Vol.3 No.2 | March-April 2015 | New Delhi, India
Amut Group Showcases Thermoforming Machine
At CHINAPLAS
CHINAPLAS brings in
new topics
to shade light on
BOY will enrich CHINAPLAS 2015
new manufacturing era
ARBURG at the
CHINAPLAS
from the start CHINAPLAS to hold over 50 sessions of technical seminar for buyers
Sacmi to showcase 4 technological winners at Fruit Logistica
SHOW REPORT interplastica and UPAKOVKA
Labelling Technology for Food and Non-Food Applications
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What make CHINAPLAS so irresistible?
CHINAPLAS 2015 (The 29th International Exhibition on Plastics and Rubber Industries) will be held on 20-23 May 2015 in China Import & Export Fair Complex, Pazhou, Guangzhou. Over the years CHINAPLAS grows with China and has now ascended to Asia’s largest plastics and rubber trade fair. This year, CHINAPLAS once again breaks its past records, with the exhibiting area reaching 240,000sqm and exhibitors exceeding 3,200. There are many reasons to make CHINAPLAS an unmissible event, visitors can gain insights of market’s present and future trends and witness the newest technologies of the year should be one of those. CHINAPLAS this year will spotlight several areas that the market is much-needed such as industrial automation, new manufacturing technologies and a board range of materials with special functionality.
Vol.3 No.2 | March-April 2015 | New Delhi, India
ANNUAL SUBSCRIPTION: INDIA: RS.2000 | OVERSEAS: US$150
I n T h e P a g e s
Plastics and Rubber Machinery
urrently, the automation level of manufacturing in many hinese firms is still low. utting edge automation technology that can provide more stable work force and proven production efficiency caught the attention of many Chinese enterprises, as well as companies around the world. In this light, CHINAPLAS has set up a new zone - Industrial Automation Zone, designed to showcase the latest robotics and automated solutions from global leading companies such as top robot makers, ABB and Wittmann Battenfeld, automation technology leaders Honeywell and Rockwell from the US, Siemens from Germany, Mitsubishi Electrics and Shini from Japan and Taiwan respectively. Plastics mold is also one of the important branches from automated machinery. Hot runner system is now in fame because it has many advantages over the traditional cold runner molds, such as shorter molding cycle, less raw materials and energy consumption, higher efficiency and fewer subse uent processes. I A AS will bring together the world’s leading suppliers of hot runner systems, including Mold-Masters, HASCO, SYNVENTIVE, YUDO, SINO and MOULD-TIP.
Chemical & Raw Materials
In recent years, local manufactures in China are ramping up their research and development efforts in a bid to enter to the high-end plastics market, which has long been monopolized by foreign companies. Among them are some rising stars. olyrocks will display its environmentally friendly ame retardant olypropylene 000( ) 0 . Its ammability can reach 9 - 0 (0. m), and meet the glow-wire test IT: 3.0mm and I: 0 3.0m. hong ing olycomp s gross I thermoplastic fiberglass not only enhances the tensile and impact strength of its kind, but also improves the gross and reduces the warpage of the finish surface. Malion ew Materials will also debut its self-developed high-end black masterbatch to compete in high-end market dominated by overseas suppliers. This product has e cellent dispersion property and can be widely applied in high speed production of cast film and thin film for packaging, construction, cables and pipes industries, etc.
High-Performance Materials
4 Amut Group Showcases Thermoforming Machine At CHINAPLAS 6 BOY will enrich CHINAPLAS 2015 8 ARBURG at the Chinaplas 12 CHINAPLAS brings in new topics to shade light on new manufacturing era 14 Labelling Technology for Food and Non-Food Applications 20 Laser melting with metals (LaserCUSING) 22 Jinming R&D team won top award in 1st Shantou Excellent Talent Awards 22 ARBURG: Process chain as highlight of the “Additive Manufacturing Plaza” 28 CHINAPLAS to hold over 50 sessions of technical seminar for buyers 34 ARBURG to present industry trends at the Plast 2015 39 Sacmi to showcase 4 technological winners at Fruit Logistica
The stiffer competition, lower energy cost and falling materials price in local market has made many hinese firms face the perils of overcapacity. Rather than blindly increase the production capacity to meet the bottom line, many plastics manufacturers today eye at more profitable and promising areas such as modified plastics, composite and highperformance materials. In response to the trend, a new theme zone called Composite & High Performance Materials Zone will be set up, at which Korean Hyosung will present its self-invented carbons based engineering plastic - Hyosung olyketone. and Taishan iberglass will feature their long fiber glass thermoplastics and apan s aneka will bring in the synthetic fiber and thermal conductivity engineering plastics compound to the fairground.
40 Ferrarini & Benelli Innovation at Plast 2015
The entry tickets have two types, namely one-day pass (RMB 30) and all-day pass (RMB 50). Admission on Saturday (23, May) is free. Pre-registration is now open until 14 May, 2015. Visitors who successfully pre-registered at www. hinaplasOnline.com prereg will enjoy free and speedy admission to the fair.
52 SHOW REPORT - interplastica and UPAKOVKA/UPAK
42 SMART from the start Improved energy efficiency of air cooled chillers 49 EREMA: Live Demonstration of the TVEplus® technology for heavily printed materials 50 Went down well – BOY at Plastindia 2015 ITALIA.
Editorial: Reny, Sarvjit, Vishwapreet & Amrita (India), Anna (Sweden), Mike (UK), Liza (Singapore), Upi (Indonesia), Ying & Adrian (China), Arvi (Australia). Public Relations Director: Winnie. Advisor: Rajiv Sanghavi. Production: Rakesh. Design, Art & Web Development: Diamond Infomedia. Publisher: Milinia Inc. Founded by: Late Mr N.S. Kanwar. B-2-B Group Publications: PRINTING REVIEW, Medical Device ASIA, autoASIA, Hotels & Culinary ASIA, E-ASIA, Beauty & Fashion World. Contacts: To advertise: advertise@plasticsandrubberreview.com, to submit a press release: editorial@plasticsandrubberreview.com, to subscribe: subscribe@plasticsandrubberreview.com, for any other enquiries: info@plasticsandrubberreview.com. Head Office: D-182, PR House, Anand Vihar, 110092 New Delhi, India. Tel: +91 11 22141542 | Fax: +91 11 22160635. Published, printed, & owned by S. Singh on behalf of Milinia Inc. at , D-182, PR House, Anand Vihar, 110092, New Delhi, India and printed by him at Technical Press, D-182/C, Anand Vihar, 110092, New Delhi, India. Views expressed in this magazine are of the contributors, authors and companies and not necessarily of the publisher and/or editors’ and they do not take any responsibility for the errors and/or accuracy of the information published in this publication. No part or design of this magazine can be reproduced without prior permission of the publisher, who reserves the right to use the information published in this magazine in any manner whatsoever.
Plastics & Rubber Review | March-April 2015 | 3
Amut Group Showcases Thermoforming Machine At CHINAPLAS • Cutting press: 60 ton • Dry cycles: 45 • Forming depth, positive/negative: 130 mm Main features: - Handling system by servomotors. - 4-columns forming and cutting press. - Upper and/or lower plug with servomotor. - Forming with compressed air and/ or vacuum. - Quick clamp system for forming and punching mould, cutting and stacking tools. - Steel-rule dies heating plate. - Upper oven partial heating (last pitch). - Wall stacker (other versions available).
The VPK-84 is composed by three stations: forming, steel rule die cutting and stacking.
AMUT GROUP is also reliable manufacturer of tailor-made extrusion lines to produce foils, sheets, films, membranes, pipes and profiles. The Recycling Division is highly specialised in washing plants to recover PET bottles and HDPE containers and offers a wide range of machinery for the waste handling and sorting. The newly settled AMUT DOLCI & BIELLONI offers printing machines, blown and cast lines for different multilayer films (stretch, barrier, technical, medical, diapers, PP and masking), coating and laminating lines.
Technical data: • Forming and punching area: 840 x 650 mm • Max film width: 880 mm • Total installed power: 105 kW • Forming press: 25 ton
AMUT GROUP shares the booth together with COMI, Italian partner leader in manufacturing customized thermoforming machinery, cutting systems, moulds and presses for several types of applications.
thermoforming machines stands clearly out due to a sturdy structure, an innovative design criteria and high running performances at low energy consumption. Both off-line and in-line solutions are provided. The machines boast a proven strength and durability also under heavy conditions of cutting tougher materials, such as PET and PP at high cycles rate.
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t Chinaplas AMUT GROUP presents in operation the VPK-C84 automatic thermoforming machine producing
rigid packaging, such as trays, punnets, containers. The AMUT GROUP range of
4 | March-April 2015 | Plastics & Rubber Review
ThE ART Of pRODUcTION EffIcIENcy
Finding the decisive perspective – that is true art. Around 3.5 billion high-quality plastic parts are produced every day worldwide on ALLROUNDER machines. If you want to produce efficiently, we are the perfect choice. We ensure your economic success. And your future perspectives!
2015 26 -28, August # c01 Booth , 1 0 1 hall k Bangko
www.arburg.com
German specialties in Far East:
BOY will enrich CHINAPLAS 2015 its production mode, the machine will be hard to hear in the exhibition hall. The compact, cantilevered two platen clamping system with large tie bar and platen distances as well as the lateral swivel-out injection unit provides the user maximum flexibility.
rocan H - eries
control for the
An essential component needed for precision and economics on injection moulding machines is the control. With a completely new design, which includes PCT technology and many new touch features, the Procan ALPHA ® 2 control was improved again in its second expansion stage. The main difference is the multitouch capability of the new system. Like with modern communication devices, operating strategies like scrolling of screen pages or page changes by wiping are available. Due to the integrated machine manual, browsing has been made much easier.
A
t this year´s Chinaplas in Guangzhou (May 20 – 23, 2015), a BOY 60 E and a BOY 22 A will be displayed in the booth (hall 5.1 / booth J 21) of the South Chinese distributor Trillion (Machinery) Co., Ltd.. The BOY 60 E with the efficient servo drive will convincingly demonstrate its capability with a fast cycling application. The BOY 22 A will impress the visitors with the production of high-precision electronic parts.
aster more energy-efficient and quieter The BOY 60 E (600 kN clamping force) is equipped with a servo motor pump drive just like all machines of the E-Series. Compared with previous drive technologies, up to 50 % energy can be saved depending on the application. During Chinaplas, thin-walled caskets made of ABS – each consisting of two underparts and upper parts – will be produced in a 2+2-familiy mould in only 5 seconds. Despite this fast cycling application and the high dynamics of the machine cycles, the BOY 60 E will be impressive because of its low energy requirement and extremely quiet operation. During 6 | March-April 2015 | Plastics & Rubber Review
roven design Since 1968, more than 25,000 BOY 22 A machines are used worldwide in ever improved and more powerful versions. This robust BOY injection moulding machine is
characterized by maximum reliability and extremely low machine hour rates. The extremely compact BOY 22 A with only a 2,4 m² footprint is equipped with a cantilevered clamping unit for easy accessibility for automation equipment or other devices. The design is simple, clear and ergonomic. The proven machine design provides 220 kN clamping force and a maximum stroke volume of 64,3 cm³. “With the renewed exhibition presence of BOY at Chinaplas, we clearly strengthen our market position. Our North Chinese distributor Andeli Co. Ltd. will be at Chinaplas, too. Attractive applications on efficient BOY injection moulding machines will enrich and increase the attractiveness of the largest plastics trade fair since the K exhibition. In addition to our numerous existing customers, who will certainly visit us at Chinaplas 2015, we will also reach again a plurality of interested people with our exhibits.“ This is the outlook from Wolfgang Schmidt, BOY Export Manager in the run-up to the four-day event. Like in previous years, the event will be again frequented by a great number of visitors from inland and abroad.
