Polymer & Packaging International Magazine by Thesis Publishing (Pvt.) Ltd.

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CONTENT

04 / EDITORâ&#x20AC;&#x2122;S NOTE 05 / MARK YOUR CALENDAR 06 / NEWS

11 / INDUSTRY ANALYSIS 13 / TECHNOLOGY UPDATE

14 / INTERVIEW

- President, AIPMA - Chairman, PPMA - ASM, Daetwyler Graphics

17 / EVENT NEWS 20 / ARTICLE

- Beyond Collation Shrink - Role of Flexible Packaging Ink

25 / EXCLUSIVE REPORT 26 / COMPANY IN FOCUS

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EDITOR’S NOTE

Dear Readers, Welcome to the 13th edition of Polymer & Packaging International. Pakistan is an important domestic market of South East Asia growing at an impressive rate of 16% per annum. While the related sectors contribute largely to government revenues and provide employment to more than 600,000 skilled and non- skilled work force, regional developments like the removal of sanctions against Iran and opening of official banking channels are considered developments that may bode well for the growth of Pakistan’s industry. Furthermore, decline in crude oil prices are hitting record lows and are having a significant impact on resin prices which in turn are expected to impact the cost of production.

As a representative of Pakistan’s industry, Polymer & Packaging International has covered a lot of ground. We recently had the privilege of covering a leading exhibition in the Middle East which was attended by industry professionals from all over the globe. Not only were we flag bearers of Pakistan’s industry but were able to rouse the interest of international conglomerates to work with local entities and mutually avail its benefits. For our current issue, we are focusing on “Injection Blow Molding” and covering how companies use this process in developing innovative bottles and containers. On our part, the crux of Polymer & Packaging International magazine’s mission is to play a role in bringing Pakistan as close as possible to cutting edge technology and the standards practised in first world nations. In our strive towards this goal, we make it a point to travel to leading exhibitions worldwide and attempt to link technical and market excellence available internationally to bring Pakistan closer to more advance technology. In the three years that we have been in publication, we have managed to win acclaim from leading concerns as well as our contributors, subscribers and advertisers for which we are humbled. We assure them that we will continue to bring them the latest developments from the world over that will help our industry raise its bar of excellence. Happy Reading! 4 polymerandpackaging.com

Our Team Managing Editor S.H. Rizvi editor@thesis.com.pk Assistant Manager Marketing Paras Ali Nawab paras@thesis.com.pk Business Coordinator M. Eijaz uddin eijaz@thesis.com.pk Editorial Assistant Karishma Zahid karishma@thesis.com.pk Layout & Visualization Rehan A Hashmi rehan@thesis.com.pk Published by: Thesis Publishing (Pvt) Ltd. Address: Room No. 706, Business Plaza Mumtaz Hassan Road, Karachi-74000, Pakistan Phone: +92-21-3246-1722 Website: www.thesis.com.pk Agent in Malaysia: Al-Shams Global Sources Sdn Bhd, Suite 33, 33rd floor Menera Keck Seng, 203 Jalan Bukit Bintang, Kuala Lumpur 55100 Tel: 603 21163444, Fax: 603 21164445 Printed at: Quick Process, Plot No; 20, Sector 24, Korangi Industrial Area, Karachi.

MARK YOUR CALENDAR Omanplast 05-07, January 2016 Muscat, Oman

19th Annual PPPEXPO 2016 16 â&#x20AC;&#x201C; 18, June 2016 Nairobi, Kenya

GPCA PlastiCon 10-12, January 2016 Dubai, UAE

19th PPP Africa 2016 12-14, July 2016 Dar-Es-Salaam, Tanzania

Gulf Packaging & Polymers Show 01-03, February 2016 Abu Dhabi, UAE

Plasti&Pack 2016 18-20, August 2016 Lahore, Paksitan

Plastivision Arabia 2016 22 to 25, February 2016 Sharjah, UAE

Iftech Pakistan 18-20, August 2016 Lahore, Paksitan

PakPlas 2016 25-27, March 2016 Lahore, Pakistan

K 2016 19-26, October 2016 Dusseldorf, Germany

Chinaplas 25-28, April 2016 Shanghai, China

Plastics & Petrochem Arabia 2016 21-23, November 2016 Dammam, KSA polymerandpackaging.com 5

NEWS Low-cost HFFR jacket compound for fiber optic cable combines enhanced flame retardance with low post-extrusion shrinkage New Halguard® 58625 Compound from Teknor Apex Costs Less than Premium HFFR Products while Meeting Stringent Requirements for General-Purpose Applications

GCC petrochemicals should increase focus on supply chain efficiencies, advises Gulf Petrochemicals and Chemicals Association

ith the GCC tripling its production capacity between the 2004- 2015 period, petrochemical producers in the region must focus on supply chain efficiencies in order to retain export market share, said the Gulf Petrochemicals and Chemicals Association (GPCA), ahead of the Supply Chain Conference in May.

new halogen-free flame retardant (HFFR) compound for fiber optic cable provides excellent flame retardance while exhibiting significantly lower post-extrusion shrinkage than similar compounds with comparable flame properties, it was announced today by Teknor Apex Company, which will feature the new product at Wire 2016 along with a previously introduced low-shrinkage grade (Hall 09, Stand E06-1). Halguard® 58625 compound has a UL-94 flammability rating of V-0 and an oxygen index of 50%, while exhibiting post-extrusion linear shrinkage of only 2%. The new product is an addition to the Halguard family of compounds providing an economical alternative to premium grades because of their innovative flame retardant formulation. Low shrinkage is especially desirable in fiber optic applications because it reduces the degree of stress imposed on the sensitive optical fibers during post-extrusion temperature cycling and over time during end use. A low-shrinkage grade introduced in 2015, Halguard 58620, exhibits a Shore D hardness of 54 and shrinkage of 1.3%, with a UL-94 flammability rating of V-1 and oxygen index of 40.0%. Teknor Apex recommends Halguard 58625 compound for cable used in mass transit, data centers, cell towers, and other infrastructure applications. For outdoor uses, the new product exhibits good sunlight resistance when tested per UL1581. “Halguard 58625 compound costs less than comparable premium materials while exhibiting little compromise in performance properties,” said David Braun, wire and cable industry manager for the Vinyl Division. “It is the newest member of a series of HFFR compounds developed by Teknor Apex to meet a range of customer needs while providing lower-cost alternatives to other Halguard and competing HFFR products in general-purpose applications.”

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Regional chemical output in plastics, fertilizers and other products are chiefly destined for overseas markets. In 2015, 80 per cent, or 70.6 million tons, of petrochemicals were exported abroad. “In just over a decade, the GCC’s petrochemical industry has expanded its capacity from 38 million tons in 2004, to 142.1 million tons in 2015,” said Dr. Abdulwahab Al-Sadoun, Secretary General, GPCA.

“At 9.5 per cent per year, this production growth is second only to China, with more and more diversified products being produced in

the GCC. As capacity expansions continue, and an estimated 40 additional products are introduced from GCC petrochemical producers till 2020, the supply chain will have to adjust. We can already see the direct impact of product expansion on the supply chain, resulting in the emergence of businessto- business style logistics industry that includes road, shipping and port facilities, with further expansion plans in railways in the near future,” he continued. New and improved port infrastructure in the region includes Qatar’s New Port Project (NPP), Yanbu Port in Saudi Arabia and Jebel Ali Port and Khalifa Port in the UAE. Port expansions are expected to continue into 2016, as the new US$7billion mega-port near Qatar’s Mesaieed Industrial Zone is set to open this year, and port construction continues in Kuwait. However, there are some serious challenges the region has to overcome including current economic conditions, port congestion, complicated customs procedures, under invested infrastructure and stalled free trade agreement negotiations with the major economic blocks like the European Union.

“Improving logistics facilities are well within the remit of the region’s petrochemical companies: petrochemical producers should also up their investment in training and education of their workshop and partner with regional universities and colleges to bridge the current gap between academia and industry said Dr. Al-Sadoun. To support regional players in this endeavor, the GCC is set to host its 8th Supply Chain Conference in Dubai, United Arab Emirates. Members Mian Zahid Javed and Shahzad Ahmed were also present on the occasion.

The LCCI Senior Vice President said that Pakistan is a huge market and this is high time for the foreign investors to tape huge potential and take full advantage of the investment-friendly policies of the present regime. He said that the Lahore Chamber of Commerce & Industry is ready to extend maximum cooperation to the businessmen of Norway in this regard.

Norwegian businessmen invited to tap huge potential of Pakistan

akistan is well positioned to take off as economic indicators are portraying an encouraging picture. Growth rate is expected to reach 6 to 8 per cent in 2018 therefore businessmen of Norway should come forward and avail the opportunities through joint ventures with their Pakistani counterparts.

These views were expressed by the LCCI Senior Vice President Almas Hyder while talking to the Ambassador of Norway Tore Nedrebo here at the Lahore Chamber of Commerce & Industry. Executive Committee

Almas Hyder said that Norway and Pakistan are well known to each other and their mutual ties range from good diplomatic, cultural and economic relations but these are not being reflected in bilateral trade. The volume of total bilateral trade and imports of Pakistan from Norway are constantly dipping since 2012. He said that total mutual trade volume has come down to $ 69 million in 2014 from $ 78 million in 2012. He said that trade figures of last three years suggest that both countries must jointly make efforts to reverse the declining trend. The LCCI Senior Vice President said that direct interaction between the business communities of two countries can make it possible to cause quantum jump in trade figures.

central container can serve one machine or, if desired, be configured to refill multiple machines running the same color. Sealed connections throughout the system, from tote to delivery tubes to drums to metering tubes, keep liquid color completely sealed off from the workplace. Each drum is mounted on a Riverdale Gravimetric Stand (RGS), which monitors the weight of color in the drum and signals a pump valve on the tote when the drum is nearly empty and again when it is full. This prevents uncolored product.

New automatic drumrefill system for liquid colors boosts productivity and reduces output of ‘off-spec’ product RGInfinity™Auto-Refill System from Riverdale Global Refills Drums On-Line, Eliminating Downtime for Switching Drums as Well as Lapses in Color Metering

iverdale Global has developed a material handling system that automatically refills one or more liquid color drums during the molding or extrusion process, eliminating downtime for switching drums and reducing the occurrence of transitional or off-specification product with little or no color. Riverdale Global supplies liquid color in patented pump-equipped drums that remain sealed while color is metered to processing machines. The RGInfinity™ auto-refill system eliminates need to replace these drums when empty by refilling them from a large central container, or “tote.” One

When the central container needs to be replaced with a full one, the sealed connectors make possible a quick changeover. Riverdale Global can provide containers in various shapes and sizes. A typical example is a 200-gallon rotomolded plastic vessel within a steel supporting framework, but it is possible to use a standard-size drum for refilling the on-line drum, replacing the empty “refill” drum with a full one while color metering continues uninterrupted. “Besides preventing downtime, the RGInfinity™ auto-refill system eliminates the time and labor required for operators to monitor color levels, transport and prepare replacement drums, and wait until on-line drums are finally ready for replacement,” said Kevin Cabana, vice president of process technologies. “Also prevented is the human error that creeps in during these procedures, particularly when there are multiple drums metering color to multiple processing machines.” The RGInfinity™ auto-refill system is an extension of Riverdale Global’s Sealed Color™ technology, which eliminates the complications of handling liquid color, such as spillage, leakage, cleanup, pump maintenance, unused color, environmental concerns, and disposal costs. Central to the technology is the proprietary “Pump in a Drum” design, which enables the drum to remain sealed during delivery from Riverdale Global, metering into the process, and replenishment through return of the drum to Riverdale Global. thus assumes increasing importance in the production chain.

