies LLC, Midland, Mich.) Researchers often wish to separate gas mixtures for many reasons. One approach uses molecular sieves with some success. The key element is pore size which must match the size of the molecules involved. Liu et al. developed useful carbon molecular sieves based on carbonized vinylidene chloride copolymer with
www.plasticsengineering.org | www.4spe.org | JUNE 2019 | PLASTICS ENGINEERING |
47
PATENTS
micropores having an average micropore size 3.0 to 5.0 Angstroms. These materials can separate gas mixtures including propane/propylene; nitrogen/methane and ethane/ethylene. Such membranes are prepared from vinylidene chloride copolymer beads. A melt extruded film or fiber are pretreated to form a precursor that is finally carbonized at high temperature. Preselection based on precursor crystallinity and maximum pyrolysis temperature enables prediction of the average micropore size if the crystallinity percentage ranges from 25 to 75 percent and temperature ranges from 800º to 1,700º C. The beads, fibers, or film may be ground, postpyrolysis, and combined with a non-coating binder to form extruded pellets. Alternatively, the fibers may be woven, either before or after pre-treatment, to form a fiber sheet which is thereafter pyrolyzed to form a woven fiber adsorbent.
Stretch Molded Containers U.S. Patent 10,239,267 (March 26, 2019). “Process for Producing Injection Stretch Blow Molded Polyolefin Containers,” Mike Rogers and Anja Gottschalk (Basell Poliolefine Italia S.r.l., Milan) Stretch blow molding is an effective method to produce polyolefin containers. This is a two-step process of molding a preform and then stretching the preform. Uniform heating of the preform is critical and difficult to achieve. Rogers and Gottschalk developed injection stretch blow molding process for polyolefin containers by preparing a preform by injection molding. This preform is heated and stretched. They solved the uniform heating problem by incorporating a parts-permillion metal compound such as Cu hydroxy phosphate in the resin.
Injection Molding Thermosets U.S. Patent 10,239,246 (March 26, 2019), “Injection Molding Machine,” John E. Burton and Christopher J. Burton (Limworks, LLC, Ludington, Mich.) Most injection molding machines are based on molding thermoplastics. Even thermoset injection units are typically built based on a screw-based injection system designed for thermoplastic polymers. Burton and Burton developed an injection molding machine with a special injecting and clamping system for thermosets. This includes a removable injection module consisting of a moveable valve between fill and injecting positions to eject material from the injection module into the mold. The actuators for the injection module are supported on the machine rather than the injection module. The clamping system includes a platen linear actuator to open and close the mold. The system also uses hydraulic forces to clamp the mold closed.
ABOUT THE AUTHOR Dr. Corneliussen is professor emeritus of materials engineering of Drexel University in Philadelphia. He has been an SPE member since 1962 and an active member of the Philadelphia Section serving as president and national councilman for several years. The above patents are selected from the 100 to 400 plastics-related patents found by reviewing 3,000 to 7,000 U.S. patents published each Tuesday. Readers can review the complete list of plastics-related patents by week at www.plasticspatents. com.
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EDITORIAL INDEX
3D Systems................................................................... 16
Honeywell International................................................ 39
American Chemistry Council........................................... 8
King Abdulaziz University............................................. 46 Kraton Corp.................................................................. 40
Baerlocher.............................................................. 24, 28 Basell Poliolefine Italia S.r.l........................................... 48
Limworks LLC............................................................... 48
BASF....................................................................... 17, 30 Becton Dickinson.......................................................... 14
MBNA Corp................................................................... 39
Biolase.......................................................................... 15
Messe DĂźsseldorf......................................................... 36
Boeing Co. (The)........................................................... 47
Camille and Henry Dreyfus Foundation......................... 41
MicroVention Inc........................................................... 47
NxTBio Technologies.................................................... 42
Carbon......................................................................... 14 Clariant......................................................................... 17 Contemporary Amperex Technology Co. Ltd................. 20 Council of Scientific & Industrial Research..................... 47 Covestro................................................................. 18, 40
Delta Pacific Products................................................... 42 Dentca.......................................................................... 17 Dow Global Technologies LLC....................................... 47 Dreve............................................................................ 17 Dupont......................................................................... 17
Empire Petroleum Partners LLC..................................... 40 ExxonMobil................................................................... 38
PlasticsEurope Deutschland.......................................... 37 Prism Plastics Products................................................. 42
SABIC...................................................................... 17, 45 SC Johnson................................................................... 42 Society of Chemical Manufacturers and Affiliates.......... 43 Sony Corp..................................................................... 46 Soochow University....................................................... 47 SPX Corp....................................................................... 39