ARBURG at the Chinaplas: Premiere of the Freeformer in Asia omplete product range production of plastic parts from one-off items to large volumes In ection moulding highlights electric and hy rid llrounders for medical and pac aging technology applications dditive manufacturing reeformer availa le in sia from the start of the hinaplas
At the Chinaplas 2015, Arburg will present the “Packaging” version of a hybrid Allrounder 570 H, which is specially designed for the packaging industry and produces four IML margarine tubs in a cycle time of 3.2 seconds.
rom to ay at the hinaplas in uang hou Hall . stand . r urg will present high-end in ection moulding machines and the reeformer for additive manufacturing to cover the entire production spectrum from one-off parts to mass-produced items. he company will also present the cost-effective in ection moulding of mass-produced items for the medical and pac aging industries with two llrounder e hi its. wo reeformers will demonstrate the potential of r urg lastic reeforming for the industrial additive manufacturing of functional parts as one-off items or in multi-variant small-volume atches. he sian sales launch of this innovative system for industrial additive manufacturing will coincide with the start of the trade fair. 8 | March-April 2015 | Plastics & Rubber Review
“
This year. the Freeformer will be a highlight on our exhibition stand and the Chinaplas will mark the start of sales in Asia. China is a dynamic, prosperous market which holds great potential for Arburg and the time is perfect to present this innovative product at one of the most influential international trade fairs,” says Zhao Tong, Managing Director of the Arburg Organisation in China. He went on to explain that, “The Freeformer is designed for industrial applications and can achieve far more than a simple 3D printer. This new system for additive manufacturing is already much anticipated. Furthermore, we will be demonstrating two
Zhao Tong, Managing Director of the Arburg organisation in China: “At the Chinaplas 2015, we will present the Freeformer for industrial additive manufacturing for the first time in Asia and simultaneously launch it onto the market there.
force of 1,800 kN produces four 200 ml margarine tubs in a cycle time of around 3.2 seconds. The automated process is performed by a two-axis robotic system. It inserts two socalled butterfly labels on both the fixed and moving mould platens and removes the finished parts from the central block.
edical technology electric llrounder
complex applications in the injection moulding sector for the medical technology and packaging industry.”
reeformer additively processes two components With two Freeformers, Arburg will demonstrate how fully functional plastic parts can be additively manufactured from standard granulate using the Arburg Plastic Freeforming process based on 3D CAD data, without use of a mould. As with injection moulding, the granulate is first melted in a plasticising cylinder. The second discharge unit can be used for an additional component in order to produce, for example, a part in different colours, with special tactile qualities, or as a hard/soft combination. At the Chinaplas, a Freeformer will combine an elastic standard TPU material with a special supporting material – a first in additive manufacturing. Possible applications include e.g. bellows, hoses, sleeves, or flexible parts for robotic grippers. The supporting structures can subsequently be removed in a water bath.
Last year, the Freeformer received the internationally renowned Red Dot Award for outstanding industrial design. It thereby takes pride of place next to products from top brands such as Apple, Audi and Adidas.
the IML application. Compared to a conventional 4-cavity mould, stack mould technology permits the use of a smaller machine. The hybrid Allrounder 570 H with a clamping
Electric machines are ideal for the production of medical items due to their high precision, speed and lowemission operation. In Guangzhou, an electric Allrounder 470 E with a clamping force of 1,000 kN will demonstrate this by producing prefillable syringe barrels made of the innovative material COP (Cyclic Olefin Polymer). COP is transparent and has similar barrier properties to glass, but is almost unbreakable and more cost-efficient to produce. In a subsequent step, the syringe barrels can be pre-filled, assembled and packaged ready for use. The Multilift Select robotic system from Arburg is used to remove the barrels.
This pioneering system is not only suitable for the additive manufacturing of one-off parts and small batches. Mass-produced parts can also be customised in conjunction with injection moulding and Industry 4.0 technologies. Arburg demonstrated the process for the first time at the Fakuma 2014 (Germany) using the example of office scissors featuring individualised lettering.
ac aging industry llrounder ac aging version At the Chinaplas 2015, Arburg will present the “Packaging” version of a hybrid Allrounder designed specially for thin-walled applications in the packaging industry. The highperformance injection moulding machine from the Hidrive series offers high productivity and reduced energy consumption. A 2+2-cavity stack mould is used for
Industrial additive manufacturing: with the Freeformer and Arburg Plastic Freeforming, functional parts can be produced efficiently from standard granulate, without a mould. Plastics & Rubber Review | March-April 2015 | 9
Rubber Tech Europe and the Future Tire Conference Messe ssen as xten e the Contract or Rubber ech urope ntil n , the uture ire Conference ill Run urin Reifen an Rubber ech urope
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fter a successful premiere in 2014, Messe Essen and the Chinese United Rubber Corporation (CURC) have extended the contract for Rubber Tech Europe up to and including 2020. In the future, too, the trade fair relating to the stage before the tyre production will take place under the roof of the premier global fair Reifen at Messe Essen. Thus, Reifen will secure for itself the important subject of the primary production for tyres in the long term and will be the only trade fair anywhere in the world to portray the entire value added chain of the tyre. In addition, the Future Tire Conference will take place during Reifen and Rubber Tech Europe for the first time in 2016. The media company Crain Communications will be the organiser of the conference. The complete range on offer at Reifen and Rubber Tech Europe at Messe Essen will extend from the stage before the production via manufacturing and trading right up to retreading and recycling. The exhibitors will include not only the world’s leading tyre manufacturers and trading firms but also, for example, chemical companies and machine constructors. Because the portfolio of Rubber Tech Europe will feature rubber chemicals and raw materials as well as testing machinery and mechanical equipment for the tyre industry. Two thirds of the exhibitors at Reifen see that as a sensible supplement to the premier global fair. Tyre City: Essen is the Global Capital of the Tyre Sector Rubber Tech Europe is a joint venture between Messe Essen and the Chinese organiser CURC with which the people from Essen have already organised Reifen China since 2007. Oliver P. Kuhrt, CEO of Messe Essen, was pleased about the joint commitment in the long term: “The triad consisting of Reifen, Rubber Tech Europe and the Future Tire Conference will show the high status of Messe Essen as the leading competence centre in the tyre sector - particularly after the departure of the Tire Technology Expo from Cologne. In this respect, the 10 | March-April 2015 | Plastics & Rubber Review
primary production will be doubly important: On the one hand, it is an economic factor and a driving force behind innovation. On the other hand, the exhibiting tyre manufacturers will meet their ancillary suppliers in Essen at the same time - and will thus obtain value added which no other meeting places in the sector offer to them.” As another advantage, Messe Essen will offer an attractive supporting programme to the exhibitors at and visitors to Reifen and Rubber Tech Europe: At the Future Tire Conference relating to the future of the tyre industry, representatives of international associations, manufacturers and other companies will discuss subjects such as new production processes and raw materials for more sustainability. Not only Crain Communications but also the European Rubber Journal
will be the organisers. Internationality as an Important Success Factor of Reifen at Messe Essen Steve Crowhurst, Publishing and Events Director at Crain Communications, justified the decision in favour of Messe Essen with the high internationality of Reifen, too: “Reifen at Messe Essen will be the ideal setting for the Future Tire Conference. All the important decision takers and experts will be in situ in Essen. One absolute success factor will be the internationality with around two thirds international exhibitors and visitors. We are looking forward to the cooperation with Messe Essen’s team which has experience in the sector.” Reifen and Rubber Tech Europe 2016 will be open at Messe Essen from May 24 to 27.
The Vision of Asia
th
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Plastasia - 2016 4 - 6 March 2016, Pragati Maidan, New Delhi.
Email : info@plastasia.in / Website : www.plastasia.in
Date : 4th to 6th March 2016 Venue : Pragati Maidan, New Delhi, India.
Title Sponsor*
Organiser #25, 3rd Floor, 8th Main Road, Vasanthnagar, Bangalore -52. Tel : 80-43307474 / Fax : 80-22352772, Mob : 98867 89641 / 98453 63225 Sponsors*
Sponsors*
*Plastasia 2013 Exhibition Supporting Media Partners
Online Media Partners
CHINAPLAS brings in new topics to shade light on new manufacturing era
T
he pace of change in global manufacturing is faster now than any time in history. With increasing customer expectation and stiffer competition, the past era of production emphasizing on heavy capitalization and economies of scale is over. Automation, innovative manufacturing technologies such as robots, vision and sensing systems, software technology, and good product design are now the hot topics of all industries. “New era manufacturing” will be about how to produce effectively with the least resources, and to manufacture unique products that can bring sustainable business. As Asia’s No. 1 and the world’s No. 2 plastics and rubber trade fair, CHINAPLAS 2015, being held on 20-23 May, 2015 at China Import & Export Fair Complex, Pazhou, Guangzhou, China, will bring in an array of concurrent events at the fairground to help industry professionals to stay close with the market trends. This year, CHINAPLAS will spotlight three events – namely “Design X Innovation”, “Industrial Automation – Robot Parade & Smart Production” and “Medical Plastics Conference”.
Highlights of the oncurrent vents “Design x Innovation” – Adsale Exhibition Services Ltd, CHINAPLAS organizer, joins hands with BASF, the world's leading chemical company and player in Performance Materials, to demonstrate how plastics combine with creative design can provide sustainable and innovative solutions and help solve real customer problems. The event will showcase well-designed industrial products made of BASF advanced materials including auto parts, building materials, consumer goods, apparels and housewares. Open Forum on the topic of “Design & Innovation” will also be held and chaired by internationally revered engineering and product designers to share their award-winning works and experiences. “Design x Innovation” will be at two spots of the fairground respectively, at booth A21 in Hall 13.2 and at Viewing Deck outside Hall 9.3 in Zone B.
Industrial utomation
o ot arade
mart roduction
Industrial Automation Zone will be set up at Hall 4.2 12 | March-April 2015 | Plastics & Rubber Review
from and which positions they are in, our visitors can find the practical solutions and inspirations from our show”. In addition to the concurrent events highlighted above, there will also be over 50 sessions of technical seminars being held during the exhibition period. CHINAPLAS 2015 will feature more than 3,100 exhibitors from 40 countries and regions, unveiling the latest plastics and rubber technologies and services across 15 product theme zones that will occupy 26 exhibition halls at China Import & Export Fair Complex, Pazhou, Guangzhou, PR China. 13 countries and regions including Austria, Canada, France, Germany, Hong Kong, Italy, Japan, Korea, Switzerland, the UK, USA, PR China and Taiwan will participate in international pavilions. at CHINAPLAS 2015 to feature a legion of tools and technologies such as robotics, automation systems and peripherals, remote control systems, drives, sensors, arm tooling and software, etc. that help turning the production lines to be more automated, smarter and efficient ones. The Zone rallies market leaders from all over the world such as top robot makers, ABB and Wittmann Battenfeld, automation technology leaders Honeywell and Rockwell from the US, Siemens from Germany, Mitsubishi Electrics and Shini from Japan and Taiwan respectively. “Robots Parade and Smart Production”, a fascinating live demonstration of robotics and fully automated production lines, will be held at the fairground to illustrate the functions, preciseness and flexibility of robotics, as well as the manufacturing advantages brought by clever automation technologies Medical Plastics Conference - a two-day conference held during CHINAPLAS on 21-22 May, 2015. The conference will present hot topics in the medical plastics field such as the latest developments in the global and regional markets, the special requirements for polymer production, additives use, molding technologies, post-processing and medicine packaging, with a view to unlocking future business potential for market players. Leading materials and technologies providers, influential associations and research units will unveil their breakthroughs, analyze the market trends and share their experience on product designs. Healthcare brands will also share their success stories over product development. The Conference is free to admit and will provide a very focused
platform for suppliers and engineers from medical devices manufacturers, OEMs, end-users to share their latest technologies and to network with professionals. Ada Leung, General Manager at Adsale comments, “CHINAPLAS is not simply a procurement and networking platform, but a place to enrich professional knowledge. We are always sensitive to the market movements and bring in new elements each year to keep visitors staying on the top of the market. No matter what sectors they are
The entry tickets have two types, namely one-day pass (RMB 30) and all days pass (RMB 50). Admission is free of charge on the last day of the fair on 23 May, 2015, Saturday. Visitors who successfully preregistered at www.ChinaplasOnline. com/prereg on or before 11 March, 2015 will enjoy free admission and receive visitor badge in advance. You can also become registered through smartphone apps and mobile website conveniently. Delegation (15 persons or above) organized by companies can enjoy VIP privileges.