TA 1600 blow moulding machine: the solution for packaging is at hand

he world packaging market is progressing and shows great vitality. The packaging industry has been one of the sectors that has suffered less during the financial crisis and indeed has shown steady growth prospects. The role of companies that produce processing technologies for packaging

As evidence of this trend, ST has recently delivered a blow moulding machine, model TA 1600, with a 150mm diameter extruder and a 38 lt accumulator head. The HEX type extruder (High Efficiency Extrusion), with a capacity of 900 kg/h, ensures a high capacity and quality of plasticization. This type of machine, usually used to blow large parts, is intended for the production of open top 220 litres screw cap drum.

Thanks to the generous platen dimensions (1000 x 2500 mm), the system is highly versatile and is designed to be adapted to the customer’s future needs for the production of IBC containers. Besides the now widely acknowledged success of the ASPI series, the TA and ISIT ranges of conventional machines are widely available on the market, reflecting the company’s ability to diversify its offer based on buyers’ demands.

Clariant Presents Colors for 2017 in the Newest Edition of ColorForward® 11th edition of Clariant’s color forecasting guide for the plastics industry Trend analysis and color-design tool offers creative inspiration

lariant, a world leader in specialty chemicals, has released ColorForward®2017, the 11th annual color forecasting guide for the plastics industry. The 2017 guide visualizes trends like data mining, growing social disconnection and the search for more meaningful lives.

“ColorForward 2017 is very different from the 2016 edition we released a year ago,” explains Judith van Vliet, ColorWorks Designer at ColorWorks Europe, Merate, Italy. “We believe the becoming a bit more fearful, more introspective and reflecting the disconnectedness that many people seem to be feeling today. There are some exceptions of course, but in general the colors are more muted, softer, darker and even ambiguous.”

The trend name: ANNOY FIRM OMIT is an anagram of the phrase “my information” and it is intended to capture the ambiguous, yin/ yang nature of the information universe. Data mining or the systematic sifting of digital information to achieve a specific purpose is central to this trend theme. The duality of the web-world is captured in the annoy firm omit trend colors. Two of the five are dark and sinister. The trend DELONELINATION in a connected world, the last taboo is being lonely. “Delonelination is a wake-up call,” says Judith van Vliet. “It is a warning that loneliness is on the rise, particularly among young people. The five colors representing this trend are generally pale and muted, ranging from beige to suggest the human need to be handled with care, to a plain brown.

The theme NEBULOVE could almost be seen as the antithesis of loneliness because it recognizes a trend toward complex connected relationships between multiple people who may be married or not depending on what gives them fulfillment. Colors representing this theme are a light green/yellow like the inside of a cucumber, and a diffuse red. There is a lilac purple and a brownish orange, almost cognac-colored shade. A deep soft pink color called Perky Star is used to represent the “happy single.”

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NEWS its compatibility with machining processes and its high dimensional stability.”

Allegheny Performance Plastics, LLC, a leading processor of high-performance thermoplastics, machined the 18-in. (45-cm) oil scavenger line from a stock shape available from Texas-based Drake Plastics. The shape was extruded with Solvay’s KetaSpire® KT820 CF30 PEEK, a 30-percent carbon fiberreinforced grade that retains high modulus and best-in-class fatigue resistance at continuous-use temperatures reaching 240°C (464°F). This is comfortably above the peak oil temperatures in Polimotor 2’s dry sump design, which can reach 138°C (280°F).

POLIGAL purchase first BOBST AlOx Metallizer for European BOPP Market

POLIGAL a leading European BOPP producer has chosen BOBST as the partner for their new metallizer which will be installed at their site in Portugal. The new BOBST machine will help the company to achieve improved efficiency in the recent extension to their Portuguese operations where BOPP and CPP films are produced. High Demand for AlOx Coated Film

The BOBST K5000 2850 with AlOx capability will be the first to be supplied in Europe for the BOPP market due to the increasing demand for high barrier transparent film to satisfy consumers’ requirements for product visibility along with a longer shelf life. Poligal have chosen the K5000 because of its innovative process approach which enables switching rapidly from Standard Aluminium to AlOx metallizing at the touch of a button. POLIGAL Expansion

POLIGAL is one of the leading European manufacturers of BOPP film with a capacity of 50,000 tonnes a year of BOPP and 12.000 tonnes a year of CPP. With over 20 years’ experience and production plants In Spain and Portugal, the company provides flexible film solutions for consumer products and industrial applications. Capacity will increase this year to 100.000 tonnes a year with a new production plant in Skarbimierz (Poland).

The BOBST machine will help POLIGAL to achieve their ambitious expansion plans for the Group which also involves a new green field investment and a new BOPP film line in Poland. With this new equipment POLIGAL increases film metallization capacity above 10.000 tonnes a year. POLIGAL Joins BOBST AlOx Conversion Project

In addition to purchasing a new K5000 Metallizer, POLIGAL has also joined the BOBST integrated AlOx Conversion Project as part of a broad team of leading players in the industry.

The objective of the project for BOBST is to develop a full turnkey solution for the conversion of AlOx transparent barrier films. The project has brought together world leading names in both raw material solutions (coatings, inks and adhesives), film producers, converters and machinery platform providers (slitters, metallizers, coating machines, printing machine and laminators). 8 polymerandpackaging.com

Solvay’s HighPerforming KetaSpire® PEEK Polymer Chosen for Oil Scavenger Line in Polimotor 2 Automotive Project KetaSpire® PEEK’s high dimensional stability and compatibility with machining processes cited as critical to the material’s selection by Polimotor 2 designers.

olvay Specialty Polymers, a leading global supplier of high-performance polymers, announced today that the Polimotor 2 automotive engine project selected a high-performing grade of Solvay’s KetaSpire® polyetheretherketone (PEEK) to fabricate an oil scavenger line for the engine’s dry sump modular oil pump system.

“Solvay’s uniquely broad offering of today’s highest performing polymer technologies has helped fuel our continuing success with the Polimotor 2 engine concept,” said Holtzberg. “For example, the high mechanical strength and chemical resistance of Solvay’s Ryton® polyphenylene sulfide and Amodel® polyphthalamide polymer families offered excellent options for this part. But we selected KetaSpire® PEEK for

Specialchem and SPE partner to bring universal raw material selector to SPE membership

he Society of Plastics Engineers (SPE) and SpecialChem announced a partnership that will offer SPE members full access to SpecialChem’s Universal Selector database of plastics and additives. The partnership will greatly benefit SPE members according to Wim DeVos, CEO of SPE. “This new Materials Database resource we are offering with SpecialChem is an

“Polimotor 2’s design for its oil scavenger line required us to machine a much longer than usual thermoplastic part from a stock shape rod,” said Greg Shoup, president of Allegheny Performance Plastics. “We found that Solvay’s KetaSpire® PEEK machined very nicely in our CNC machining processes, and the finished part was within print tolerance, which allowed it to fit perfectly on the dry sump.”

As a class of materials Solvay’s semicrystalline KetaSpire® PEEK polymers also provide excellent high-temperature chemical resistance to fuels, ethylene glycol, automatic transmission fluids and other common engine chemicals.

“KetaSpire® PEEK is one of the highest performing polymers in our automotive portfolio,” said Brian Baleno, global automotive business manager for Solvay Specialty Polymers. “The Polimotor 2 project is one of the latest and most innovative showcases for this advanced polymer’s outstanding combination of hightemperature mechanical stability and strong chemical resistance. These qualities are also attracting interest in the commercial automotive industry, as well as in aerospace, chemical processing, medical, oil and gas, electrical, electronics, energy and other markets.”

exciting match for SPE, enriching the value we offer our members,” said Mr. DeVos. “Whether they are looking for materials with specific properties or searching for alternatives or even technical solutions, our engineers and purchasers will find this tool a very valuable asset.”

“This strategic partnership with SPE is completely aligned with our corporate mission to help engineers faster select the products they need by giving them access to all products in the world and the knowledge to select them,” said Christophe Cabarry, founder and CEO at SpecialChem. “Our Universal Selector proposes 10 dimensions of search including the ‘new’ property search. We constantly strive to standardize the heterogeneous ways suppliers publish product data and to add new products as soon as they are launched, which has proven to be valuable for both formulators and engineers.”

underwater pelletizing system, 7EAC from Gala Kunststoff GmbH.

ELIX Polymers announces new compounding line Dedicated for ABS and ABS blends

LIX Polymers has announced that it is to invest in a new compounding line at its Tarragona site. The company’s planned investment is part of its strategic objective to become a leading manufacturer of high quality pre-colored ABS resins and derivatives as well as tailor-made specialties used in Automotive, Healthcare, Consumer, Appliances and Electronics applications. The new line will incorporate state of the art technologies for thermoplastics compounding production, specifically for ABS and ABS blends, and will be developed in cooperation/partnership with the leading suppliers of these technologies. The line will include a twin screw compounder, ZSK 92 Mc18 from Coperion GmbH, and an

Tetra Pak creates a fully renewable gable top package for the US

etra Pak has successfully produced a regional version of Tetra Rex® Biobased for the US market. Known as the “Gable Top Bio-based ”, the package is made

APMT Inc. ACOMP System Installed in Polymer Production Plant and Achieves Milestone in System Availability

dvanced Polymer Monitoring Technologies, Inc.’s automatic continuous online monitoring of polymer reactions (ACOMP) product for industrial scale polymer production monitoring has been installed and operating in a polymer facility since fall 2014. Mike Drenski, APMT’s Chief Technical Officer said, “Our team has done an excellent job taking a laboratory technology and converting it into an automated industrial system. Our hard work paid off; our first deployment has achieved over 97% availability during the first 18 months after installation.” ACOMP technology was developed through R&D and lab use over 17 years with over

The line, which will come into operation by Q2 2016, will provide ELIX Polymers with greater flexibility to deliver a wider range of tailor-made solutions and will increase capacity on top of the current compounding line. The new investment is an important step forward in ELIX´s Excellence in Operations Program, and it will improve efficiency in operations and energy resources, whilst ensuring highest safety standards. ELIX´s Excellence in Operations Program is part of the company’s strategy, focusing on customers’ demands for increased flexibility in customized solutions and reduced lead times as part of ELIX´s service differentiation.

Over the last 2 years, ELIX Polymers has invested in a number of state-of-the-art assets at its facilities, to meet customers’ requirements and support expected growth. In parallel, ELIX Polymers has improved its operations by redefining procedures and processes in line with LEAN management principles. This has resulted in a more flexible plant and improvements of the scrap rate levels and reduced consumption of water and energy. entirely from plant based materials and has been configured to be used on existing gable top filling machines, without the need for any modification or additional investment. Like all Tetra Rex Bio-based packages, this version is manufactured solely from a combination of paperboard and plastics derived from plants, which can be traced back to their source. It offers customers a package that is good for the environment … and excellent for their brand. Launched in October 2014, Tetra Rex Biobased quickly gained popularity among customers and consumers. Last week, the company announced that it expects to deliver more than 100 million fully renewable packages to customers globally during 2016.

50 peer reviewed publications and a suite of patents from Prof. Reed’s group at Tulane University’s Center for Polymer Reaction Monitoring and Characterization (PolyRMC). This marks the first time the technology has been used for Industrial reactor monitoring and control. APMT is actively expanding ACOMP’s technology to new chemistries where the value of continuously monitoring polymer properties real-time during production can improve cost, improve polymer product quality and decrease the environmental footprint of polymer production. “Now that we have demonstrated reliable industrial scale operation, we are actively engaged with several manufacturers assessing new, high value applications for the technology,” said Alex Reed, APMT Chief Executive Officer. This work was supported in part by the Department of Energy’s Advanced Manufacturing Office. This work continues targeting the development of next generation ACOMP based control algorithms for chemical reactions.