Techmer PM.................................................................. 10 Trinseo......................................................................... 39 Tupperware Brands Corp.......................................... 8, 39
Freescale Semiconductor Inc......................................... 39 Ultimaker North America............................................... 14 GE Capital..................................................................... 40 German Association of Plastics Converters.................... 38
Vertera Inc.................................................................... 46
German Engineering Federation.................................... 38 German Plastics and Rubber Machinery Association...... 38
Westfall Techik Inc........................................................ 42
Guill Tool & Engineering Co. Inc.................................... 46
Whip Mix...................................................................... 17
Plastics Engineering (ISSN 0091-9578) is published monthly, except bimonthly in July/August and November/December, by Wiley Subscription Services, Inc., a Wiley Company, 111 River Street, Hoboken, NJ 07030 USA. The magazine is compiled and edited by the Society of Plastics Engineers, Editorial and Business Office, 6 Berkshire Blvd., Suite 306, Bethel, CT 06801 USA. Telephone +1 203-775-0471, Fax +1 203-775-8490. SPE Home Page: www.4spe.org. Communications should be sent to the Editor. Send subscription orders and claims for non-receipt to Wiley Subscription Services at the Wiley address given above. SPE members receive the magazine as a benefit of membership. Subscription rate for nonmembers is $233 for 1 year; add $100 per year for subscriptions outside North America. Single-issue price is $20. Plastics Engineering is printed by Dartmouth Printing Co., a Sheridan Group Company. Copyright 2018 by the Society of Plastics Engineers, Inc. Postmaster: Send all address changes to Plastics Engineering, John Wiley & Sons Inc., C/O The Sheridan Press, PO Box 465, Hanover, PA 17331 USA. Reproduction in whole or in part without written permission is prohibited. Plastics Engineering is indexed by Engineering Information Inc. Neither Wiley Subscription Services, Inc., nor the Society of Plastics Engineers, nor Plastics Engineering is responsible for opinions or statements of facts expressed by contributors or advertisers, either in the articles published in Plastics Engineering or in the technical papers that are presented at the meetings of the Society. Editorials do not necessarily represent the official policy of Wiley Subscription Services, Inc., or the Society. Display and classified advertisements are included as an educational service to readers of Plastics Engineering. Advertising appearing in Plastics Engineering is not to be taken as an endorsement, expressed or implied, of the respective company’s processes, products, or services represented in the ad.
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Aaron Equipment Company, www.aaronequipment.com/sniff...............52 Allgrind Plastics, www.allgrind.com......................................................53
Advertising Sales For print and online digital advertising sales in Plastics Engineering magazine, please contact:
Bruker, www.bruker.com/optics.................................................... Cover 4 BYK, www.byk.com.................................................................................13
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Ewikon, www.ewikon.com......................................................................45
Dan Nicholas
ID Additives, www.iDadditives.com........................................................27
Tel: +1 716-587-2181
IMS Company, www.imscompany.com/G27................................... Cover 3
E: dnicholas@wiley.com
J.P. Curilla Associates, email: jpcecl@aol.com........................................52 Japan Steel Works, www.jswamerica.com...................................... Cover 2
Sr. Account Manager
John Anderson & Associates, www.plasticsjobsearch.com....................52
Print & E-Media Advertising
Konica Minolta, sensing.konicaminolta.us/products/colibri-color-software.....1
Roland Espinosa
LSR, www.executive-conference.com......................................................11
Tel: 1+ 201-748-6819
Plastic Flow, www.plasticflow.com.........................................................52
E: respinosa@wiley.com
Polyhedron Laboratories, Inc., www.polyhedronlab.com.......................52 Process Design & Technologies, www.processdesigntech.com.............52 Recycled Fillers.....................................................................................53
Product and news releases for Plastics Engineering can be sent directly to:
Rheo-Plast Associates, Inc., www.rheoplastusa.com..............................52
PEreleases@wiley.com
Roscom, Inc., www.roscom.net...............................................................53 Sam North America, www.sam-na.com..................................................52 Shepherd, www.shepherdcolor.com.........................................................5 SPE, www.4spe.org............................................................................. 4, 44 SPE ANTECÂŽ, www.4spe.org/antec.........................................................49 SPE ACCE, www.speautomotive.com/acce-conference.............................35 SPE CAD RETEC, www.specad.org..........................................................49
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SPE IAG, www.speautomotive.com/innovative-awards-gala.....................35 SPE Preferred Partner Program, www.4spe.org.....................................55 SPE Thermoforming, www.thermoformingdivision.com/conference.......55 Struktol, www.4struktol.com..................................................................33 Tangram Technology, www.tangram.co.uk............................................53
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