About CHINAPLAS 2015 CHINAPLAS 2015 is organized by Adsale Exhibition Services Ltd. and co-organized by China National Light Industry Council - China Plastics Processing Industry Association, China Plastics Machinery Industry Association, Guangdong Plastics Industry Association, Messe Düesseldorf China Ltd., the Plastic Trade Association of Shanghai and Beijing Yazhan Exhibition Services Ltd. The event is also supported by various plastics and rubber associations in China and abroad. First introduced in 1983, CHINAPLAS is China’s only plastics and rubber trade show approved by UFI (The Global Association of the Exhibition Industry). CHINAPLAS has been exclusively sponsored by the Europe’s Association for Plastics and Rubber Machinery Manufacturers (EUROMAP) in China for the 26th time. CHINAPLAS is currently Asia’s No. 1 and the world’s No. 2 plastics and rubber trade fair.
Plastics & Rubber Review | March-April 2015 | 13
In-Mould Labelling Technology (IML) for Food and Non-Food Applications
Premiere: Reduced opening stroke for IML applications thanks to patented solution from Beck Automation - ypical High productivity than s to -cavity mold - I technology in a nutshell opening stroke to be used on the injection molding machine.
IML has arrived in North America. IML, introduced in Europe more than 25 years ago, is currently gaining in significance in North America. Reason enough for Beck Automation to take up this trend. Beck Automation will be presenting the highly dynamic IML system B4 on the stand of the KraussMaffei Group (West Building, Stand 903 W) at the NPE 2015 in Orlando (USA). The turnkey production cell consists of a Netstal ELION 3200-2900 all-electric injection molding machine and a 4-cavity injection mold from Glaroform. The object is a stadium cup (44 oz cup with a wall thickness of 0.86 mm) frequently encountered in the USA in football, baseball or soccer stadia. The reference product comes from the Churchill Container Company (Shawnee, Kansas (USA)). The secret behind the IML automation is a concept developed by Beck (patent pending) that allows a reduced 14 | March-April 2015 | Plastics & Rubber Review
The B4 IML system from Beck Automation is regarded as a reference with respect to productivity, speed, footprint, availability, and process reliability. “Performance is the key word in IML automation. The key elements are investment costs in relation to the life cycle costs. Productivity and reduced scrap rates, long operating intervals and life cycle times play a major role here for cost-effective operation of the IML system. The B4 IML system with the new “in-line concept” (patent pending) with reduced opening stroke on the injection molding machine offers a significant economic boost. Particularly when stack molds are used,” explains Nick Lewis, Beck sales partner in North America. Typically Swiss-made: Experience
and know-how form the basis for an IML system with extremely high availability: The B4 IML system is characterised by a very sturdy design in conjunction with the use of high-quality guide elements and powerful, highly dynamic drives that Beck Automation synchronises perfectly with one another. “The B4 IML system is very quiet and allows “stress-free” movements. Thanks to the design principle and the wide range of tests before delivery, we can keep the installation time in the customer’s works very short and can go into production with the system in just a few days. We’re not just talking about “just-in-time”, we mean exactly that.”
I
growing in importance in orth merica
IML is one of the emerging decoration trends in the packaging industry in North America. IML, introduced in Europe more than
for cups in sizes from 12oz to 32oz to 44oz.
onsistently high productivity
25 years ago, is currently gaining in significance in North America, because IML offers a visually attractive “look” for numerous food applications, such as cups or foodstuffs containers. Nick Lewis: “IML is pure attractiveness. It is taking the packaging scene by storm here. The stadium cup on show is a very typical example of a food application. In view of the large numbers in the USA, the 4-cavity system being shown is very interesting for the whole of North America due to its reliability and productivity.” The B4 IML system is also user-friendly when it comes to product changes: The machine is very flexible and quick to convert
As always at Beck Automation, this B4 IML system is a high-speed application (total cycle time: approx. 7.5 seconds, manipulation time: 1.8 seconds). According to Beck Automation, the production capacity is 32 cups per minute, or 1920 cups per hour. Equipped with the latest control and drive technology, the B4 IML system is operated via touchscreen. An integrated remote access provides the option to log into the system from outside in order to provide cost-efficient and fast operator assistance when required.
remiere In-line concept for I ent pending
pat-
Beck Automation is presenting an innovative IML system at the NPE 2015 for the first time that requires a reduced opening stroke of the injection molding machine. The key to the system is a dynamic modification of the kinematics from a 2+2 product arrangement to 4-cavity in-line. The method of operation of the “in-line principle” (patent pending) can be described as follows: The finished cups are taken from the mold in 2+2 pairs while the labels are being placed into the other mold half at the same time. At the moment the IML cores have fully entered the mold, the finished cups are rearranged into a 1x4 line on the removal side between the two mold halves. In the next cycle the IML cores are again retracted from the mold and the main shaft out of the mold area back into the IML system. This “smart in-line principle” offers particular advantages for products with an “unfavourable” diameterto-length ratio, such as the stadium cup. This saving pays off double with stack molds that are very widespread in North America. With single-face molds this allows a reduced opening stroke that is calculated as follows: Product height x 2 plus 120 mm manipulation space (e.g. for the
stadium cup: 2 x 216 mm + 120 mm = 552 mm). In the conventional process, i.e. without kinematic rearrangement of the products into 4 in-line, the opening stroke is calculated as follows: Product height x 3 plus 120 mm (3 x 216 mm + 120 mm = 768 mm). That means a 39% reduction in the opening stroke of the mold halves. For the same application with a stack mold, this effect is reflected in a reduction of 39%: Product height x 4 plus 240 mm (4 x 216 mm + 240 mm = 1104 mm), compared with the convention product height x 6 plus 240 mm (6 x 216 mm + 240 mm = 1536 mm). The practical benefits of the “in-line principle” are manifold: • Increased independence, i.e. lower space requirements (smaller footprint) in the product stack on the conveyor • Less cameras with the optional visual control on the main arm • The use of a smaller injection molding machine with lower clamp tonnage are possible • Optimum support is provided for stack molds and no increase in the opening stroke is required • A further benefit is the time saving for the opening and closing of the injection molding machine which has a positive effect on the overall cycle time Expanding service in North America IML expert Nick Lewis is at the “front-end” for Beck Automation and Glaroform in North America. Beck Automation provides support for clarifications, concept proposals, quotations or financing solutions. Technical service such as for installation, maintenance or prevention is provided from Switzerland. All systems from Beck Automation are fitted as standard with remote diagnostics capabilities. In combination with the 24/7 availability of the service technician, this allows very short reaction times to be guaranteed. Beck has announced the establishment of
Plastics & Rubber Review | March-April 2015 | 15
a new service organization in North America for 2016. Certain components have already been “Americanized” to enable faster reactions. For example, the servo motors come from the U.S. manufacturer Kollmorgen in Radford (Virginia).
wiss-made mold technology from laroform Glaroform AG, Näfels (CH), is presenting a highspeed injection mold with 4 cavities for a stadium cup on a Netstal ELION 3200-2900 all-electric injection molding machine. The mold has a hot runner system developed in-house with pneumatically actuated needle valve. The molding is decorated on the side wall by IML. In order to guarantee a very short cycle time and a high, reproducible product quality at the same time, a highly efficient near-net-shape cooling system has been implemented in accordance with Glarofom standards. The thermally balanced cooling system reduces distortion of the part very effectively and reliably. And to guarantee the very long service life of the molds for which Glaroform AG is renowned, the relevant components are of very sturdy design and treated using the latest surface coating processes. The molds are manufactured with the highest precision and to close tolerances to ensure outstanding process reliability. The 44 oz stadium cup has an average wall thickness of 0.86 mm with a part weight of approx. 52.8 g and is made from the material Vistamaxx (polypropylene (PP)) from ExxonMobil.
Product communication through high-quality labels IML Étiquettes/IML Labels give the stadium cup its elegant appearance. The labels used are made from a white 70 µ multilayer polypropylene film, printed and punched 16 | March-April 2015 | Plastics & Rubber Review
by IML Étiquettes/IML Labels, St. Eustache (Quebec, Canada). Although it is also common to use labels with a smooth surface, the “orange peel” effect is probably the most attractive characteristic of an IML application. In order to achieve this effect, IML Étiquettes/ IML Labels use a “hollow” BOPP film. Structured like a sponge, the film breaks open during injection molding and changes its surface structure. It creates a brilliant visual effect that further enhances the print. Photo-realistic images, such as of fresh fruit, magically attract the viewer.
enefits of I
ilms
IML Étiquettes/IML Labels is a highly specialized and well established label supplier in North America with high IML competence. IML Étiquettes/ IML Labels summarizes his own expertise as follows: “We are the only printer in North America that specializes exclusively in IML (in-mold labeling).” Important for IML Étiquettes/IML Labels is also the environmental aspects: The IML process has minimum impact on the ecosystem and satisfies the highest environmental standards. Its
components and materials, including the paints and lacquers, can be full recycled. Regular audits ensure that all the standards are observed. IML Étiquettes/IML Labels achieves 80% of its production in the foodstuffs industry where minimum residual odor and a “zero printing media migration” are demanded. The shape of the stadium cup requires labels that are stamped with the utmost precision on the one hand, and that can guarantee the fast cycle times with a good electrostatic charge on the other. The 220 lpi sheet-fed offset process guarantees the highest printing quality for both fourcolor photographic images and for Pantone colors. IML Étiquettes/IML Labels can print IML labels with up to 8 colors including lacquer coating. The polypropylene base films can be white, opaque, transparent, matt or glossy. They protect the packaged product effectively against cold or heat, moisture and scratches. A team of specialists supports the customer with the design and its technical implementation. This gives IML users a broad range of options to lend their products an upmarket look and feel at the point of sale in order to influence the purchasing decision.
Russian BOY distributor overcame a crisis Although the Interplastica plastics trade fair in Moscow was ill-fated due to the domestic political situation in Russia and the Ukraine, the Russian BOY distributor BIM Engineering was on site and showed the visitors a BOY XS V.