Flexible PVC compounds for automotive waterdrainage tubing meet diverse requirements and are now available worldwide Already in Commercial Use for OEMs in the U.S., Apex® 1583 Series from Teknor Apex Can Be Supplied in Clear and Custom-Colored Formulations for Global Car Platforms

eknor Apex Company has optimized a series of flexible PVC compounds used successfully in the U.S. for automotive drain tubing and will now make them available to manufacturers worldwide, the company announced today. Drain tubing is used to divert water from areas around sunroofs and roof ditch moldings to discharge in the wheel wells of vehicles. Apex® 1583 Series compounds have been used in the U.S. for tubing on General Motors, Honda, and Nissan cars. Teknor Apex has expanded the series to include grades ranging in hardness from 60 Shore A to 50 Shore D, offering the compounds in custom colors as well as clear formulations, and supplying them from facilities in the U.S., China, and Europe. “The long experience of Teknor Apex in the transportation market enables us to help customers comply with OEM specifications for Apex 1583 compounds on a worldwide basis,” said Steve McCormack, auto industry manager for the Vinyl Division. “We have enhanced these proven compounds for improved processability and clarity, and we have developed molding grades to be used with the tubing as fittings.” Apex 1583 compounds exhibit minimal property change upon extended heat aging and stay flexible at temperatures down to -30 °C.

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NEWS

Total and Nissei ASB access new markets for polyolefins using onestage ISBM technology Leading global companies Total and Nissei ASB team up to market polyolefins using existing and performer one-stage ISBM technology

N Rim Polymers unveils new tote application

im Polymers Industries Pte Ltd announces today that they will be jointly developing a new solution for automatic IBC Polyurethane (PU) chemical transfer system for In-Plant PU foaming factories with their sister company, International Pump Manufacturing Inc (IPM) .

Targeted at in-plant Polyurethane foaming factories, the new IBC system is industry 4.0 enabled and will bring about major cost saving benefits in the long run. Some of the benefits include enabling factory operators to spend minimum effort in monitoring the IBC tank, chemical temperature control and also the reduction of foam product rejects. It will also reduces down time, and bring about an overall increase in the efficiency of the production.

The highlights of the system include a PLC controlled electrical panel which minimizes chemical spillage and also an auto lifting cylinder which minimizes the changeover time of the stirrer. The system also includes an alarm system which could be pre-set to alert the operator of the liquid level when it is low.

For this system, the IBC will be connected to IPM’s patented OP300S stubby transfer pump to achieve a continuous recirculation between the IBC tank and the PU machine‘s 3-way valves and back to the IBC tank. This will ensure that the required chemical temperature condition is achieved during winter or summer season in order to speed up the foam production cycle. “With industry 4.0 enabled systems, we hope to provide more winning technologies and services which can benefit our global customers in the long run,” says Mr Oei Han Tjing, Executive Vice President of Rim Polymers.

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issei ASB, the world’s leading manufacturer of one-stage stretch blow molding equipment, relies on Total’s expertise in polymer raw materials to break into new markets in the packaging industry by expertly processing polypropylene into a PET-designed ISBM machine. Bottles for sports drinks, pharmaceuticals, food and baby nourishment are the projected market targets for this winning combination of ISBM technology and polyolefins.

“ISBM technology is amazing,” explains Gabriela Quevedo Silvetti, Market Development Engineer for Rigid Packaging Applications at Total. “It enables not only multiple product size and shape manufacturing but also the smooth switch from one material to another, in this case from PET to PP, giving a lot of flexibility and opportunities for diverse applications. By collaborating with Nissei ASB, we can rapidly penetrate new markets for polyolefins using existing and performer ISBM machines. This is key to lowering investment costs for our customers”.

Exhibited late last year at both the Eurasia Packaging and Plast Eurasia Fairs in Istanbul, Turkey, the ISBM machine Nissei ASB-12M - an energy-efficient, versatile and low-noise one-stage machine - demonstrated the processing of Total Lumicene® Polypropylene, a resin specifically designed for the ISBM system. Karel KeersmaekersMichiels, Managing Director at Nissei ASB GmbH, stated, “The advantage of the ASB12M machine is its improved capability for wide mouth jars and higher cavitation for many common bottle sizes. It incorporates advanced technology that results in superior energy efficiency. Moreover, processing Total Lumicene Polypropylene resin requires only a few ISBM machine parameter adaptations. This provides us opportunities to broaden market applications where PET could normally be technically limiting”.

Flow control and versatility of coextrusion die system enhances pet packaging firm’s capabilities for multiple barrier structures Nordson EDI Die System Enables Evertis de México to Maintain Tight Tolerances and Avoid Instability Even When Running Complex or Asymmetrical Configurations

coextrusion die system from Nordson Corporation has enabled an extrusion processor specializing in PET-based semirigid packaging sheet to maintain layer uniformity well within tolerances while avoiding product defects arising from asymmetrical layer structures. Evertis de México S.A. de C.V., a manufacturer of thermoformable sheet for food packaging such as poultry, cheese, and processed meat, as well as non-food applications, recently installed a Nordson

EDI coextrusion die system for producing a range of structures. These include standard multi-layer, medium-barrier, and highbarrier sheet with thicknesses from 180 to 1,016 µ (0.180 to 1.016 mm). The barrier sheet structures are often asymmetrical, in that the materials or layer thicknesses above the central layer differ from those below it. The precision flow control of the Nordson EDI system has made it possible to maintain tight layer tolerances in such structures while preventing “wave,” “zig-zag” and other defects caused by instabilities at the interface between layers.

INDUSTRY ANALYSIS

Thin wall Packaging industry undergoes structural changes

New AMI Consulting report details trends in Thin Wall Packaging Markets in Europe

A report from industry consultants, AMI Consulting, pinpoints that in recent years Thin Wall Packaging has become a space

of dynamic structural changes in the rigid plastics market.

With the consumption of 3.1 million tonnes of polymer in 2015, Thin Wall Packaging is a large and relatively stable market in Europe. Nonetheless, the search for higher margins

and market positioning causes the industry to focus on improvements in material and process engineering. The past few years have been particularly productive for the industry and advances in process technology synergistic with polymer science have enabled changes which have facilitated the emergence of new applications.

Concomitant with these changes have been the changes in the supply chain. The industry actively consolidated and the leaders attempted to re-define and re-structure their businesses to maximise technical competence and to create a stronger negotiation platform. This has driven the disposal of non-strategic business units and targeted investment. There has been significant site rationalisation, exchange, production re-location and acquisition amongst the leaders.

Market growth and improving margins drives global BOPP film investment

A modest improvement in margins, along with continuing steady growth helped to lift investment confidence in the BOPP film industry last year - but not in China. After years when 60-70% of new capacity was being installed in China, the focus is now shifting to new markets and those with the highest growth potential. Over the next two years new manufacturing will be established in Europe, Africa, Asia and the Americas along with new lines for many of the industry’s more established players. This though will also drive the need for rationalisation of old capacity. The situation looks particularly risky for Europe’s less profitable players where the addition of new players in Poland and Russia is likely to drive the need for upwards of 100,000 tonnes of capacity to go if Europe is to return to the 80% utilisation rate achieved in 2010. This is the equivalent of 4 or 5 lines or potentially one or two producers.

potentially a further 37 new lines, adding another 1.5 million tonnes of capacity in the pipeline for the period 2016-2017 utilisation rates are expected to remain at around 7075%. Utilisation rates are also being impacted by the trend to downgauge to produce thinner films and by the development of more speciality films. The strength of the BOPP film industry stems from the high volumes used in primary packaging, particularly for food, which are not easy to cost effectively replace. Growth in packaged foods markets around the world will continue to be a key driver for

Multi €b converters have started emerging in the global multi-sector packaging arena, including Reynolds (Rank Group), Berry Plastics and Amcor. RPC Group following the acquisition of Promens and Global Closure Systems, and Coveris have reached these ranks as well.

In 2015, the top 10 converters of Thin Wall Packaging in EU28+3 accounted for 43% of the market. Outside of the leader base, the supply in Europe remains relatively fragmented and more consolidation is expected. Retailers remain ever stronger customers of Thin Wall Packaging, driving improved quality standards of value products. Brand owners employ a range of packaging solutions to capture discrete marketing opportunities, using multiple formats. This enables brand owners to monitor and compare costs, alter the packaging mix and spread risk. Over the next five years those suppliers with a focused business strategy are expected to continue to strengthen their market position.

This report is aimed at assisting industry participants and investors in anticipating change, formulating response strategies, directing R&D investment, and proactively managing the threats. It focuses on EU28+3 markets, across different applications. future demand underpinned by population growth, urbanisation and rising incomes in developing markets. A key focus for the industry will be how to manage the demands from converters and brand owners for a global supply of BOPP film. With many customers expanding their global footprints and increasingly offering standardised solutions, they need consistent, reliable product across multiple regions, and the ability to partner with BOPP producers to achieve this. This could be a motivator to drive consolidation in the market, and there are signs this is starting to happen. The 10 largest BOPP producers now account for 30% of global production. This compares with 25% in 2011 and 27% in 2013. This consolidation is not just affecting heritage companies in Europe and North America, but is also leading to the emergence of new market leaders in China and South America.

These are some of the findings from AMI’s latest report on the global BOPP film industry just published which reports that demand for BOPP film grew by 4% in 2015. With a focus on increasing production efficiencies, reducing waste and the development of value-added film, many companies enjoyed improved profitability in 2015. This led to another up lift in capacity announcements during the year, but this time led by new players and new markets. However, with

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TECHNOLOGY UPDATE

Advanced Sensor Technologies Chooses Solvay’s New Veradel® HC A-301 PESU to Replace PEI in Highly Durable Sensors for Demanding Healthcare Applications Solvay Specialty Polymers, a leading global supplier of high-performance thermoplastics, announced today that its new healthcare-grade polymer, Veradel® HC A-301 polyethersulfone (PESU), is helping to enable a new line of extremely durable sensor products for medical and biopharma applications from Advanced Sensor Technologies Inc. (ASTi), an industryleading designer of laboratory, medical and industrial electrochemical sensors. Available in a range of sizes, ASTi’s new liquid analytic sensor design seals sensitive electronics safely inside an internal plastic

sleeve that is fitted within an outer sleeve – also made of plastic – which houses the electrochemical sensor components. ASTi evaluated Veradel® HC A-301 PESU in molding trials to form inner sleeve components where it found Solvay’s material helped address moldability, cost and thermal cycling issues posed by an incumbent polyetherimide (PEI) grade. Specifically, ASTi found Solvay’s comparatively high flow PESU enables the design of family molds that produce very little waste, and allows molding of selective parts with flip gates. Veradel® HC A-301

PESU’s superior flowability also permitted the design of thinner walls, more complex shapes and different cross sections within finished parts. Its high transparency further facilitated final assembly of integrated parts. ASTi engineers favor bound and pressfitted parts vs. less reliable washers and O-rings to seal the sensors. Consequently, the comparatively similar thermal expansion rates between Veradel® HC A-301 PESU and the polymer specified for the outer sleeve of the sensor also helped minimize strain on these critical seals during thermal cycling. Solvay’s healthcare-grade PESU offers a continuous use temperature up to 204°C (399°F), which can potentially contribute to more durable sensors and components.

“Based on our molding tests, Solvay’s Veradel® HC PESU is now the polymer of choice for designs targeting medical and biopharma applications, as well as industrial and laboratory electrochemical products,” said Martin Patko, president and founder at ASTi. “Solvay’s high-flow polymer delivers more cost-effective processing options, improved mechanical performance and higher transparency than the PEI grade we had previously used. Further, its biocompatibility along with the availability of a complete Master Access File will help us transition future sensor designs to quickly address applications in the fast-growing healthcare market.”

Solvay Specialty Polymers introduced Veradel® HC A-301 polyethersulfone (PESU), a transparent, tough and highly processable amorphous polymer for advanced healthcare applications. Solvay’s material is available in ready supply to medical device designers worldwide, and offers welldocumented test and compliance records.