PLAST, Milan, 5-9 May 2015, Hall 15 / Booth B121: showcases plus technology for production waste and system for edge trim and cele rates uropean premiere of new
During the four days of the exhibition, the BOY XS V overmoulded the metal inserts of a small nail file with a PP handle. This thermoplastic application on the smallest BOY insert moulding machine (100 kN clamping force) was of great interest to the visitors of the Interplastica. Last year elastomer applications were the main topic but the processing of thermoplastics was this year’s focus at Interplastica.
tremely compact and accessi le The BOY XS V requires a footprint of only 0,64 m² to overmould precise inserts with its cantilevered lower clamping platen. Shot weights up to 7,3 g (PS) and injection pressures up to 3128 bar are achievable in a trouble-free, industrial continuous operation. High-precision applications, minimum dimensions and lots of free space for peripheral devices on the machine frame are decisive advantages of the BOY XS V. It is most suitable for fully automatic overmoulding of inserts and integration into production lines. The diagonal arrangement of both tie bars allows open accessibility to the plasticizing unit, the mould area, and ejector. Andreas Janzen, BOY Project Manager, who attended the plastics trade fair in Moscow, was quite satisfied with Interplastica. Promising talks during the exhibition and some following customer visits has led to high expectations for the future.
ompany profile Dr. Boy GmbH & Co. KG is one of the leading worldwide manufacturers of injection moulding machines with clamping forces up to 1,000 kN. The very compact, durable machines work precise, energy-saving and therefore highly economical. BOY continually sets new standards in our industry with innovative concepts and solutions. Since the company was founded in 1968, over 40,000 injection moulding machines have been delivered worldwide. The privately owned company continues to put special emphasis on engineered performance and high-class “made in Germany” workmanship. For further information visit http://www.dr-boy.de/.
sister company EREMA’s focus at PLAST 2015 will be on its top-selling hit, the new INTAREMA® generation of systems featuring the core technology Counter Current. The global market leader in plastics recycling system engineering has already been able to sell more than 210 new systems worldwide after only 18 month since sales began in 2013 and the trend is set to continue. Visitors will see live in action: an INTAREMA® 1007 TVEplus® system with EREMA melt filter SW/RTF 4/134, designed especially for the recycling of heavily printed and metallised production waste, plus the fully automatic edge trim system INTAREMA® 605 K with enhanced development for the inhouse recycling sector.
uropean premiere of The European presentation of the newly founded sister company PURE LOOP will be a further highlight at PLAST 2015. The company, which was founded on 1 January 2015, specialises exclusively in the recycling of clean production waste using shredder-extruder technology. In terms of strategy, PURE LOOP as the sister company of EREMA pursues the clear positioning in the market and further development of the shredder-extruder technology. This is used for the repelletising of production waste in a wide variety of forms such as film, tapes, fibres, nonwovens, fabric, hollow bodies, solid plastic parts and much more. PURE LOOP will present its “ISEC” (Integrated Shredder Extruder Combination) plant systems in its own presentation area using 3D models, among other things. Plastics & Rubber Review | March-April 2015 | 17
Total Plastics Manufacturing Solution
9-12 JULY (THU. - SUN.) BITEC • BANGKOK
More Space. More Opportunities. A to Z of Plastics Manufacturing. Fro la t ol to t o a l at o o a to o to o t a to o t a a l o o o o ot t t t olo t al t o o l lo o t t o o a o o o ot t t o at o a a ll a t o o a T ta o a t o t t o o l ot
at a o t a t to t t a t o t
to la t a a la T a la ll a a o o ll o t l o t t o o ot o al a t t o a al t o
Thailand’s Only International Trade Exhibition and Conference for Plastics and Petrochemical Manufacturing Machinery and Technology – 24th Edition
Exhibit space is open for reservation. +66 2686 7299 t la ta ww t la t a la o a oo o t la t a la a
ot
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Total Plastics Manufacturing Solution
Thailand’s Only International Trade Exhibition and Conference for Plastics and Petrochemical Manufacturing Machinery and Technology – 24th Edition
Exhibition Title
InterPlas Thailand 2015
Exhibition Description
Thailand’s Only International Trade Exhibition and Conference for Plastics and Petrochemical Manufacturing Machinery and Technology – 24th Edition
Date
9-12 July 2015
Time
10:00 - 18:00 Hrs.
Venue
BITEC, Bangkok, Thailand
Scope of Exhibits:
Fact Sheet
In Focus:
Plastic Packaging & Blow Molding Machinery Components, Parts, Semi-finished products Extrusion Machinery Injection Molding Machinery Chemical & Raw Material Metrology & Testing Mold Plastic Recycling Machine Services
Food & Beverage Packaging Bag and Sack making equipment Beverage Packaging Bottling Technology Cap / Crown / Sealing Technology Coding, marking and Printing equipment Cutting machines Filling machines * Labellers / Labels Liquid Handling / Conveying Liquid Packaging Packaging Materials Plastic Packaging Machinery PET Preforms Plastic Mold Auxiliary Equipment CAD/CAM/CAE/PDM/PLM Hot Runner Systems Machine Components Measurement and Testing Equipment Mold Parts Mold Base Mold Design Software and Engineering Mold Materials & Components Mold Treatment and Maintenance
Visitors:
Manufacturers / Agents / Distributors / Servicing organization from the industries of: Automotive Building and construction Chemical and Petrochemical Electrical & Electronics Food & Beverage Furniture Household Products Medical and Pharmaceutical Packaging and Printing Sports / Leisure Products / Stationary / Toys
Chemical & Raw Material, Composite Additives Adhesives & Glues BMC Coating compounds Colorants Composite Elastomers Fibers Fillers & reinforcements Foams & intermediates GMT Granulates Modifiers Paint resins Pigments & Colorants Pultrusion Resins Reinforced plastic Rolling Rubber & synthetic fibers SMC Starting materials & intermediates Thermoplastics Tube
Participation Fee Raw Space Only (min. 36 sq.m.) USD 450 / sq.m.
Standard Shell Scheme (min. 12 sq.m) USD 550 / sq.m.
Inclusive of Exhibit Space
Inclusive of 3 Sides/Back Walls, Company’s Name on Fascia, 1 Information Desk, 2 Chairs, Carpet, One 5-Amp Socket, 2 Fluorescent Lights
Corner Charge
Registration Fee USD 250 / Company
Co-Exhibitors Charge
USD 350/Corner
Inclusive of Security, Cleaning and Listing in Show Directory
USD 670 /Company
7% Value Added Tax (VAT) will be added. As of 7 May 2014
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Laser melting with metals (LaserCUSING)
Concept Laser outperforms the market – sales rise by 75% ales figures for reach the three-digit range for the first time echanical and plant engineering specialist oncept aser sees a ove-average growth in “3D printing that has the potential to revolutionize the way we make almost everything.” - US President Barack Obama, February 2013
Dominant in its environment: New fully integrated M2 cusing with a reduced footprint. The M2 cusing gained a new filter concept, increasing its filter surface five-fold from 4 m2 to 20 m2. The new M2 cusing is also available in a multilaser version called M2 cusing multilaser with either 2 x 200 watt or 2 400 watt lasers.
3D technologies are electrifying the markets with continuous growth reports. Additive manufacturing has long been no secret among experts – it has become a strategic industrial production strategy. In fact, experts predict up to 400% growth for additive manufacturing methods within the next 5 years.
20 | March-April 2015 | Plastics & Rubber Review
Prognoses like these are forcing the main players in the market to step up their technological and capacity efforts. Concept Laser, as an owneroperated medium-sized business, is relying on organic growth. “We invest nearly 10% of our sales revenue directly in research and development,” says Frank Herzog, President & CEO of Concept Laser. “The conservative and long-term mindset of small and mediumsized businesses offers, in my view, the ideal basis for fully realizing our strengths in the market.” The company’s efforts in 2014 have clearly paid off: Concept Laser was voted one of Bavaria’s “Best 50” firms by the Bavarian Ministry of Economic Affairs for its innovative capacity as well as its entrepreneurial philosophies and practices. The company was also a finalist for the 2014 German Innovation Award for co-developing the first additively manufactured titanium component onboard the Airbus A350 XWB.
results re ect rapid growth The fast-growing acceptance of additive manufacturing in the markets and the attractiveness of laser melting systems from the Lichtenfels-based manufacturer are reflected in above-average growth figures. The company received 110 new machine orders in 2014 versus 84 in 2013, a 31% increase. With sales growth in recent years averaging 40-50% annually, sales in 2014 were up 75% from the previous year, driven primarily by large-system sales in the 1000W laser class. The
number of employees had also increased as of the end of the 2014 to 103, 30% more than the previous year.
High innovation speed According to President & CEO Frank Herzog, 2014 was the most successful year in the now 15-year history of Concept Laser: “In our competitive environment, we not only kept pace with the rapid growth in the market, we even exceeded it. This was the result of our R&D efforts and continuous product expansion. Today, 160 employees in the group are involved in the LaserCUSING process. At Concept Laser alone, 40 of our 103 staff members work in research and development.” Key focus areas include series adaptation of multilaser technology for increased building speed, as well as pioneering work in the area of real-time monitoring for quality assurance, known as “QMmeltpool 3D.” Multilaser technology has a direct impact on exposure times, for instance. Empirical values show an increase in build rates of up to 80%. For 2015, Concept Laser has announced an X line 2000R, which will feature two 1000-watt lasers and variable optics.
apacity e pansion in all areas The company’s infrastructure at its headquarters in Lichtenfels was also expanded in 2014 to meet demand, including a brand-new 3,500 m2 production hall, which is nearing completion and will
QMmeltpool 3D – 3D mapping in real time ensures greater transparency during processing
increase machine output by a factor of 2.5. Separate inspection chambers for confidential customer projects and improved delivery times are important considerations for customers. A new, 600 m2 stateof-the-art process development and material research center was also launched in 2014. Last but not least, to meet the enormous demand from the aerospace industry in the US, Concept Laser Inc., with headquarters in Dallas, Texas, was founded in the summer of 2014.
utloo for 2015 marked the 15-year anniversary of Concept Laser. Throughout its history, the company has been a pioneer and technology groundbreaker with numerous patents and innovative products. Based on extremely solid sales figures and the more than favorable prognosis for additive manufacturing, Concept Laser has announced midterm plans to continuously expand its capacity and develop ambitious new products. The R&D department has been working hard on various projects for LaserCUSING with a focus on increased productivity and effective 3D process monitoring, material qualification and automation. The Benchmark division was also greatly expanded at the beginning of 2015. As a “reference workshop,” Benchmark plays an important service role for customers. In addition to adding more space, the division has increased its capacity to ten machines. The high demand in recent years has also required changes in logistics, including a new 1,200 m2 logistics center which is
slated for operation in Q1 2015. The company will also soon break ground on a new administrative building. The international sales network is slated for further expansion. Concept Laser Inc., headquartered in Dallas, Texas, will add new service staff and will soon occupy a new building with its own showroom. China continues to be one of the fastest-growing sales markets for LaserCUSING. Currently there are concrete plans to increase the company’s presence in the Middle Kingdom with more staff and infrastructure. Frank Herzog, President & CEO of Concept Laser: “I believe we are optimally positioned at all levels to be just as successful and innovative in the future as in the past.”
About LaserCUSING® The LaserCUSING® process is used to create mechanically and thermally stable metallic components with high precision. Depending on the application, it can be used with stainless and tool steels, aluminum and titanium alloys, nickel-based superalloys, cobalt-chromium alloys or precious metals such as gold or silver alloys.
rocedures With LaserCUSING®, finely pulverized metal is fused using a high-energy fiber laser. After cooling, the material solidifies. Component contour is achieved by directing the laser beam with a mirror deflection unit (scanner). Construction takes place layer by layer (with each layer measuring 15-100 microns) by lowering the bottom surface of the construction space, then applying and fusing more powder. Concept Laser systems stand out due to their stochastic control of the slice segments (also referred to as “islands”), which are processed successively. The patented process significantly reduces tension during the manufacture of very large components.
their own metal laser melting systems or rely directly on service and development services.