The latest addition to Solvay’s healthcare portfolio, the new Veradel® HC PESU grade has been tested under ISO 10993 biocompatibility standards for cytotoxicity, irritation and acute systemic toxicity. It is the first PESU polymer for use in medical devices to offer a Master Access File (MAF) on record with the U.S. Food and Drug Administration (FDA). Thus, its selection can help facilitate the regulatory application process for molded components, and speed time to market. polymerandpackaging.com 13

INTERVIEW

AIPMA: Representative of India’s plastics industry A Dialogue with Mr. Er. R. K. Aggarwal, President All India Plastics Manufacturers’ Association (AIPMA) Q. What are the recent developments that are influencing the Plastic industry?

The All India Plastics Manufacturers’ Association (AIPMA) was established in the year 1945. It is a non-profit organization. At present, it has five offices located at Ahmedabad, Delhi, Kolkata, Chennai and Mumbai. There are approximately 30,000 Plastics processing and manufacturing member companies that AIPMA represents. Polymer & Packaging International recently met up with Mr. Er. R. K. Aggarwal, President of AIPMA and Managing Director of Prayag Polytech Pvt. Ltd at the sidelines of Plastivision Arabia 2016. Here is what he had to say: Q. What role does AIPMA plays to promote India’s Plastic Industry both at local and international platforms?

A. AIPMA participates in different plastics exhibitions all over the world. We exchange booths from the global event organizers on barter terms. Our members promote AIPMA activities that it conducts throughout the year. We also conduct training practices and coach individuals so that they may find jobs in the industry. We are also establishing Plastic Parks where the companies of raw material processing, manufacturers, assemblers and finished good producers will participate from different parts of India. We are already in partnership with a number of companies which will encourage other industry players to join hands in this initiative.

14 polymerandpackaging.com

A. We all can see new and innovative products of plastics on daily basis. The developments in the plastics industry are continuously taking place. It is also a fact that plastics have almost replaced materials such as ceramics, metals and jute. On the other hand, packaging innovations cannot be disregarded as trends are changing in this realm as well. In addition to this, people are also becoming conscious about the waste that they produce and its impact on the environment. Moreover, flexible packaging is now preferred over conventional packaging. Consumers are now demanding smaller units of product packaged separately so that they can consume single units and it fits their budget. Furthermore, consumers are also demanding products with a longer shelf life. For example, the packaging of “Roti” has to be such that it remains fresh for longer and has a product expiry cut off of at least 30 days. In order to meet such demands, companies are now using high-quality multi-layer plastics which in turn are leading to higher consumption of plastics. Q. What are the major challenges faced by India’s plastic industry that is hampering its development?

A. If we see from the consumers’ perspective, one of the biggest challenges is for companies to develop products that do not pollute the environment. Today, consumers are more likely to purchase environment friendly products. Although plastics have more advantages rather than disadvantages, companies need to be more conscious about the waste they produce. The concept of circular economy in the recycling industry is practiced by very few companies. Circular economy means there should be no wastage in any way. Plastic products should be designed in such a manner that they ensure there is little or no waste produced. Q. Please share with us the major achievements of AIPMA that have benefited the industry and led to its growth?

A. The major achievement of AIPMA is organizing exhibitions and providing forums for industry professionals where particular technical issues can be discussed with subject area specialists. Such forums are ultimately beneficial for all individuals associated with the plastic

and packaging industry. In addition to this, we also work on policy matters with the government so as to ensure the health of industry and to maximize its growth. Q. Does AIPMA actively forge relationships with other international associations so as to provide benefits to its members?

A. Our relationship with international associations is limited to exhibitions only. Other than this, we do not as coordinate with them. However, if any international association visits India, not only do we welcome them but also set up meetings depending upon their requirement.

There is scope for Indian and Pakistani companies to work in tandem in a win-win situation Q. What strategies have you developed to ensure growth of the Industry?

A. We continually provide knowledge to our association members that we dissipate through our magazine and via mass emails. Our magazine carries articles that not only educate our members but also share latest research, technical developments and trends with them. In addition to this and a personal initiative, I also actively browse the internet and make it a point to share interesting material with our members so as to keep them abreast with latest industry developments worldwide. Q. How do you rate the Indian plastic industry as compared to other leading countries and is there any scope of Indian entities to work with Pakistan’s industry?

A. In India, there are no new patents and companies are doing business from scratch to finish. The only thing that we can do is to import technology from other countries. We do not conduct research in India in order to compete with the giants of industry. I also feel that there is scope for Indian and Pakistani companies to work in tandem in a win-win situation. However, due to some conflicts from the government side, we cannot collaborate with them.

PPMA: Unified Voice of Pakistan’s plastics industry An interview with Mr. Imran Ghani, Chairman Pakistan Plastics Manufacturing Association (PPMA)

Recommendation Letters to our members. In the best interest of the industry, PPMA also provides suggestions on the annual budget to the Federal Board of Revenue either directly or through FPCCI each year. Q. What are the recent developments that are influencing the Plastic industry?

Pakistan Plastic Manufacturers Association (PPMA) is the eminent business association of Pakistan. Established in 1980 as a not for profit organisation, it is the voice of Pakistan’s plastics industry and strives to serve as a spokesman of the community by dealing with the government and other bodies. Polymer & Packaging International recently had the privilege of meeting up Mr. Imran Ghani, Chairman of Pakistan Plastic Manufacturing Association (PPMA) who is also the Director of Dollar Industries. Here is what he had to say: Q. What role does PPMA play to promote the plastics industry of Pakistan at local and international platforms?

A. PPMA organises exhibitions and also supports exhibition organisers in arranging events on plastics and its allied machinery/products. Our members also exhibit in K fair Germany, ChinaPlas, Paper World Germany & Dubai. In order to promote the industry, we also participate in expos and trade fairs organised by Trade Development Authority of Pakistan & Federation of Pakistan Chamber of Commerce and Industry. PPMA also conducts seminars and awareness programmes on recycling, energy conservation and educates members on the latest happenings and product quality improvements in plastic industry around the world. In addition to this, we also publish Pakplas Magazine and directory annually that provides an opportunity for local and international companies to introduce their products by advertising in the magazine which also carries relevant articles about cutting edge technology and processes. Furthermore, PPMA also issues Plastic Raw Material Valuation Chart and Visa

A. There is a technological change in materials, processing machineries and oil prices. A Polypropylene grade is under development that will have properties of ABS. This will not only reduce the cost of material itself but also processing cost as it does not require preheating. In addition to this, electrical injection moulding machines of Chinese origin have been introduced over the last few years that are cheaper, have low maintenance costs and high efficiency. Other than this, oil prices internationally have declined to a large extent that has reduced the price of plastics materials. There is also a probability that plastics may further replace mediums like metals and wood. If this happens, then the consumption of plastics would further increase. Moreover, Iran would be free to compete in the global export market after uplifting of international sanctions. This in turn would increase economic growth of the overall industry. Due to the factors mentioned above, I foresee tremendous growth for the plastics industry overall.

Iran would be free to compete in the global export market after uplifting of international sanctions. This in turn would increase economic growth of the overall industry. Q. What are the major challenges faced by Pakistan’s plastic industry that are hampering development?

A. I believe that installation of Petrochemical plant will make the industry competitive globally. Our industry needs to diversify their business, start producing nontraditional items rather than just traditional ones and also improve the quality of their product range. They also need to install state-of-the art machinery. Secondly, knowledge based human resource plays a vital role in any growing industry. Although we have a few institutes that impart technical education, we need even more to train and educate

our workforce. Thirdly, public and private sectors including academic institutions should expand and improve their existing capacities to play a larger role. In addition to this, the capability and capacity of local mould manufacturing should be enhanced so that the cost of products would reduce further. Q. Please share with us the major achievements of PPMA that have benefited the industry and led to its growth?

A. PPMA has overseen over $500 million exports of plastic non-traditional items. We also participate in FTAs, PTAs, and SAFTA meetings and are able to protect the interests of Pakistan’s plastic industry. Q. What should our plastic industry do in order to avail maximum benefits from the China Pakistan Economic Corridor (CPEC) when it comes through? A. I think plastic industry should closely monitor developments and interact with government officials to seek opportunities such as installing plastics units alongside the CPEC corridor. This will increase the potential of plastics sector and ultimately contribute in the economic growth of Pakistan.

Q. How do you see the global plastics market in near future?

A. The market share of the industry is shifting from Europe to Asia. I think that the Asian market will be the focal point of interest in the near future. India and China are the two major countries in Asia and their growth pertaining to plastics is significant. Due to their combined potential, other countries will also be urged to do more in their respective domains. If Pakistan can install a petrochemical plant, it can also play a vital role in the global plastics market. Not only will this ensure availability of basic raw materials in the country but will also save time and valuable foreign exchange. Furthermore, it will also attract international investors that will allow our local plastics sector to prosper. Q. What would you propose to the local industry players to increase their stakes and profitability?

A. In order to improve product quality and performance, we must work towards increasing efficiencies, invest on cutting edge technology and Balancing, Moderation and Replacement (BMR). I think focusing on manufacturing valueadded items will also help the industry greatly in becoming a regional leader. polymerandpackaging.com 15

INTERVIEW

Heliograph is specialized in complete gravure cylinder making solutions for the Flexible Packaging industry. Its main focus is to provide economical, complete solutions for printing factories who want to integrate cylinder making. In 2014, it has completed a reference installation at Kompass Pvt. Ltd. in Karachi while other projects are in the pipeline. The team of Polymer & Packaging International Magazine recently had a one on one with Mr. Thomas Roth who looks after countries including Pakistan, the Eastern European region and Africa. Here is what he has to say: Q. What are the current goals of your company and how do you work towards achieving them?

A. Our goal is to not only provide machines or to sell products, but to provide a complete “carefree” solution. The Heliograph Holding team, which is based in different sites in Europe and the US, is working jointly to support customers from A to Z. This includes the manufacturing of machines, consumables, spares parts but we also offer a vast range of services. In our business, machines play a significant role but even more important is the process knowledge and support. We have a highly dedicated team of process specialists who help our customers with any queries that they may have. Q. What is your corporate profile in terms of products and services? Can you tell us about your new products or plans for growth?

A. As indicated above, our product portfolio includes: - Cylinder making machines (galvanic lines, CFM & polishing machines, engraving machines) - Installation & training support

- Project management (e.g. we advise customers on site how to prepare their building optimally) 16 polymerandpackaging.com

- Consumables (chemicals, polishing stones, engraving styli’s, etc.) - Spare parts

- Workflow support (chemical laboratory in Switzerland & process specialists) - Retrofit’s & upgrades for old machines - Troubleshooting worldwide)

(30+

engineers

Q. What is the work flow of carrying out business activities? How do you optimize work activities?

A. We have standardized internal workflows in order to be able to maintain a high quality standard. E.g. all spare parts which are on stock, are tested before we send them out to our clients. Moreover, we work closely with a small pool of suppliers with whom we have a longterm business relationship. Heliograph Holding offers only 1st class products to its customers. Moreover, we always pay heed to customer feedback which we use to improve ourselves further and to optimize our machinery and business approach.

Q. What are the technological trends or applications that you are implementing in your products? How does your equipment/machine help reduce waste output? A. We are working on several projects right now. The two main projects are:

- Automatic cylinder making line for max. 1400mm hollow cylinders. This line was mainly designed for customers in Asia, including Pakistan as local printing companies in the country mostly use hollow cylinders only. As these are usually lighter than shafted ones, we managed to design smaller sized machines which helped to lower the investment barrier for our customers. This is a very interesting product for customers, who struggle to

[

find highly skilled staff and thus want to maximise automation.