Concept Laser Overview Concept Laser GmbH is an independent company based in Lichtenfels, Germany. Since its founding in 2000, it has been a leading innovator in the field of laser melting with the patented LaserCUSING® technology across many industries. The term LaserCUSING®, a combination of the C from CONCEPT Laser and the word FUSING (to fully melt), describes the technology: the fusing process generates components layer by layer using 3D CAD data. The method allows the production of complex component geometries without tools to create parts that are difficult or even impossible to achieve through conventional manufacturing. With the LaserCUSING® process, conformal cooling can be used to create tool inserts as well as direct components for the jewelry, medical, dental, automotive and aerospace industries. This applies to prototypes and series parts. The company offers both standard systems and custom concepts for metal laser melting. With Concept Laser, full-service as an option means that customers can either purchase
Laser machining systems from Concept Laser process powder materials made from stainless steel, hot work tool steels, cobaltchromium alloy, nickel-base alloy as well as reactive powder materials such as aluminum and titanium alloys. Precious metals such as gold or silver alloys for jewelry making are also an option. LaserCUSING® offers new perspectives in terms of cost and speed for efficient product development in industries such as: • Jewelry • Medical and dental technology • Aeronautics and space industry • Tool and mold construction • Automotive and racing • Mechanical engineering The systems reduce development time and costs substantially while offering much greater flexibility in product development. The high quality standards, level of experience and successful track record of Concept Laser guarantee reliable and cost-effective solutions with proven performance in daily production, with a particular focus on unit cost reductions.
According to resident & CEO Frank Her og, 2014 was the most successful year in the now 15-year history of Concept aser: In our competitive environment, we not only kept pace with the rapid growth in the market, we even e ceeded it. This was the result of our R&D efforts and continuous product e pansion. We invest nearly 10 of our sales revenue directly in research and development, says Frank Her og, resident & CEO of Concept aser. The conservative and long-term mindset of small and medium-si ed businesses offers, in my view, the ideal basis for fully realizing our strengths in the market.” Plastics & Rubber Review | March-April 2015 | 21
Jinming R&D team won top award in 1st Shantou Excellent Talent Awards -Attracting talent through the platform, promoting development through R&D innovation
he multipurpose environmentally friendly film intelligent lowing equipment team from uangdong inming achinery o. td. inming won the utstanding alent ward--Innovative eam the top award in the st hantou cellent alent wards and received an ample reward of million uan.
On November 21, the CPC Shantou Municipal Committee and the Shantou Municipal People’s Government held the Shantou Technical Innovation and Talent Work Conference to generously reward an array of outstanding talent who have made remarkable contributions to Shantou’s economic, social, talent and technological development. The multipurpose environmentally friendly film intelligent blowing 22 | March-April 2015 | Plastics & Rubber Review
equipment R&D team from Guangdong Jinming Machinery Co., Ltd. (Jinming) won the Outstanding Talent Award--Innovative Team, the top award in the 1st Shantou Excellent Talent Awards, and received an ample reward of 5 million Yuan. Shantou’s “1+10”
Talent Policy for high-level talent introduction, training and use was released concurrently at the conference. The concrete policy support and the huge financial incentive showed the city’s thirst for innovative talent and consensus on talent introduction.
Jinming received the “Notice on Selection and Commendation for the 1st Shantou Excellent Talent Awards” from the Organization Department of the CPC Shantou Municipal Committee and the Shantou Talent Work Leadership Group in May 2014. To implement the strategy of talent priority and motivate various talent to make innovation, start businesses and strive for excellence, according to the decision of the meeting of the Standing Committee of the CPC Shantou Municipal Committee, Shantou set up the Excellent Talent Awards and organized the selection and commendation of talent for the 1st Shantou Excellent Talent Awards to recognize and reward an array of excellent talent, teams and institutions which have made remarkable contributions to Shantou’s economic and social construction and talent development. Jinming’s management attached great importance to the selection and commendation work upon receipt of the notice, and decided that the multipurpose environmentally friendly film intelligent blowing equipment R&D team should enter for the Outstanding Talent Award-Innovative Team, the top award in the 1st Shantou Excellent Talent Awards. The team has made remarkable achievements in polymer material and functional film equipment research. Led by Li Hao, Jinming’s technical director and senior engineer, this vigorous R&D team has a history of nearly 20 years and an average age of about 40. The 10 members are specialized in fields such as polymer materials, automation control, plastic machinery, economics and business administration. In recent years, the team has won four patents for invention, one municipal gold patent award, two national outstanding patent awards, seven provincial science & technology progress awards, three national machinery industry science awards and seven municipal science & technology progress awards. The team’s products have filled many domestic gaps in support of the company’s leading the country and ascending to the world advanced level. After more than three months’ strict evaluation, several rounds of application material reviews and field inquiries, and upon study and approval by the municipal committee and government, Jinming R&D team stood out to exclusively win
the Outstanding Talent Award and get 5 million Yuan in prize. The concept of attracting talent through the platform and promoting talent development through R&D innovation After nearly 30 years’ development, a competitive industrial cluster of plastic package printing equipment has taken shape in Shantou. However, for lack of theoretical research foundation, Shantou’s equipment remains far behind foreign high-end products in terms of overall performance and still relies on imported control devices and auxiliary machinery. The overall industry faces impact and challenges. As a national high-tech enterprise and one of Guangdong’s 50 key equipment manufacturers, Jinming has attached great importance to promoting development through R&D innovation in the long term, invested over 3 percent of its annual sales revenues in R&D every year, and established major research platforms such as the provincial engineering technology research and development center for multi-layer co-extruded plastic processing equipment and the postdoctoral research workstation to pioneer the industrial technical development. The award has been attributable to Jinming’s adherence to the concept of attracting talent through the platform and promoting development through R&D innovation. Jinming’s technical director Li Hao joined Jinming for technical R&D immediately after graduation and settled down in Shantou afterwards. This exactly shows that Jinming has created a good work platform for researchers. Painstaking efforts behind the Outstanding Talent Award-Innovative Team Behind the grand honor and huge
prize are the team’s day-and-night painstaking efforts, which vividly interpret the gradual expansion of Jinming’s innovative team. The team began to develop China’s widest (5,500mm) multi-layer co-extruded cast film line last May. The “giant” 30 meters long, 18 meters wide and 10 meters high is critical of precision. After working overtime for three months, the team completed the design scheme and set out to manufacture the machine for an exhibition to be held by the China Packaging Federation at Jinming on November 6. Two days before the exhibition, the machine’s screw was stuck during operation. Pressed for time, Li led the team into rush repair. After working around the clock for two days and nights, the team eventually eliminated the problem in time to ensure that the equipment appeared at the exhibition. The equipment aroused wide interest from domestic and foreign purchasers, and was considered by experts to be up to advanced international standards. This year Jinming has got orders for six similar production lines, including two for Israel. Working day and night is common to Jinming R&D team. With the award as an opportunity and based on the 3,000-squaremeter technology center newly established this year, the team will go all out for platform construction and develop new products with higher technical content and more popular with the market. While constantly improving their business level, the team members will pass on their experience to cultivate another array of talent. Jiming has set up scholarships at Beijing University of Chemical Technology, Xi’an Jiaotong University and Sichuan University so as to attract and make better use of talent in a favorable environment, thus making new contributions to Shantou’s talent and technology construction as well as economic and social development.
Plastics & Rubber Review | March-April 2015 | 23
peedmaster lus hermoforming achine for e ter In elgium WM Wrapping Machinery SA the Swiss manufacturer of thermoforming machines has recently delivered a vacuum pressure forming machine with steel rule cutting and holes punching to De Ster Company at their headquarter facility in Belgium. De Ster is a worldwide well known Company specialized in the supply of prestigious tableware, designed and developed in partnership with world-class brands for onboard service of Aviation and Rail. De Ster’s extensive product range for the contemporary leisure traveler offers convenience by meeting all needs for cost effectiveness and practicality. Range of products includes caps for beverage solutions, hot meat solutions , premium tableware and packaging. List of De Ster Customers is impressive and includes all the most important worldwide airway Companies. The thermoforming machine 24 | March-April 2015 | Plastics & Rubber Review
supplied by WM Wrapping Machinery SA is an FC 780 E IM2 HP Speedmaster Plus model and sizes 780x570 mm of forming area. This is a four stations unit equipped with reel-holder with automatic unwinder , double heating oven, first station for forming and possibility of in mould cutting, holes punching press, additional cutting press and final counting stacking system with a 3 axis robot. In the forming/cutting station a servomotor driven plug assembly is installed as well as quick mould locking and centering and in the additional cutting press XY adjustment of the steel rule cutting tool are available on both the upper and lower platens and heating plate for the steel rule is also fitted as standard supply.
IKV and TU Dortmund cooperate in research into new combined process om ination of deep-drawing and ac moulding in a single step for plastic metal parts
At the heart of the process is the combined tooling technology which brings together the elements of the deep-drawing die with those of the injection moulding tool. The drawing punch and draw die are the forming elements here. A clamping mechanism controlled independently of the injection moulding machine’s clamping unit provides for controlled passage of the steel sheet and prevents any creasing on the deep-drawn part. The combined
Together with the Institute of Forming Technology and Lightweight Construction (IUL) at the Technical University of Dortmund, the Institute of Plastics Processing (IKV) in Industry and the Skilled Crafts at RWTH Aachen University is carrying out research into a combined process that involves the deep-drawing of metal and its backmoulding with plastic for the production of hybrid plastic/ metal structural parts. Hybrid parts of this kind are being used increasingly as lightweight, load-bearing structures in vehicle production. They consist of a deep-drawn sheet steel component with a thickness of approx. 1 mm, backmoulded with plastic. The plastic serves to increase the
stiffness, and may also contain functional and/or fixing elements. One requirement for the reliable production of such hybrid parts is a suitable bonding agent, which is first applied to the steel component. This provides a cohesive bond that ensures a homogeneous stress profile in the hybrid part. This combined process makes use of the closing motion of the injection moulding tool to form the metal sheet, because the kinematics of an injection moulding tool are similar to those of a deep-drawing die. This saves a complete process step. A metal insert is first formed by deep-drawing during the integrated process and is subsequently further moulded into shape with the plastic melt.
injection moulding tool was made by Herrmann Rausch Formenbau, Hösbach, Germany, and is available with immediate effect to the project partners IUL and IKV for their studies of the combined process. The systematic analysis of the combined process is being funded via the AiF as part of Joint Industrial Research (IGF) by Germany’s Federal Ministry for Economic Affairs and Energy (BMWi).