Q. How do you ensure cost effectiveness of your technology?

A. Based on our experience, one of the main cost factors in cylinder making are waste rates and inefficiently used consumables. Thanks to our comprehensive product range, which includes a great deal of chemistry, we are able to reduce the running costs of our customers to the maximum possible extent. Q. What much emphasis does your company lay on research & development? A. All seven companies of Heliograph Holding have their own R&D team who continuously works improving systems and tweaking technology. This starts with minor improvements on existing machines and goes to large-scale projects (e.g. new line concepts). Q. What is your opinion about Pakistan’s market for plastic and packaging and how do you rate its prospects in the near future?

A. The Pakistani Flexible market has been growing impressively in recent years. There are several hurdles and challenges ahead in near future. Since the competition in the local market is expected to grow, in my opinion there is bound to be a dearth in the availability of skilled labour like operators, mechanical engineers. Although Pakistan produces enough graduates but text books do not necessarily teach them how to operate a printing press. I trust that the country will need to start apprenticeship programs like we have done in Switzerland where the youth can learn how the operate printing and converting machinery so that they can serve the growing needs of the industry effectively.

Machines play a significant role but even more important is the process knowledge and support

]

EVENT NEWS

BASF drives effective design through highperformance materials at CHINAPLAS 2016 BASF co-hosts “Design x Innovation” event to showcase new designs inspired by high-performance materials 30th edition of CHINAPLAS celebrates evolution of plastics industry in China

t CHINAPLAS 2016, BASF will showcase a range of new innovations demonstrating the power of high-performance materials to enable high-performance design.

“Good product design has a role in addressing evolving customer needs, sustainability demands and regulatory requirements.

Nordson will install 16 of its energy-saving Crystallcut® pelletizing systems at a new megascale PET plant in China

ordson Corporation will supply sixteen of its process-patented BKG® brand CrystallCut® pelletizing systems for a megascale PET resin plant scheduled for startup this year by Jiangyin Chengold Packaging Materials Co., Ltd. in Jiangsu Province, China. The big project reflects the intensified focus on pelletizing systems for the Asian marketplace that will be evident in Nordson’s exhibit at Chinaplas 2016 (Stand W2-J01).

Nordson’s CrystallCut process provides substantial energy savings in comparison with standard PET polymerization systems by using the thermal energy of the molten polymer in PET pelletizing for subsequent crystallization. In the Jiangyin Chengold facility, the CrystallCut systems will deliver PET pellets to EcoSphere™ solid state

SABIC LEXAN™ resin brings light and color to award-winning auditorium and conference center

he “El Batel” state-of-the-art building in Cartagena, Spain, covers 17.000 m² and was designed by renowned Spanish architects José Selgas and Lucía Cano. Crowned with the prestigious Biennial Spanish Architecture award, El Batel’s design is influenced by the harbor and sea. In addition to its eye-catching architectural design, the building is known for the use of innovative materials, made locally in

Additionally, design plays an increasingly important role in the success of new products in the region, as it shapes the look, feel and perceived value. At CHINAPLAS 2016, we aim to bridge the gap between creative ideas, form and function to help our customers to bring great products to market,” said Mr. Andy Postlethwaite, Senior Vice President, Performance Materials Asia Pacific, BASF.

For the second year, BASF is co-hosting the “Design x Innovation” event at the International Exhibition on Plastics and Rubber Industries (CHINAPLAS 2016). The event will feature industry expert discussions at open forums and showcase new designs based on BASF’s high-performance materials for mobility, sports and leisure, as well as building and living segments. CHINAPLAS 2016 will be held on April 2528, 2016 at the Shanghai New International Expo Centre, Shanghai, China. The “Design x Innovation” event will be located at the Shanghai New International Expo Centre, Shanghai, China. The “Design x Innovation” event will be located at Hall N1, Booth B41. polycondensation (SSP) systems built by Polymetrix AG, Oberbüren, Switzerland, which contracted for the use of the CrystallCut units. Chemtex Group, Wilmington, NC, U.S.A. is the prime contractor for the entire bottle-grade PET resin plant.

The CrystallCut system integrates underwater pelletizing, drying, water filtration and direct crystallizing at temperatures of up to 180 °C and crystallinity up to 40%. In the new PET plant, the system will provide a pellet temperature adjusted to the process for crystallization and delivery to the SSP equipment, which will be supplied by Polymetrix. Nordson BKG will also supply sixteen condensation systems for the water recovered from the hot air in the process, These are expected to provide substantial additional savings through reduction in water filling.

“In the new mega-scale plant to be operated by Jiangyin Chengold, we anticipate that the energy savings provided by the CrystallCut process in comparison with conventional PET polymerization will be truly dramatic,” said Ralf Simon, Nordson BKG managing director. “As part of the streamlined system engineered by Polymetrix, our BKG equipment will help the new plant to achieve unprecedented levels of efficiency.” Cartagena. SABIC supported this awardwinning project through the development of a polycarbonate material with special luminescent pigments. The result is a special grade of LEXAN™ resin, a polycarbonate that enables light transmission and the creation of color effects inside and outside the building. Furthermore, LEXAN™ resin helps to absorb sunlight and to illuminate the corridors at night. A total of 110 tons of LEXAN™ resin was used to create a surface of more than 1.500m² in tubes and façade profiles. SABIC collaborated with Polimer Tecnic, the molder responsible for the design feasibility, to supply the material in specific colors and sizes on a strict deadline.

At MD&M West, Teknor Apex will present the industry’s broadest range of compounds for medical tubing New Products to Be Featured Will Include Apex® Flexible PVC Compounds with non-DEHP Plasticizers, a Medalist® TPE for Solvent Bonding, and a Rigid PVC for Connectors

eflecting its commitment to providing medical device manufacturers with multiple polymer alternatives, Teknor Apex Company has developed the industry’s broadest range of compounds for tubing, and featured these products at MD&M West 2016 (Booth 2438). Teknor Apex now offers a comprehensive portfolio of medical-grade tubing compounds, including Apex® flexible PVC, Flexalloy® PVC elastomers, and Medalist® thermoplastic elastomers (TPEs). In addition, the company has developed Apex SCR™ stress crack resistant rigid PVC compounds for tubing connectors. “Because its portfolio of medical tubing products is so diversified, Teknor Apex can take a ‘polymerneutral’ approach to the support it offers customers, helping them to select exactly the right compound to meet a particular performance or regulatory requirement,” said William J. Murray, president of Teknor Apex. “And regardless of which compounds they select, our customers benefit from the decades of medical-market experience that we draw on to assist them in solving problems or addressing new opportunities.”

The Medalist product line for tubing includes 13 standard and specialty compounds, ranging from 37 to 83 Shore A and covering a broad spectrum of physical properties. Medalist elastomers are ISO 10993-5 compliant and plasticizer-free, with a low level of extractables. They can be sterilized by e-beam, gamma, ethylene oxide (EtO) and steam (autoclave). These grades are good candidates for single and multi-lumen tubing for catheters, IV, drug delivery, gas supply, and chest drainage. Medalist tubing compounds meet such functional requirements as kink resistance, clamp resilience, and resistance to “necking” when subjected to longitudinal force, according to Ross Van Royen, senior market manager of regulated products for the Thermoplastic Elastomer Division. polymerandpackaging.com 17

EVENT NEWS

BOBST & industry partners highlight latest technologies for flexible packaging at roadshow in Cairo, Egypt

OBST and industry partners Apex International, Atlas Converting, COIM, DEC Impianti, Kodak, Reifenhäuser and Rossini, convened in Cairo, Egypt, to meet representatives of the Egyptian flexible packaging and label converting industries who attended the roadshow on 26 January 2016 at the Fairmont Heliopolis & Towers hotel.

Co-hosted by the BOBST agent in Egypt, Sidhom Co., the event gathered around 100 participants, who braved a day of inclement weather to be present, as did representatives of local financial institutions. The event provided the opportunity for delegates to hear from world-leading equipment and consumables manufacturers about the advantages and opportunities provided by the latest technologies and processes for the production of flexible packaging and labels, as well as enjoying the networking sessions that the day also offered.

The equipment presentations spotlighted the performance and technologies of printing and converting equipment throughout the production chain, for both flexible packaging and labels, from film extrusion to slittingrewinding, by way of vacuum metallizing, flexo and gravure printing, lamination, extrusion coating and coating. These were complemented by the latest updates on new generation high performance adhesives and on food contact legislation, flexo plate technology, printing sleeves and rollers, the future of flexo with fixed palettes, and solvent recovery systems for flexible packaging.

Sherif Sidhom, CEO of Sidhom Co., co-hosts of the roadshow, said “For many years we have been the BOBST agent in Egypt for their range of web-fed equipment and we have a solidly established position in the printing and converting market for wide-web equipment. Further to their acquisition last year of the Italian company Nuova Gidue, which is now Bobst Firenze, BOBST has extended its solutions in the different segments of the label industry to now encompass narrowweb printing and converting equipment. The roadshow has provided us with a tremendous opportunity to touch base with narrow-web and label converters, along with existing BOBST customers, which is invaluable for the development of our business in this sector of the industry.” 18 polymerandpackaging.com

Egeplast International and National Grid Gas to present at AMI’S Plastic Pipes in Infrastructure 2016 Conference

he 4th edition of AMI’s Plastic Pipes in Infrastructure Conference will take place at the Hilton Kensington in London, United Kingdom from 19-21 April 2016.

Plastic pipe systems (made of PVC, polyethylene, polypropylene, polyamide and GRP) are already widely used in many applications, such as drinking water supply & distribution, gas transmission & distribution, underground drainage & sewerage, road & railway drainage, land drainage, underground cable protection and district heating, having made good progress in substituting ‘traditional’ materials – metal pipes, clay, concrete, etc. Plastic systems are easier to transport and install, environmentally

friendly and provide improved reliability by eliminating the risk of corrosion. Despite these important benefits, however, ‘traditional’ systems continue to be used in certain market segments – for instance in large diameter pipes. To generate profitable growth, the plastic pipes industry needs to continue to innovate, constantly improving its value proposition. Innovation is indeed taking place at all levels and AMI’s Plastic Pipes in Infrastructure 2016 conference will provide an invaluable opportunity to highlight such innovation and discuss current and future challenges faced by the industry.

The two-day programme will commence with market and end user overviews from AMI’s Vice President, Noru Tsalic and AFFINITY WATER’s Joseph Sanders, Leakage and Network Strategy Manager. The rest of day one will comprise sessions on Testing and Qualification and New Approaches in Joining and Installation.

Day two’s session on Developments in Materials and Design will see NATIONAL GRID GAS partner with EGEPLAST INTERNATIONAL to present their construction and operational experience in high pressure reinforced PE pipes. The speakers list also includes pipes and fittings manufacturers such as Friatec (Aliaxis Group), Fox Fittings, Polyplastic, Amiantit, Flowline, and Advanced Drainage Systems.

Arburg at the Medtec Europe 2016: Electric machine for medical technology • Complex production: Y-shaped connectors for use in intravenous drip therapy • Electric injection moulding machine: Allrounder 470 A in clean room version • Arburg: Broad range of medical technology products

rburg will present a complex medical technology application at the Medtec Europe 2016 in Stuttgart from 12 to 14 April 2016. On Stand 7B03 in Hall 7, a clean room version of an electric Allrounder 470 A will be used to produce Y-connectors made from PMMA for use in intravenous drip therapy. One of the highlights will be lateral injection by means of a needle-type shut-off nozzle to produce a high surface quality on the part.