About IKV, the Institute of Plastics Processing at RWTH Aachen University, is Europe-wide the biggest research and education institute engaged in the field of plastics processing enjoying outstanding reputation. More than 300 staff are employed in finding solutions to problems connected with processing, materials technology and part design in the plastics and rubber industries. IKV’s close contacts with industry and science, together with its outstanding facilities, enable cuttingedge research in plastics technology and ensure that students benefit from a comprehensive, practically oriented course of study. Plastics engineering graduates from IKV are thus sought-after experts in industry. In organisational terms, IKV is divided up into the four specialist departments of Injection Moulding, Extrusion and Rubber Technology, Part Design and Materials Technology, and Composites and Polyurethane Technology. The Institute also takes in the Centre for Analysis and Testing of Plastics, and the Training and Further Education department. IKV is run by an Association of Sponsors, which currently has a membership of more than 230 plastics companies from all over the world. Univ.-Prof. Dr.-Ing. Christian Hopmann is Head of the Institute and Managing Director of the Association of Sponsors. He also holds the Chair of Plastics Processing at the Faculty of Mechanical Engineering at RWTH Aachen University. www.ikv-aachen.de www.ikv-aachen.com Plastics & Rubber Review | March-April 2015 | 25
ARBURG: Process chain as highlight of the “Additive Manufacturing Plaza” r urg clusive partner at the Hannover esse Individualisation of mass-produced articles using additive manufacturing including Industry . igital actory leading international trade fair pecial dditive anufacturing e hi it illustrates industrial additive manufacturing
With the Freeformer for additive manufacturing and Allrounder injection moulding machines, Arburg covers the entire industrial production spectrum. At the Hannover Messe 2015, Arburg combines two processes for the individualisation of mass-produced parts.
wo worlds will converge at the Hannover esse the worlds of additive manufacturing and in ection moulding. s an e clusive partner of the dditive anufacturing la a the special new e hi it at the leading igital actory trade fair from to pril r urg will demonstrate how this wor s. r urg is the ideal partner to eutsche esse the organiser of the Hannover esse ecause with its reeformer and llrounders the innovative machine construction company covers the entire industrial manufacturing spectrum of efficient plastic parts production from one-off parts to mass production. 26 | March-April 2015 | Plastics & Rubber Review
T
he main focus of the fair, “Industrial Automation and IT”, combines two leading trade fairs, “Industrial Automation” and “Digital Factory”. In 2015, the “Additive Manufacturing Plaza” will be held for the first time as part of the “Digital Factory”, with exclusive partner Arburg, in a prominent position in Hall 7 of the exhibition centre. This special exhibit deals
specifically with the use of additive processes in industrial production. Heinz Gaub, Arburg Managing Director Technology & Engineering, comments: “We are delighted to have the opportunity to present our Freeformer and the patented technology of Arburg Plastic Freeforming in this setting. Firstly, this confirms both the significance of our new industrial system for
additive manufacturing and the individualisation of plastic parts as well as the importance of Arburg as a source of expertise in this future-oriented sector.” Additive manufacturing generates more value from high-volume products In collaboration with cooperation partners, Arburg demonstrates how, through additive manufacturing, mass-produced articles can be finished with plastics in such a way that manufacturers can generate added value from them. The objective of producing individual plastic parts on an industrial scale is presented by means of a process chain with Industry 4.0 technology. The items under production are “rocker-type light switches” from Gira, the renowned manufacturer of facility management systems. The technology and expertise in the field of additive manufacturing and the injection moulding of high-volume products, as well as the networking of processes via a host computer system, all originate from Arburg. In addition to Gira (product design and mould construction), other project partners are Trumpf (lettering applied to parts by laser), Fuchs Engineering (quality checks) and Fpt Robotik (Automation). The entire process chain, “development – production – application”, is demonstrated by means of individual process modules. The process steps commence with product design, followed by the recording of an order and injection moulding production, including lettering applied by laser, plus a quality check. This is followed by the main step of additive part individualisation. The process is rounded off by packaging and the demonstration of comprehensive traceability via a linked host computer.
he process modules in detail The “Product design” station, which includes a CAD workstation and a Freeformer, shows the production of prototype parts. The process chain for the production of the rockertype light switches starts at a PC station where the individual orders are recorded and the visitor selects his own symbol/name combination. The light switch basic body is series produced on an Allrounder injection moulding machine. This is part of an automated production cell, which also includes part inspection and code applied by laser. The laserapplied DM code enables the process and quality parameters of each moulded part to be retrieved online – in accordance with the individual part traceability required by Industry 4.0. Here, the Arburg host computer system plays a key role.
The Freeformer turns every rocker-type light switch into a unique item by applying the individual symbol/name combination in an additive process with plastics. As the next step, the finished products are placed in “their” packaging in a robotic cell. The packaging is conveyed inline to the process chain and the relevant rocker-type light switch is printed with the symbol/name combination and a QR code, which also enables the product parameters to be retrieved online. Specialists are at hand to answer questions at every station of the process chain.
perfect match
igital actory and r urg
As a leading international trade fair, the “Digital Factory” provides answers to important questions about tomorrow’s production. The answer lies in the digital harmonisation of different steps in the value-added chain, from development to production, through to the use of innovative products. The “Digital Factory” plays host to many high-ranking decision-makers and innovators from research, development and design. This future-oriented process chain is of interest to both target groups. The example of a rockertype light switch, which is representative of numerous potential value-added production processes or products, highlights the possibilities of combining injection moulding and additive manufacturing. Basically, many massproduced parts can be simply individualised by applying these techniques. In this way, we can exploit new market potential for individual components, which were previously not economically viable. About Arburg German machine manufacturer Arburg is one of the world’s leading manufacturers of injection moulding machines with clamping forces between 125 and 5,000 kN. This is complemented by robotic systems, customer- and sector-specific turnkey solutions and further peripherals. An innovative additive manufacturing system was added to the plastic processing range in 2013. The company places the topic of production efficiency at the centre of all its activities, taking into account the entire value-added chain. The objective is to enable the Arburg customers to manufacture their plastic products, whether one-off parts or high-volume production, in optima<l quality and at minimum unit costs – e.g. for the automotive and packaging industries, communication and entertainment electronics, medical technology, or the white goods sector. An international sales and service network guarantees first-class, local customer support. Arburg is represented by its own organisations at 32 locations in 24 countries and by trading partners in more than 50 countries. The machines are produced exclusively at the parent factory in Lossburg, Germany. From a total of around 2,350 employees, around 1,950 work in Germany. About 400 further employees work in Arburg’s organisations around the world. In 2012, Arburg became one of the first companies to gain triple certification: to ISO 9001 (Quality), ISO 14001 (Environment) and ISO 50001 (Energy). Further information about Arburg can be found at www.arburg.com.
Plastics & Rubber Review | March-April 2015 | 27
Learning, networking and knowledge sharing
CHINAPLAS to hold over 50 sessions of technical seminar for buyers
CHINAPLAS will hold more than 50 sessions of technical seminar, with exhibitors to share their new developments and technology achievements.
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HINAPLAS 2015 is not only an international showcase of exhibits from over 3,200 companies from 40 countries/ regions, but also a place to facilitate technical knowledge transfer and networking between suppliers and buyers. CHINAPLAS 2015, which will be held on 20-23 May, will bring in over 50 sessions of technical seminars where prestigious firms will share their latest technologies. Topics range from green building materials, energy savings, vehicle light weighting and safety, electronic devices performance to packaging materials safety and environmental issues. With the rapid development of the plastics industry, the traditional production process has been unable to satisfy the needs of manufacturers who pursue
28 | March-April 2015 | Plastics & Rubber Review
more stable, efficient and smarter manufacturing technologies. Germany Industry 4.0, being one of the ten major projects strenuously promoted by German government, has been brought into limelight. Arburg Machine & Trading (Shenzhen) Co., Ltd. will share about how injection molding industry can be more intelligent with the technology of Germany Industry 4.0 and how it helps the traditional manufacturing to be transitioned to intelligent production, with the combination of automation, internet of things, logistics management, Human-Computer interaction and 3D technology, etc. In addition, Lubrizol Management (Shanghai) Co., Ltd. will send their two experts from global footwear and global foaming technology divisions to share about the new TPU physical foaming technology - BounCell-X in superior cushioning application. Polyurethane is a new organic polymer material, known as the “fifth largest plastics”. BounCell-X is designed for applications requiring recycle-friendly and more automated production processes, resulting in products having a longer term of cushioning property. TSRC Corporation, one of the world’s largest producers of styrenic block copolymer, will explore about the processing and resulting properties of the pure polymer and combinations with a variety of polyolefin (POE). In the same event, the company will also debut their new hydrogenated styrenic
block copolymers (SBC) designed for polyolefin-like processing, compounding, films and fibers. While being processed as a single phase melt, the product can retain its two phase nature at use temperatures to provide strength and creep resistance. It eliminates a variety of problems with mixing and small dimension articles such as films, fibers and thin walled parts when general SBC being processed in the phase separated state. As one of the Asia’s leading extrusion machine suppliers, Nanjing Ruiya Extrusion System Ltd. will hold a session to share about the ways to optimize a twin-screw compounding extrusion line to its highest productivity. The seminar will bring in the simplified approach of Design of Experiments (DOE) and strategies for optimizing the screw design and to identify the best operating range for screw speed, feed rate and barrel temperature settings.
uilding
onstruction
Plastic building products have a big role to play in energy savings and efficiency in our living environment. Choosing the right materials and compounds that perform the desired functions is also the key to success. Chemical industry giant BASF will bring in three new applications of plastics in construction industry, viz. application of engineering plastic materials in water meter and sanitary industry; performance of energy efficient windows made of PVC-PBT co-extrusion profiles; introduction of SPS in construction application to
the audience.
Elastomers to meet these requirements.
Plastics have been widely used in E&E products, lending to their exceptional properties of anti-static and thermal conductivity. With the growing popularity of personal electronic devices, many electronic manufacturers and assemblers are looking for plastics with outstanding properties to improve device quality. Dongguan Calvin Plastic & Tech Co., Ltd. has invited two experts of Electronic Instrument Anti-static Equipment Technology Committee in Ministry of Industry and Information Technology of China, Mr. Kong and Mr. Zhuang to
BYK Additives (Shanghai) Co., Ltd., a subsidiary of BYK-Chemie, will bring in the interior application to the audience. The company will introduce an innovative additive for polyolefin compound that can effectively reduce odor and VOC level at the interior car compartment to meet the requirements of OEMs in auto industry. Reportedly, the new products can be able to reduce up to 80% of VOC.
ac aging China is one of the world’s biggest packaging manufacturers and consumers. At the same time, plastic packaging is one of the four major packaging materials in the industry and occupies a lion’s share of 30% of the sector’s GDP. The competitiveness and technology levels of many Chinese packaging companies have improved a lot in recent years as they strive to adapt new technologies from foreign countries as well as are through selfinnovation.
share the application and key technology of thermally conductive / heat-removal materials, as well as the requirements and GB testing standards of anti-electrostatic technology of domestic markets. Sumitomo Chemical, the world’s leading super engineering plastics (SEP) manufacturer, will debut their latest developed SEP such as liquid crystal polymer (LCP), polyethersulfone (PES), etc. in the seminar. Recently, SEP is on high demand among the fields of electronics, home appliances, film, and automobile due to its extraordinary heat resistance and stability.
utomotive With more stringent international safety and environmental protection regulations imposed, lightweighting is the future direction of the automotive industry. To align with the market trends, BASF will introduce their performance materials that provide solutions in automotive exterior application, such as roof system and lighting system. In addition, the company also cares about the consumer’s driving comfort and safety and will introduce a special Thermoplastic Polyurethane
Phthalate is the most common form of plasticizer widely used in the packaging industry, but over the years their health and environmental issues are in concern. The US based Emerald Kalama Chemical, LLC will introduce two environmentallyfriendly phthalate-free plasticizers - benzoates and dibenzoates. The fast-fusing plasticizers improve the process speed of flexible vinyls, effectively increasing line speed and/ or lower processing temperature, thereby improving productivity and energy efficiency. The light stabilizer in sheet and film products is an important additive as it can block off the ultraviolet rays and delay the photo-aging process, thereby extending the service life of the film products. ADEKA Corporation will introduce their light stabilizer ADK STAB
LA-81. This product has excellent weatherability, making it an excellent candidate being used as agricultural films and membrane sheet. It is just to name a few. Many more such as DSM, ExxonMobil, Borouge, SK Global, Farrel Pomini, along with other prestigious firms will together deliver over 50 sessions of technical seminar at CHINAPLAS. At the same time, a series of inspiring concurrent events and themed activities will be put on concurrently, namely, “Design x Innovation”, “Industrial Automation: Robot Parade & Smart Production”, “Medical Plastics Conference”, “Haier’s Suppliers Communication Conference” , “Open Up Asia and Latin America Emerging Markets” Seminar, making the show a must-go event. The entry tickets have two types, namely one-day pass (RMB 30) and all-day pass (RMB 50). Admission on Saturday (23, May) is free. Pre-registration is now open until 14 May, 2015. Visitors who successfully pre-registered at www. ChinaplasOnline.com/prereg will enjoy free and speedy admission to the fair. They can also use the function of “My Exhibitor”, which is available at the official website, mobile website and smartphone apps to mark their interested exhibitors and make notes of each. For details of Technical Seminars, visit www.chinaplasonline.com/ TechnicalSeminar For details of the Concurrent Events, visit www.chinaplasonline.com/ Events To learn more about CHINAPLAS 2015, visit www.ChinaplasOnline. com .