“Based on the example of the production of Y-connectors for use in intravenous drip therapy, we will be demonstrating a production-efficient clean room concept,” explains Sven Kitzlinger, Application Engineering Medical Technology at Arburg. “The electric machine and the complex mould are perfectly matched to one another. The production cell can be docked with a clean room with ease. This saves space and costs in comparison with clean room production.” Arburg, for example, can supply a stainless steel version of the Allrounder that meets the highest hygiene requirements in accordance with ISO 13485, as well as the specifications of the FDA and the GMP directives. Moreover, Arburg has a number of clean room concepts and extensive expertise in the areas of automation and LSR processing, as well as collaborating with expert cooperation partners.

this plastics-industry milestone at Chinaplas 2016 (Booth E7K21)

On exhibit at the Maguire booth will a unique copper-plated version of the company’s widely used MicroBlender™, the smallest model in the Maguire blender range. In following months, this celebratory blender will be on display at local events around the world as the company’s agents and their customers mark the milestone sale.

At CHINAPLAS, Maguire will open a ‘World Tour’ to mark the shipment of its 50,000th Gravimetric Blender Maguire Plans a Year of Special Events to Celebrate the Sales Milestone of an Auxiliary Equipment Innovation that Revolutionized Plastics Material Handling

aguire Products, Inc. is on course to ship the 50,000th Maguire® gravimetric blender in coming months and will inaugurate a year-long celebration of

Jinming at Chinaplas 2016: “Internet+” technology of film machinery

Jinming(booth no.: W5-B21), Asia’s leading film machinery maker will present a Superex 5-layer blown film machine through the up-to-date Internet technology at Chinaplas(April 25-28, 2016). To be specific, this machine line will run in Jinming factory based in Shantou, while with the help of remote control technology, technicians can simultaneously control and manage the processing of machine in the exhibition hall. It will definitely ensure the audiences to closely experience the “Internet+” technology which is recently applied in film machinery.

The Superex blown film line is high intelligent with great production performance, launched by Jinming in 2014. The whole line is featured with high production capacity and high automation. It is also superior in film uniformity control and has strong adaptability to resins. Integrated with intelligent manufacturing and the software

“The Maguire blender is the world’s most widely used gravimetric blender, employed in every type of molding, extrusion, and compounding process and in markets ranging from automotive to wire and cable,” said Hubert Nerlich, managing director of Maguire Products Asia Pte Ltd. “When Maguire president and chief designer Steve Maguire developed the first gravimetric batch blender in 1989, he revolutionized the way raw materials are metered into the plastics processing machine.” A gravimetric batch blender sequentially dispenses each batch ingredient in its target proportion into a weigh chamber; then, by monitoring each gain in weight of a batch, the blender control makes adjustments to subsequent batches to maintain accuracy and control raw material consumption. The Maguire system holds batch accuracy to within +/- 0.1%, according to Frank Kavanagh, vice president of sales for Maguire Products, Inc.

and hardware function of “Internet+” technology, the exhibited machine enables customer with automated operation, remote film diagnosis and multi-device networking. In the production process, the Superex can also realize remote activity allocation and order dispatching management, reducing labor and production cost. With the application of Internet technology, traditional manufacturing industry has been developing rapidly in the latest 5 years. The information-based system and big data are gradually transforming from electronicconsuming industry to mechanical one. Moreover, it is widely believed that the entire film production management and processes will embrace an unprecedented innovation and power by the successful application of “Internet+” technology in film machinery. In addition, Mr. Li Ziping, the general engineer of Jinming intelligent equipment research, mentioned: “The intelligent technology not only have been successfully applied on the Superex blown film machines, but also gradually be used in cast film machines and biaxially oriented film machines.”

According to customers’ demands, the Superex can intelligently retrieve information about the running situation, status parameters and operating data. The machine starts production directly, which effectively reduces the commissioning time and the consumption of raw material before running, meanwhile, it maintains the processing precision as well. When it comes to business management, the Superex helps the enterprises to build up their “Smart Factory”.

Davis-Standard to Promote New Technology and Regional Capabilities at Chinaplas

Davis-Standard’s new technology and regional capabilities will be promoted at booth C01, Hall W1 during Chinaplas in Shanghai, April 25-28, 2016. Davis-Standard has seen strong demand throughout Asia for feedscrews, control systems, medical tubing technology, and its dsX™ product line for cast film, blown film and packaging applications. Davis-Standard’s regional presence has continued to grow since opening a subsidiary in Suzhou two years ago. This facility is Davis-Standard’s manufacturing base in China and houses an R&D laboratory for process development and trials. DavisStandard will also promote the expansion of its film technology and aftermarket services with the recent acquisition of Gloucester Engineering. “With strong demand in Asia and continued expansion at our Suzhou facility, we anticipate a very busy Chinaplas show,” said Sekaran Murugaiah, Davis-Standard Vice President of Business Development, Asia. “Customers appreciate our regional presence and the availability of the medical tubing laboratory in Suzhou to test new resins and processes. The addition of Gloucester is especially exciting for our film customers because we are able to offer the largest installed base of film technology and aftermarket services under one roof.”

The medical tubing sector is one of DavisStandard’s strongest markets in China. The lab in Suzhou has been instrumental in supporting customers in this segment. The lab features direct-drive 19mm and 24mm single screw extruders, each with a polymer melt pump, a sophisticated three-layer spiral flow tubing die, PLC line control with data acquisition, precision vacuum sizing tank for both rigid and flexible products, closed loop ID/OD control via an ultrasonic gauging system, a servo controlled combination puller/cutting system, and a transport conveyer with single-zone air eject. It also includes a single layer tubing line designed specifically for the production of FPVC tubing for IV & fluid delivery applications. Products ranging in size from 2mm OD to 10mm OD can be produced with an accuracy of +/- 50u at line speeds up to 100mpm. Davis-Standard’s facility in Pawcatuck, Connecticut, also has a fully equipped medical tubing laboratory. polymerandpackaging.com 19

ARTICLE

Thermoforming Technologies Responding Thin Wall Packaging Market Trends As a machine builder, it is very important to be in constant contact with our suppliers, converters, operators and distributors as all of them contribute an essential part in developing new market trends in the packaging industry.

In order to successfully gathering all market information, a team of six area managers of WM Thermoforming Machinery is working day-by-day with 30 agents who cover 56 different countries worldwide. We summarize the major overall trends of the year 2014-2015 for you. The market is looking for more personalized packaging solutions with unique shapes, sizes and colors in order to offer more diverse and personalized food packaging products. We notice also a continuous growing demand of recycled and composted materials. The food industry in particular is demanding more transparent containers with higher clarity that are showing even better the characteristics of the final product. • Raw materials: During the past years, the material applications have been changing with a notorious increased demand for polypropylene material.

• Machinery: Highly automated machines that run faster, more efficient and at a lower cost. • Distribution: The biggest players are becoming bigger through new acquisitions while the niche distributors 20 polymerandpackaging.com

have to adjust their strategy in order to maintain their competitiveness.

• Operations: Foodservice operators are looking for product differentiation by offering sustainable products and new menus in order to respond to the changing demographics and consumption habits.

WM has been able to respond customers’ requirements with its technology, by carrying through the following objectives: - Higher clarity of packaging: WM Inline extrusion and thermoforming assures better PP transparency thanks to solid forming for providing linear orientation. - More tamper evident solutions: WM contributed to several successful projects in collaboration with renowned mold makers in order to ensure customers satisfaction. - In line labeling and marking system: WM has delivered several machines provided of labeling and marking system integrated.

- Portion packaging instead of large containers and beverage downsizing: WM new stacking systems are able to stack, count and bag in that allows even very complex product shapes being processed fully automatic. - Flexible machinery to run small and medium productions due to the growing customized and downsized product

packaging: WM Robot stacker and quick mold changes ensure 45-production change time.

- Reducing resin cost by using fillers or expanded material especially in PP material that is replacing materials such as EPS, PS, OPS. PET on the other hand is gaining some the PP products due to the lower density. WM IN-LINE extruder and thermoforming line with IN-MOULD trimming technology a state-of-the-art solution for processing PP material and two colors with fillers in order to achieve close tolerance for food packaging products at a lower cost.

- Lower Energy Consumption: the regenerative feeding system, Latest technology of heating elements, Latest technology of heating elements, improvements to align to the European Direction EuP2005/32/EC (Eco design of Energy-using Products)

- Labor cost reduction: this is put in effect since the system is fully automated and can operate with only one machine supervisor. - Contributes to continuous processing for increased efficiency and consequently decreasing the CapEx cost $ versus labor cost (fully automated vertical production)

Contributed by WM Wrapping Machinery sa, Switzerland

BEYOND COLLATION SHRINK: The POD Concept Has Come of Age billon US$ worth market by 2020, according to the report) indicate them as a packaging technology that will impact on our lives. Pouches are lighter and consume less storage space volume; they offer a larger printing area, enhancing brand visibility, can be made as high barrier containers for perishable food or as convenience container for meals ready to eat. Accessories such as reclosable zips or pouring nozzles are even widening the application potential. Traditionally they are laminates consisting of a thick PE film bonded to a reverse-printed BOPET or POPA substrate. The good news on the stand-uppouch segment is the new trend to made the structure fully recyclable, by using different grades of polyethylene that the chemical industry is offering nowadays. An extrusion line designed since its inception to film thinner, stiffer and stronger products is just the icing on the cake, if you want to venture into this business. And the line is a five layer POD, obviously. In a fast paced race to regain the lost time due to a not yet subsided recession, the flexible packaging industry and film extrusion in particular, are setting the new global standards to cater for the sustainability and economic goals of a global population soon to account for 8 billions of mouths to feed. In this process, machinery makers such as Macchi are deeply involved, actually instrumental; to make available the production tools required to fulfil the requirements of output capacity, quality and overall economies necessary to accomplish the many tasks the industry is facing.

Todayâ&#x20AC;&#x2122;s flex-pack business is crossed with legal and environmental burdens -many times conflicting- that do not clearly set the actual meaning of thick and thin products, whilst new materials and technology advancements may suggest different approaches. The Plastic Bags Banning policies scattered around all the Countries and territories are a sufficient example of this contradicting situation.

On the other side lie the fully legitimate requirements of an industry that is producing a final product where about 80% of the cost is represented by the raw material, and where, in no way, the prices of plastic polymers are expected to decrease, as they are only marginally interested by oil quotation. This situation leads to two very well visible considerations. On one side the competitive landscape of producing company shows how, in Europe, the top ten Converters are

covering more than 43% of the market (AMI source). On the other side, this polarization calls for processing systems and machinery having high level of capacity, whist keeping an extremely high level of production flexibility.

Since a few years Macchi is trend-setting the POD concept of non barrier multilayer lines toward the now ubiquitous status that claims that five is the new three (addressing to layers number).This new standard, already well rooted in the collation shrink film business, is now mature to go further. The advantages of a system that is born to be thin-skin-capable opens to applications where the surface technology plays a role and cling or surface protection films come to mind, along with the intrinsic possibility of a targeted sharing of expensive additives in the different layers to optimize the effects and minimize the drawbacks. Commonly cited case is the use of antiblock and slip agents with their optical effects on the final product. Plastic films dominates in the food packaging arena, especially in Europe and Asia, where the almost absolute totality of flexible packaging is represented by glue or extrusion-laminated structures.

A recent analysis is predicting that standup pouches will attract wider usage because of their adaptability to a variety of applications. Mainly designed to carry liquid or paste-form products, they represent a true challenge to bottles and metal cans and for a number of factors their growth rate (over 33

So far the production possibilities projected into just a sample of next-to-be industrial hit.

But technology keeps charging ahead also in the barrier film business, where the new drive solutions and the design features now available are giving clear costs and time saving effects. For instance the new torque motor drives, jointly developed with Siemens are today available with the extrusion screw ejection from the backside, easying the cleaning routines on the shop floor. Additionally, new surface coating solutions are used on coex 7/9/11 ply systems to achieve extremely low micron unit layers, whilst keeping excellent layerto-layer variations, paramount to guarantee the product specifications without over gauging to compensate the defects .