CHINAPLAS 2015
- ay uang hou hina
Plastics & Rubber Review | March-April 2015 | 29
DAVID BRAUN JOINS TEKNOR APEX AS WIRE & CABLE INDUSTRY MANAGER
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eknor Apex Company has appointed David Braun to be wire and cable industry manager for the Vinyl Division. He will take part in Interwire 2015 at the Teknor Apex exhibit (Booth 212). Mr. Braun will direct all marketing and business development activities for the Division’s wire and cable products, including ApexÒ PVC compounds, FlexalloyÒ vinyl elastomers, FireguardÒ low-flame, low-smoke plenum compounds, and HalguardÒ halogenfree flame-retardant (HFFR) compounds.
“David brings more than 20 years of management experience in wire and cable, including sales, marketing, business development, and top executive positions,” said Mike Patel, director of marketing and business development for the Vinyl Division of Teknor Apex. “His extensive understanding of the industry will benefit our customers and play a vital role in the continuing growth and diversification of our wire and cable business.” David Braun comes to Teknor Apex from Cable Components, LLC, which he joined in 2007 as vice president in charge of business development and for the past four years has served as vice president and managing director. He entered the wire and cable industry in 1992 when he joined NEPTCO Inc., beginning as a sales engineer and subsequently serving as product manager and then business unit manager. Mr. Braun holds an MBA from Bryant University in Smithfield, RI and a BSc in chemical engineering from the University of Massachusetts at Amherst. He is a member of the International Wire and Cable Symposium Committee and was 2012 chairman. He is also active in BICSI and serves on the board of the Communications Cable & Connectivity Assn. (CCCA). He is the holder of two patents relating to cable technology.
About Teknor Apex. Teknor Apex Company, a privately held firm founded in 1924, is one of the world’s leading custom compounders of plastics. Teknor Apex produces flexible and rigid vinyl, thermoplastic elastomers, nylons, toll and specialty compounds, color masterbatches, specialty chemicals, bioplastics and hoses. The company is headquartered in Pawtucket, RI, U.S.A. and operates thirteen facilities worldwide in the United States, the Netherlands, the United Kingdom, China and Singapore. To learn more visit: www.teknorapex.com. The Vinyl Division of Teknor Apex Company is a leading manufacturer of compounds based on PVC, including ApexÒ flexible and rigid vinyl, FlexalloyÒ vinyl elastomers, FireguardÒ low-flame, low-smoke compounds for wire and cable, and BioVinyl™ compounds with bio-based plasticizer. The Division is an international supplier to the appliance, automotive, construction, medical device, wire and cable, and other industries. READER INQUIRY INFORMATION: Address all mail inquiries to Teknor Apex, 505 Central Avenue, Pawtucket, RI 02861 U.S.A. Tel: 1-401-725-8000. Tel. from U.S. only: 1-800-554-9892. Fax: 1-401-729-0166. E-mail: vinyl@teknorapex.com.
Process Control GmbH Introduces the Asr In-Line Recycling System
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rocess Control GmbH will participate in CHINAPLAS 2015, the 29th International Exhibition on Plastics and Rubber Industries, which will be held on May 20-23, 2015 at China Import & Export Fair Complex, Pazhou, Guangzhou, PR China. With a plenty of innovations on existing products and complete new products, PROCESS CONTROL is participating in the Chinaplas Guangzhou. PROCESS CONTROL is well-known for the high quality equipment for extrusion
30 | March-April 2015 | Plastics & Rubber Review
industry with office and production plant for the European and Asia market in Birstein(Germany). Product range: - X-Series Continuous Gravimetric Blenders - GUARDIAN Gravimetric Batch Blenders - Pneumatic Material Handling Systems - GRAVITROL Extrusion Control - Asr In-Line Recycling Asr In-Line Recycling is a recycling
system for edge and bleed trims in film production lines. Compared to repelletizing this system does not bring thermal energy into the product. So Asr saves a lot of energy costs and prevents the materials from a chemical degeneration. The system consists of venturi trim transport device, a film grinder and the refeed machine which compresses the fluff and feeds it back into the extruder. Pumping of the extruder is securely avoided. The payback time of such a system is typically between some weeks and a few months.
VERSATILE NEW-DESIGN CUTTER HUBS AND BLADES FOR UNDERWATER PELLETIZERS INCREASE THROUGHPUT AND ENHANCE PELLET TRANSPORT while reducing wear to die plate and blades.
ew Hu esign for ordson elleti ers ccommodates traight or ngled lades instead of dding hroughput sers an educe to tend ie late and lade ife
New-design cutter hubs and blades for Nordson BKG’ underwater pelletizers increase throughput, improve transportation of pellets from the cutting area, simplify cutter assembly, and provide new options for reducing wear to die plates and blades, it was announced by Nordson Corporation. In an underwater pelletizer, the cutter hub and blade assembly produces pellets from polymer as it exits the holes in the die by rotating rapidly against the die face, with blades mounted at angles to the face of either 45 degrees (‘angled’) or 90 degrees (‘straight’). The new design increases throughput by accommodating up to 100% more angled blades per hub (36 instead of 18) or 54% more straight blades (40 instead of 26). As an alternative to increased throughput, the operator can reduce pelletizer RPM, maintaining standard throughput
Nordson carried out the redesign using the same metal as in the standard hubs and blades but employing a casting process rather than machining the metal, according to Adam Cowart, global product manager. ‘Besides making possible an increase in the maximum number of blades, our new manufacturing method has enabled us to increase the space between the blades, reduce the volume of the cutter hub assembly, and use countersunk fasteners for mounting the blades to the hub,î said Mr. Cowart.’ As a result, there is improved transportation of the pellets, which enhances efficiency, improves pellet formation, and is particularly beneficial for producing micropellets [pellets with diameters less than 1 mm].’ The redesign also makes it possible for the first time to use the same hub for accommodating either angled or straight blades, providing new versatility for users who run multiple materials. ‘The new-design hub and blades can be used on any Nordson BKG underwater pelletizer with throughputs from 1,000 all the way to 35,000 kilograms per hour,î said Mr. Cowart. While it is too early to quantify the range of throughput increases that the redesign makes possible, we do expect that the new cutter assembly will enhance productivity for our customers or in some cases even extend the applicability of smaller pelletizers.’
Plastics & Rubber Review | March-April 2015 | 31
Feiplastic 2015: Arburg Brazil presents efficient injection moulding solutions Cooperation Arbur implements in ection moul in solutions with ra ilian partners i h performance Allroun er i ri e with automation solution for thin walle pac a in items Cost effecti eness ro uction of technical in ection moul e parts with Allroun er ol en ition
At the Feiplastic 2015, a production cell based around a high-performance Allrounder 570 H hybrid machine will produce high-speed packaging items.
r urg will present two production-efficient in ection moulding applications on e hi ition stand H at the eiplastic e hi ition in o aulo. production cell uilt around a hy rid llrounder H with a clamping force of will produce thin-walled disposa le cutlery. he highperformance machine from the hy rid Hidrive series distinguishes itself through high productivity short cycle times and energy efficiency. urthermore a hydraulic llrounder olden dition machine will e presented which com ines high-tech with an attractive price and produces applicator tips for creams. 32 | March-April 2015 | Plastics & Rubber Review
“
One of our key strengths is our ability to provide production-efficient injection moulding solutions that can be tailored precisely to the requirements of our customers,” explains Kai Wender, Managing Director of Arburg Ltda. “At our stand, we will be demonstrating two high-performance solutions that we have developed with Brazilian partners. As South America’s largest trade fair, the Feiplastic 2015 is an important barometer for market developments in the plastics industry in a difficult economic environment.” High-performance machine produces thin-walled parts A hybrid Allrounder 570 H with a clamping force of 2,000 kN and a size 800 injection unit will demonstrate the potential of the high-performance Hidrive series at the Feiplastic 2015 using a 32-cavity mould from RK Ferramentaria. Thin-walled disposable spoons made from PS and weighing 1.3 grams will be produced. Production is fully automated. The injection moulded parts are removed
At the Feiplastic 2015, a hydraulic Allrounder 470 C Golden Edition with a clamping force of 1,500 kN will be producing 16 applicator tips for creams in a cycle time of 7.5 seconds.
and stacked by a horizontally operating robotic system from OK Automation, Braço do Norte. A six-axis robot then packages the items in packs of 50. The total cycle time is around 4.8 seconds.
Hidrive series high production capacity The Hidrive series unites proven electric and hydraulic components from the Arburg modular system. The hybrid Allrounders combine servo-electric toggletype clamping units with hydraulic injection units and performance-adapted hydraulic accumulator technology to create a high-quality machine concept. Thanks to the servo-electric toggle-type clamping unit, extremely short cycle times are made possible due to very short dry cycle times, fast accelerations and high final speeds as well as simultaneous clamping unit and ejector movements. With regard to the injection unit, the combination of position-regulated screw and servoelectric drives for mould and dosage also contribute to cycle time reductions. The hydraulic accumulator technology supports high production capacities. Thanks to the high efficiency of the servo-electric toggle-type clamping unit and servo-electric dosage drive, the Allrounder H machines also provide for highly energy-efficient operation. All Allrounder H machines therefore bear the Arburg “e²” energyefficiency label. Golden Edition: entry-level hydraulic model The second exhibit, an Allrounder 470 C Golden Edition with a clamping force of 1,500 kN and a
size 400 injection unit belongs to Arburg’s entry-level hydraulic machine series. This series, which is the highest-selling in Brazil, features fixed clamping force/injection unit combinations and offers the high-quality technical components and excellent price/performance ratio that you expect from Arburg. It is therefore of interest to many different sectors of industry – from automotive suppliers through to packaging producers who do not work in the area of thin-walled products. At Feiplastic 2015, applicator tips for creams will be produced using a 16-cavity mould from Artis Matriz, Campo Largo. The technical injection moulded parts made from PE HD/LD, each weighing 0.5 grams, are produced in a cycle time of approx. 7.5 seconds.
Kai Wender, Managing Director of Arburg Ltda, on Feiplastic 2015: “At stand H108 we will be demonstrating two high-performance, highly productive injection moulding solutions, which we have developed with Brazilian partners.”
About Arburg
German machine manufacturer Arburg is one of the world’s leading manufacturers of injection moulding machines with clamping forces between 125 and 5,000 kN. This is complemented by robotic systems, customer- and sector-specific turnkey solutions and further peripherals. An innovative additive manufacturing system was added to the plastic processing range in 2013. The company places the topic of production efficiency at the centre of all its activities, taking into account the entire value-added chain. The objective is to enable the Arburg customers to manufacture their plastic products, whether one-off parts or high-volume production, in optima<l quality and at minimum unit costs – e.g. for the automotive and packaging industries, communication and entertainment electronics, medical technology, or the white goods sector. An international sales and service network guarantees first-class, local customer support. Arburg is represented by its own organisations at 32 locations in 24 countries and by trading partners in more than 50 countries. The machines are produced exclusively at the parent factory in Lossburg, Germany. From a total of around 2,350 employees, around 1,950 work in Germany. About 400 further employees work in Arburg’s organisations around the world. In 2012, Arburg became one of the first companies to gain triple certification: to ISO 9001 (Quality), ISO 14001 (Environment) and ISO 50001 (Energy). Further information about Arburg can be found at www.arburg.com. Plastics & Rubber Review | March-April 2015 | 33
ARBURG to present industry trends at the Plast 2015 Allroun ers an reeformers entire spectrum for the ef cient pro uction of plastic parts A iti e manufacturin reeformer has its premiere in taly n ection moul in pac a in technolo y, SR processin , automation an more
r urg will e hi it a road range of efficient plastic part production applications from to ay in Hall tand at the last trade fair in ilan Italy. he reeformer will e presented for the first time in Italy demonstrating how one-off parts and small multiplevariant atches can e produced from standard granulate without a mould in an additive manufacturing process using r urg lastic reeforming . he applications on view in the in ection moulding area will include multi-component and processing including automation as well as applications for the pac aging industry and the medical technology sector.