As specialists in the manufacture of film extrusion lines, on the hardware side Macchi is keeping on with the refinement and development of new solutions to enhance the global machinery level.

2015 Company activities resulted in a further leap ahead over the past years, placing the line around the 60 million Euro threshold, and with a pipeline showing a complete line, to go on weekly-basis delivery, well extended in the first months of 2107. In the solid hands of the Family holding Macchi, currently staffed by 120 people, has new expansion plans already underway to further extend the manufacturing area of their second factory, dedicating to large size and special machines the suitable operative space they demand. Contributed by Macchi S.p.A., Italy

polymerandpackaging.com 21

ARTICLE

Lamination Suitability for Flexible Packaging Application remedial actions need to be taken during lamination process.

Abstract

Lamination is the process of bonding a plastic film to a printed sheet by means of heat and pressure for protection of the work or to improve the appearance of the work. The printed cover of books, record cover, jacket etc. laminated with a thin clear transparent acetate film which protect from moisture scratch, wear and tear and also provide a high gloss. Lamination protects paper from tears; spills, wrinkles, and any other substance that could alter the text or graphic were it to make contact with the original paper. It also intensifies colors and improves the overall appearance of printed document and signs. Different projects require a different weight of lamination film, depending on use and location of the item to be laminated, and finishes are available in matte, gloss, or satin.

Types of Laminations Different methods classified as below:

lamination

Data analysis

As there are many factors which are discussed during study of shelf life of biscuits. On the basis of these factors data is recorded and charts are created. These are shown below with their values. These charts will show how the shelf life of biscuits affected by these factors and changes in values will extend shelf life or retard it. For all this analysis data is plotted in charts and shown to realize values to check shelf life of biscuits. These factors are firstly discussed and then, charts are plotted to show them literally. 1.

are

Heat & Pressure Lamination- In this process heat & pressure are applied to join two substrates. One of the substrates has to be a good conductor of heat and the other could be a plastic film such as Polyethylene which has been corona treated A corona treating system is designed to increase the surface energy of plastic films, foils in order to allow improved wet ability and adhesion of inks, coatings and adhesives.

a) Adhesive Lamination - The process where a solution or emulsion of low molecular weight polymer adhesive material is coated on to the surface of one substrate, before joining the second substrate is typically called adhesive lamination. b) Hot melt lamination - The molten wax is roller coated on to the substrate and the other substrate is laminated under nip pressure and passed over a chill roll immediately. Wax impregnation is carried out by entirely dipping the substrate in molten wax tray. Wax coated or laminated or impregnated papers are widely used in biscuit and confectionery industry c) Extrusion Coating lamination - The material in the barrel is heated, molten and extruded through a flat die in the form of thin layer. This thin layer is coated on to the other substrate and passed immediately through the chilled roller and wound in a reel form. Research objectives. To study & determine lamination suitability and degree/amount of adhesive coating needed for lamination on different flexible packaging products. â&#x20AC;˘

To identify problems and their possible

22 polymerandpackaging.com

Suitability for product packed inside: Lamination process for different product is selected on the basis of characteristics of product packed inside. We find that solvent base lamination is suitable for all type of lamination like laminate for food products, metalize film lamination, chemicals, petroleum products etc. Solvent less lamination is less preferable for metalized film laminations. Solvent less lamination is suitable for all type of juice packaging and in some packaging where ethylene solution is not required in solvent. Solvent less lamination is suitable for ready to eat products and for light weight products. Extrusion lamination is used for all bulk products packaging which require more strength in lamination. In all type of laminated woven BOPP bags we will use extrusion lamination. Wet lamination is used where one of the laminating substrate is paper or any porous substrate. Suitable for all type of light weight product packaging. Adhesive GSM: By analyzing the data from above tables it is quite evident that GSM of adhesive used is more in solvent base lamination as compare to solvent less lamination. This is because some amount of solvent in adhesive evaporates in the environment. In extrusion lamination the amount of LDPE extruded in much higher but that LDPE is used as a film as well as adhesive in laminate.

Curing Time: From the above data collection, we find that curing time in solvent base lamination is more. Because in solvent base adhesive, there is less solid content as compare to solvent less adhesive. In extrusion lamination there is no requirement of curing because during lamination when laminate comes in contact with chilling

roll then molten LDPE transforms in solid form.

Green Bond: Green bond is that bond in laminate till the adhesive dried completely. It is more in solvent base lamination as compare to solvent less lamination because more curing time is require in solvent base lamination. There is no green bond in extrusion lamination because when molten LDPE come in contact with chilling roller, it becomes solid. Eco-Friendly: From the above data, we find that there is volatile content in solvent base lamination. The volatile content evaporates in environment during processing that is environment hazards. Such types of volatile contents not evaporate in solvent less lamination and extrusion lamination.

Problems during lamination and their remedial solution

1. Accurate and Reliable Web Tension Control: The tension of the substrateform unwind to rewind- should be precisely regulated to avoid formation of creases, wrinkles, curl etc. and obtain a good finished roll of laminated material. The winding pressure must also work uniformly over the whole web width as otherwise there will be risk of telescoping. 2. Regular and Uniform Adhesive Application In the solvent process, the speed differential, temp determines the adhesive quantity. and gap between the coating rolls. These variables should be monitored and controlled accurately as this will not only influences the overall properties of the final laminate but also affect the economies of the process. 3.

Nip Pressure and Temperature Control

Corona Treatment While some films may be treated to the proper level, other films may need additional treatment on the laminator to promote adhesion. Poly principally has to be treated above 38 dyne/cm. In case of additional treatment in the machine i.e. online

The adhesive coated web is combined to the corona treated secondary web at 500C to 700 C, by heating the nip roller. The nip pressure must be worked evenly over the web. If the pressure is too low the air will get entrapped. If pressure is too high it will lead to squeeze.

corona treatment on the backside must be avoided (sealing weakness).

5. Roll Stage the rolls are stored in hot room (480C) to accelerate curing which result in better bond strength and visual characteristics. To avoid the rolls taking a set during the curing process, they should be suspended horizontally and the store in a track. 6. Speckling this occurs when there are while spots in the laminate at various positions. This is due to incorrect gsm of adhesive used in the process of lamination 7. Delamination

This is the problem where the two webs which were laminated together are somehow not adhered properly. This problem arises whenever lamination machine is to be stopped for any defect or some other reason and this then has to be removed while slitting.

8. Blocking in the Laminate The problem of blocking in the laminate results if the adhesive application is such that some portion of adhesive is not entirely in

between the two webs due to which one web tends to stick over the other one which during storage over a period of time, with the pressure of rolled laminate tends to block the lamination. Lamination Wrinkles

Two different forms of wrinkles can occur: those which form in the lamination nip, and those which appear some time after lamination (also known as post-lamination wrinkles). Both of these wrinkles are closely associated with the polyester base film which supports the photopolymer layer but are caused by factors independent of the base film. 10. Adhesive Line

Foreign particles like dust, dirt and some unwanted matter may stick to the engraved cylinder which makes a continuous line in the laminate .this problem arises time to time hence it is important to clean the cylinder within specified time to eliminate the problem.

11. Curling the cause of curling during drying is two sidedness and therefore

non uniform dimensional changes when exposed to temp and humidity. Due to this shrinkage takes place in the coating side and curling occurred.

12. Tunneling Web tension of the two substrates should be proper otherwise this problem can come. Second reason may be the ratio of the adhesive can be different or some different grade of adhesives. 13. Blister and Speckling It may form during drying.

Conclusion

The entire analysis shows that suitability of lamination for different product depends on the property of product inside packed. As regard we are choosing lamination process we have to check product properties and process characteristics like adhesive used, curing time, solvent used etc. Also during lamination process we have to take proper care so that to avoid defects occurs during process. Contributed by Dr. NKS Raghav DGM-RND, Uflex Ltd (Chemical Div.) Noida

Role of Flexible Packaging Ink in Packed Food Safety

As a revolution, traditional grocery shops are getting closed and super markets are coming very fast with the introduction of big names like Big Bazar, Walmart, Easy Day... etc. Big and small cities are almost covered but still huge area is pending for coverage. As experienced, supermarket is a selfservice shop offering a wide variety of food and household products, organized into aisles. It typically comprises meat, fresh produce dairy, and baked goods aisles, along with shelf space reserved for canned and packaged goods. Food in packed condition exhibits several advantages like Physical protection, Barrier protection, efficient handling, information, marketing, portion control and security against open & traditional sale. Packaging plays a vital role in ensuring the final product is safe and secure for consumption. As a result, flexible packaging gets tremendous importance in terms of above mentioned advantages as well as food safety. When we talk about food safety in package, role of plastic films, packaging

ink and printing processes come into picture. Besides plastic films and printing process, inks used for printing must not contain dangerous substances that may migrate through the packaging into the food. Considerations on packaging safety should always be of utmost importance in terms of formulation and supply of printing inks for food packaging. Brand owners and consumers expect safe food packaging which should not contaminate the packed food at any circumstances.

Several issues of food safety have been occurred in the past which affected people and business both adversely like migration of mineral Oil in foods through cardboard packaging Jute Sacks, BADGE from metal coating, ITX in milk and other liquid food from UV printing in Europe, Benzophenone from printing inks...etc. As mentioned above, migration is one of the ways for food contamination from package side. Migration can take place by 4 ways i.e. Penetration (Migration from printed side through the substrate onto the unprinted side), Contact (Migration from printed side to unprinted side of another sheet in a roll), Evaporation (Migration due to evaporation of volatile materials by heating) and distillation migration (Migration through steam distillation). These migrants are those materials which move from printed side to the food side, due to their chemical nature and molecular size. In the month of Juneâ&#x20AC;&#x2122;15, one of big brands of Nestle, Maggi was banned in India

by FSSAI due to presence of unsafe and hazardous amounts of Lead and Mono Sodium Glutamate. FSSAI (Food Safety and standards authority of India) is responsible for protecting and promoting public health through regulation and supervision of food safety. It is an agency of Ministry of Health and Family Welfare, Govt. of India. Every pack of packed food will have FSSAI logo on the label.

An ink manufacturer should take care while formulating and manufacturing packaging inks so that these hazardous substances/ materials are absent. Raw materials of formulated ink should follow food safety guidelines. Ink raw materials should not be classifiable under globally harmonized system such as toxic, mutagenic, carcinogenic and reproductive toxicant category. These should not contain phthalate, tin catalysts and any banned materials. Besides, these should not contain those polymeric materials also whose molecular weight is less than 1000 Dalton as low MW material tends to migrate. Selection of raw materials for packaging ink should be based on known standards, guidelines and regulations such as REACH (EU), CEPA, TSCA (US), DSL (Canada)... etc, as applicable country wise. Written by: Anuj Johri (AGM â&#x20AC;&#x201C; Ink R&D) UFLEX LTD (Chemical Division), NOIDA, UTTAR PRADESH, INDIA

polymerandpackaging.com 23

ARTICLE

R – RECYCLED P – POLY E – ETHYLENE T - TEREPHTALATE Zainul Abedeen

Manager Product Development, Gatron Industries Ltd. Pakistan INTRODUCTION

PET (polyethylene terephthalate) is a major polymer with diverse applications. The semicrystalline nature of this polyester allows one to generate a wide variety of both physical and mechanical properties well suited for the fabrication of fibers, films, bottles and different molded parts. These parts are converted into finished products such as garments, home textiles, carpets, packages and industrial goods. Most of the physical and mechanical properties of PET improve as the molecular weight increases. A direct measure of molecular weight is the Intrinsic Viscosity (I.V). The I.V. required is dictated by the end use of the polyester. So the PET resins (especially food grade) undergo solid state polycondensation in order to lift up its I.V. PET – Poly Ethylene Terephtalate is a type of POLYESTER, a thermoplastic produced by Esterification followed by polycondensation reactions.

Esterification is a reaction between an Acid and an Alcohol resulting in an Ester plus Water.

Polyester is a chain molecule formed by many basic ester molecules through condensation reaction. Monomer (single) > Oligomer (some) > Polymer (many)

Before going into details of R-PET one must develop a better understanding about what is PET. Once we know the PET production processes, scale of investment, required resources, energy and raw materials then can realize the benefits for adopting R-PET technology. PET - Poly Ethylene Terephthalate raw materials are

Ethylene Glycol + Pure Terephthalic Acid (Esterification process) or

Ethylene Glycol + Di MethyleneTerephthalate (Trans estrification process)

CHEMICAL RECYCLING

It is cost effective in case of high capacities >> 50, 000 t / y. Such lines can only be seen with in the production sites of very large pet

24 polymerandpackaging.com

producers. Till 2008 not successful due to difficulty in consistent & continuous supply of waste bottles in such a large amount and increasing prices of collected / bailed bottles. Processes involved are: • Glycolysis: PET -----------> oligomers (addition of pet in eg or other glycols during thermal tratment) • Hydrolysis: PET -----------> PTA + MEG (by means of super critical water steam)

• Methanololysis: PET ----------> DMT (under pressure & catalyst)

MECHANICAL RECYCLING

These are typically small & medium - sized industries 5, 000 ~ 20, 000 t / y. Established PET recycling industry has 3 major sections: 1. PET bottle collection & waste separation --- waste logistics (pet content > 90%) 2. Production of clean flakes --- flake production.

3. Conversion of pet flakes to final products --- flake processing.

For example, film, bottles, fibre, filament, strapping or Intermediates like pellets for further processing.

Aside external bottles recycling there are internal recycling process: • fibre waste -------> fibre production. • preform waste production.

--------->

preform

• film waste -----------> film production.

MARKET FOR R-PET

R-PET products are mostly produced from recycling of pet bottles. Environmental laws forced America & European countries to start recycling. Thin population & high wages in these countries discourage the industries. From these countries and rest of the world bailed bottles are being imported in China. Bottle picking & collection is feasible in thickly populated countries like china and India, etc. In Pakistan studies being done, but feasibility yet not concluded. Market depends on collection rate (unofficial in china it is 90%).

PROCESSING EXAMPLES

Simple re-pelletizing of bottle flakes involves 1. conversion of bottles into flakes. 2. crystallizing & drying flakes. 3. plasticizing (extrusion). 4. filtering melt.

5. quenching melt & palletizing.

product is amorphous re-granulate of I.V. 0.55 ~ 0.7 dl/g depends on how much complete pre-drying of flakes has been done (as moisture degrades PET during processing). Special features that to be kept under consideration while PET recycling are: Acet aldehydes & oligomers to be contained at lower level for achieving better quality. Proper drying to be done to achieve moisture in dried flakes < 30 ppm to ensure there is no PET degradation and viscosity reduction to be minimized.

Pellets are amorphous needs to be crystallized & dried before processing to 1. Non - woven with required I.V. range 0.58 ~ 0.65. 2. Staple fibre with required I.V. range 0.58 ~ 0.62, addition of chain length modifier like EG / DEG is being done. 3. Filament yarn with required I.V. range 0.62 ~ 0.64, with blend of virgin PET 4. Carpet fibre

5. A-PET film for thermoforming 6. Package strapping 7. BoPET film

8. BGC- Bottle Grade Chips by SSP – Solid State Polycondensation with required I.V. range can be rebuild to 0.85 & acetaldehydes controlled < 1 ppm 9. Engineering plastics

10. Addition to PET virgin production

11. Also direct process where pellets are directly crystallized & subjected to SSP e.g., B-2-B process of Buhler. About 70% of R-PET consumption is in above mentioned applications from 1 to 4. The major challenge in R-PET production is how to prevent I.V. drop ? It can be minimized by use of twin screw or multi rotation system and by use of coincidental vacuum degassing system.

THERMAL & MECHANICAL PROPERTIES OF R-PET

DSC – Differential Scanning Calorimetric & Thermogravimetric analysis are used for determination of thermal properties of R-PET. While tensile test at ambient & elevated temperature are used for determination of mechanical properties. Most of physical & mechanical properties improves with molecular weight which can be increased by SSP and decreases due to degradation.

So by means of blending Virgin PET with R-PET optimized Thermal and Mechanical properties can be achieved depending on end use.

EXCLUSIVE REPORT

“Greenovation” for a Smart Future: CHINAPLAS to hold three concurrent events to embrace innovation, automation and sustainability CHINAPLAS will be celebrating its 30th edition in the coming exhibition. The organizer, Adsale Exhibition Services Ltd., has planned to put up a myriad of exciting activities to the show to share the joy of this commemorative event with the show participants. CHINAPLAS 2016 will be held on 25-28 April, 2016 at the Shanghai New International Expo Center (Pudong), PR China. The show is expected to welcome 3,200 exhibitors and 140,000 professional buyers, on over 240,000 square meters of exhibition area. Greenovation for a Smart Future - is the theme for CHINAPLAS 2016 and three concurrent events will be held to further elaborate around the theme, namely the 2nd Medical Plastics Conference, Industry 4.0 Conference, “Design x Innovation”.

Medical Plastics Conference

The global medical products industry has never been more dependent on plastics and rubber suppliers to help them meet today’s healthcare needs. Over 90 different kinds of medical products have used polymers as their major components, including: drugdelivery systems; sophisticated diagnostic imaging equipment; surgical tools; prostheses and life-maintaining implantable devices; pharmaceutical packaging; various disposables such as tubes, infusion bags, catheters, syringes, etc. Medical plastics are lucrative markets yet also the challenging one. Challenges are on all fronts such as constantly changing policies, raising the bar for material requirements and quickening of new product developments.

In response to the rapid development of this area, CHINAPLAS 2016 will organize “The 2nd Medical Plastics Conference” on 25-26 April, 2016 in attempts to give visitors insights on new technology breakthroughs and latest development on medical plastics and their applications on medical devices, medical disposables and packaging. Provisional topics include: automation technology for

production upgrade, production technology for cleanrooms; medical grade polymer applications for disposables; pharmaceutical packaging solutions; innovative applications of 3D-printing; sterile barrier systems for medical packaging. The conference will be in bigger scale as compared to the last edition.

Industry 4.0 Conference

The concept of Germany-led Industry 4.0 has been taken the world by storm since its introduction in 2014. It had laid down a roadmap of the fourth industrial revolution for realizing “Smart Factory” that the world has been pursuing of. As China’s economy matures, the Chinese government has launched “Made-in-China 2025” to promote industrial automation in its own right in a bid to help Chinese enterprises to stay competitive in the world.

4.0 and ultimately improve productivity, production efficiency, product quality and level of automation in the factory. Some of the topics are: Use of Industry 4.0 Concepts in one company – smart factory by Haier Inc.; Industry 4.0 from the perspective of an injection molding machines manufacturer by KraussMaffei; Individualized mass production by Arburg; Inject 4.0 – solutions for a smart factory by ENGEL, and many more.

“Design X Innovation”

Building on the success of “Design X Innovation” at CHINAPLAS 2015, this event will come around in Shanghai in 2016.

The event’s Exclusive Partner – BASF – the world’s leading chemical company, will join hands with CHINAPLAS to give new perspectives to visitors on how design and plastics technology can together drive innovation, that in turn helps to make customer more successful and leads to a more sustainable future. The event showcases samples of the latest designs on outlook, structure and function designs inspired by high performance materials for different industries.

Adsale’s General Manager, Ms. Ada Leung says, “At present, China has been undergoing the economic transition, from the stage of low-cost labor-intensive production to the research-intensive, high-end manufacturing one. Coupled with the threats of labor shortages, rising labor costs, and the intense competition in the surrounding regions, Chinese companies are urged to transform and upgrade.

“Design X Innovation” will engage and inspire audience in an array of offers including display gallery, open forum led by revered international experts, as well as interactive activities.

Being held on 26-27 April, 2016 in conjunction with CHINAPLAS 2016, the conference will invite leading firms and heavy-weighted speakers in this field to share their know-how and technologies on helping companies to realize Industry

“The format is good”, “Ideas are innovative”, “I can see something innovative”, “It’s inspiring” were the visitor comments for the concurrent events in 2015. We welcome you to experience the same at CHINAPLAS 2016!

In this light, Adsale has teamed up with VDMA -- German Engineering Federation -- currently the largest industry association in Europe, to organize Industry 4.0 Conference. She believes that this conference not only will give the audience a better understanding about Industry 4.0 in the context of plastics and rubber industries, but also its implementation and future developments, providing practical solutions for manufacturing sectors to follow.

Speaking about the reasons for choosing these three concurrent events for CHINAPLAS 2016, Ms. Ada Leung explains, “All these topics have been meticulously picked to reflect the macro trends of the current manufacturing sectors, where innovation, automation and sustainability are essential elements to bring the industry to the next level. It is also the extension of last year’s theme and topics to deepen audience understanding for these hot topics.”

polymerandpackaging.com 25

COMPANY IN FOCUS

Your Partner in Success FAV Plastico Pvt. Limited

FAV Plastico (Pvt) Ltd. has an expertise in the making up and rendering of masterbatches and pigments to the plastics and other industries. Such offerings are summed up by their valued end-users during the manufacturing process to impart color and performance properties to their end product. FAV Plastico having the best of its repute and credibility in textile industry prides itself in delivering superior products and service to all the customers. It has a vast range of colors and additives or it can also custom engineer a masterbatch to suit the requirements: 1 Quality control checks to ensure consistency from batch to batch 2 Supplies as well as customers counts us on service and operational excellence 3 FAV offers a convenient way of adding color and performance enhancing additives FAV Plastico promises a quality excellence in order to earn its vision of being one of the leading suppliers of masterbatches in Pakistan. As the leading manufacturer of color concentrates and additive smasterbatches, it offers exceptional products and services. The black, white, color and additive masterbatches meet the diverse appearance and functional demands placed on plastic products. FAV provides thousands of black and white masterbatches, including those having high pigment loadings, temperature resistance, UV resistance and electrical conductivity. The broad palette of color concentrates encompasses all organic and inorganic pigments and those for pearlescent, metallic and other special effects. These are supported by the color team formed of multiple disciplines working together to create colors and effects that support customerâ&#x20AC;&#x2122;s brand initiatives. The fully equipped laboratory at FAV enables the technical staff to rapidly prototype new formulations, conduct extensive in house testing and offer customers a first rate sampling service. FAVâ&#x20AC;&#x2122;s goal and strategy is to develop tailor made solutions and technically advanced masterbatches and compounds for the polymer industry. It offers a comprehensive sampling service with excellent laboratory and technical service back-up. The products are thoroughly tested independently for each customer application as part of their service and safe products are available. 26 polymerandpackaging.com

Company Name: FAV Plastico Pvt. Ltd Established in: 2011 Founded by: Farid Ahmed Vawda

Technical Services:

1) State of the Art laboratory. 2) Technical Information and Solution Plastics Industry 3) Fast and Easy Customer Problem Solving 4) Training System 5) Good Communication System

Areas of expertise:

1) Master batch manufacturing (Color & White) 2) Technical support is provided to the valued clients as per their requirements and demands 3) Testing Facility for polymer 4) After sales services is provided to resolve customer problems

Projects:

1) Filler masterbatch 2) Liquid masterbatch 3) Special effect masterbatch

Core Competencies:

The current capacity of FAV Plastico is 500M/T per month and it is involved in manufacturing White, color and Black masterbatch in polyolefin, PET and engineering polymers for Injection molding, Blow molding, Blown film, extrusion and thermoforming process.

Target for next 10 years:

FAVâ&#x20AC;&#x2122;s target for next 10 years is to meet 2000 M/T per month for national and International market so that it can plan to export Asia and Europe also.

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