“
The Plast in Milan is a must for the Italian plastics industry and the perfect platform in order to gain insight into where Italian market is moving and which new areas of activity we can open up for our subsidiary,” explains Björn Noren, Managing Director of Arburg Srl. “Our strengths lie in technically sophisticated precision applications in the areas of medical technology, packaging and cosmetics in combination with complex automation. A special highlight this year will be the Freeformer. This innovative system for the industrial additive manufacturing of one-off parts and multi-variant small-volume batches is close to be launched onto the Italian market.”
reeformer additively processes two components With the Freeformer, fully functional plastic parts can be additively manufactured from standard granulate using the patented “Arburg Plastic Freeforming” process based on 3D CAD data, without the need for a mould. As with injection moulding, the granulate is first melted in a plasticising cylinder. Plastic droplets are applied layer-bylayer onto a moving part carrier via the nozzle of a stationary discharge unit, using high-frequency piezo technology at a specified duty cycle of 60 to 200 Hertz. The second discharge unit can be used for an additional component
34 | March-April 2015 | Plastics & Rubber Review
– for example, to produce a part in different colours, with special tactile qualities, or as a hard/soft combination. At the Plast 2015, a Freeformer will combine standard ABS material with a special support material to produce a key fob featuring a ball joint. The supporting structures are simply removed later in a water bath. Innovative packaging applications Arburg will present a broad range of industrial applications and processes in the area of injection moulding in Milan. These will include multi-component injection moulding and liquid silicone rubber (LSR) processing, as well as high-performance machines for the medical technology sector and the packaging industry.
Arburg will demonstrate a highend application built around a hybrid Allrounder 720 H in the “Packaging” (P) version as an example for the drinks industry. A 72-cavity mould from z-moulds is used to produce so-called PCO1881 closures for carbonated soft drinks (CSD) in a cycle time of only around 3.5 seconds. A Motan system is used for the material feed. The material throughput is over 160 kilograms per hour. Downstream, the production system comprises a closure cooling unit made by Nova Frigo and an optical quality control system from Intravis. An electric Allrounder 520 A with a clamping force of 1,500 kN and a size 400 injection unit will demonstrate a thin-walled
In applications such as the additive manufacturing of key fobs with an articulated joint (orange part), the Freeformer uses the second discharge unit to construct supporting structures that can easily be removed at a later stage.
At the Plast 2015, a packaging system built around a hybrid Allrounder 720 H will be used to produce so-called PCO-1881 closures for carbonated soft drinks (CSD). application. A 2-cavity mould from DZ Stampi is used to produce lids with a part weight of 5.3 g in a cycle time of around two seconds.
ulti-component and
in ection moulding
The production of ballpoint pen caps from two components will be demonstrated by a hydraulic Allrounder 520 S with a clamping force of 1,600 kN and size 400 and 100 injection units. An 8+8-cavity mould from Fila is used here. The main body is produced from PP in a cycle time of around 20 seconds, after which it is overmoulded with soft TPE-S. An electric Allrounder 520 E, with a clamping force of 1500 kN and size 800 injection unit will demonstrate the cost-efficient production of a technical medical part made from PVC. An electric Allrounder 470 E with a clamping force of 1,000 kN and size 290 injection unit will be configured for processing liquid silicone (LSR). iPhone
covers weighing 21 grams are produced in a cycle time of around 20 seconds. The mould is from Prover, while the LSR dosing system comes from 2 KM. Handling is performed by a Multilift Select robotic system with a load weight of 6 kilograms. Cost-effective automation solution The Multilift Select is the entry-level model among the linear robot systems from Arburg. It features servo-electric drive axes and is fully integrated in the Selogica machine controller. For the operator, this means: only one data set, a familiar approach during programming and perfect synchronisation of robotic system and machine. Moreover, the Multilift Select is extremely simple to program thanks to the teach-in function. The advantages of this strategy are evident. Programming times and conversion processes are efficiently shortened, handling sequences are more reliable overall and training expenses are much lower.
Industrial additive manufacturing: with the Freeformer and Arburg Plastic Freeforming, functional parts can be produced efficiently from standard granulate, without a mould. Plastics & Rubber Review | March-April 2015 | 35
ordson olymer rocessing rands a e irst om ined hi it t pe ith any Innovations nd nified lo al hrust these brands after the last NPE and has now integrated them into the Nordson polymer processing range of products, combining more than 200 years of experience with polymer processing technology. ‘Nordson has put into place strong regional leadership, local production capability, support infrastructure, and sales and technical teams to provide customers in the Americas, Asia, and Europe with comprehensive solutions for all of their needs,’ said John J. Keane, Nordson senior vice president. ‘All of our melt processing components will be available through Nordson offices worldwide and can even be sourced together as part of a package system.’
ordson Is uilding a lo al anufacturing and ervice etwor to rovide ustomers with uperior ocal upport for ll I reyen org and aloy rand roducts.
A
t NPE2015 Nordson Corporation introduced to the marketplace of the Americas a unified, global strategy encompassing all of the technologies in its polymer processing range, which includes four well-established and respected brands of production-line components for melting, homogenizing, filtering, metering, and giving shape to plastic and fluid coating materials. At the Nordson exhibit (Booth 6263), all four brands represented by new technologies, including a breakthrough Nordson EDI flat-die mechanism for sheet extrusion, new Nordson BKG equipment designs that increase throughput in underwater pelletizing, Nordson Xaloy plasticizing units that solve special problems in injection molding and extrusion, and Nordson Kreyenborg melt filtration systems that reduce downtime in extrusion, compounding and recycling. Nordson Corporation, a publicly traded multinational with annual sales of nearly US $1.7-billion, began acquiring 36 | March-April 2015 | Plastics & Rubber Review
Nordson Corporation directly operates facilities in nearly 40 countries in Europe, Asia, and the Americas. Thirteen facilities dedicated to the design and manufacture of polymer processing products are located in the United States, Germany, Belgium, Japan, China, and Thailand. There are also extensive polymer processing laboratory, technology, and training centers at four facilities in the United States and Germany. ‘Nordson specializes in components for melt processing systems and works in partnership with processing companies and with extrusion and molding equipment OEMs,’ said Mr. Keane. ‘This specialization involves us in critical phases of melt processing and includes the screws and barrels that generate the melt, the dies that give shape to film, sheet, coatings, or pellets, and other critical components such as filtration systems, pumps, and valves. As a result, Nordson is well positioned to help customers optimize their
process, increase productivity, reduce costs, and enhance product quality. We give equal weight to sales and service.’ Reinforcing this emphasis on service is Nordson Corporationís substantial commitment to investment in local infrastructure, noted Mr. Keane. ‘Nordsonís way of doing business is to operate in each region of the world as a local company that is backed by a strong central organization but engages customers in their own language, culture, and time zone,’ he said. ‘Our goal is to make products globally to improve service and shorten lead times, and we already have the leadership and infrastructure in place worldwide that enables us to do this.’ Regional Nordson polymer processing organizations are in place for the Americas, Asia, and Europe, Africa, and the Middle East (EAME). In every region, Nordson has employed a strategy of focusing more closely on the processes in which customers actually employ Nordsonís polymer processing products. Each of the sales teams in a given region is dedicated to a specific family of applications: extrusion, injection molding, and polymerization / compounding. As a highly diversified manufacturer of precision systems, Nordson invests heavily in R&D and holds thousands of patents. Over the past three years, Nordson has accelerated new product development within the polymer processing range, as demonstrated by the innovations at NPE2015. Nordson plans to announce more new products and improvements in existing systems for polymer processing customers, according to Mr. Keane.
FUNDAMENTALLY NEW MECHANISM FOR CHANGING SHEET THICKNESS INCREASES PRODUCTIVITY, BROADENS GAUGE RANGE, IMPROVES QUALITY or son Smart ap ip an an ositionin System Re uces ob Chan es from ours to Minutes an Rea ily ransitions o er a roa hic ness Ran e while nhancin uality Breakthrough technology for sheet dies enables manufacturers to make changes in thickness with unprecedented speed, extend the range of thicknesses that they can produce, and achieve these improvements while enhancing sheet quality, it was recently announced by Nordson Corporation. Called SmartGap’, the new, patent-pending system from Nordson EDI uses a single-point adjustment mechanism that changes the lip gap while simultaneously modifying the length of the lip land to provide the most appropriate conditions for the newly adjusted thickness as the sheet exits the die. The lip land is the final gap in the die that forms the lip exit. By mechanically linking the adjustment of these two key process variables for the first time, the SmartGap system ensures a proper set-up of the die and takes substantial time and guesswork out of the process for achieving desired sheet properties. The SmartGap system, available only on new dies, eliminates the extended shutdowns for changes in lip components that have often been necessary when transitioning to new job runs, reducing to a matter of a few minutes changeovers that used to take two hours or more. Also overcome are previous limitations on thickness range caused by the complexities of die modification; the SmartGap system readily encompasses die gap adjustments over a range of 0.400 in. (10.2 mm), enabling processors to efficiently run with multiple product changes per day. At the same time, the SmartGap system enhances product quality and consistency, in part by keeping the lip faces and lip lands parallel while carrying out changes in thickness. ‘Because the product quality standards that governed the sheet industry only a decade ago are no longer acceptable in an increasingly competitive marketplace, Nordson EDI has developed the SmartGap system as a means of eliminating the uncertainties and compromises that have often accompanied significant changes in thickness,î said Sam G. Iuliano, chief technologist. ‘We believe SmartGap to be the first real breakthrough in sheet die technology since the start of this century.î
uilt-In Intelligence utomatically d usts ip and ength as It hanges the ip ap
length, increasing back pressure at large lip gaps and helping to reduce extrudate swell.
Operators set the thickness-change process in motion by using an adjustment mechanism at the end of the die to make a new setting for the lip gap. Simultaneous change in the length of the lip land automatically takes place on an as-needed basis, depending on the target sheet thickness. Thus, for thin sheet, the lip land is short, which helps to control back-pressure at smaller die gaps, reduces deflection, and lessens the need for draw-down. For mid-range sheet, the lip land changes from short to medium length, providing sufficient pressure for effective adjustments to the flexible lip of the die while helping to reduce swelling of the extrudate. For thick sheet, the lip land is extended to full
Prior to the development of the SmartGap system, there have been two methods of varying the lip gap. The simplest was to adjust the flexible upper lip of the die. This has a limited range of gauge variation, or ‘travel,î requires several adjustments across the width of the die, and necessitates an extended shutdown period to exchange a removable lower or fixed lip to effect a step-wise change in both lip land and lip gap. A more recent method involves use of a single-point adjustment system such as the Nordson EDI FastGap’ to bend the fixed lip, extending the range of travel but without providing for change in the lip landóso that the lip land used is a compromised
Plastics & Rubber Review | March-April 2015 | 37
design of medium length.
gauge
profile is now more
Bending die lips over significant distances results in lip lands that are not parallel, causing
undesirable diverging or converging flowpath geometry. This can exacerbate certain problems such as lip contamination that leads to streaks. When there is either no provision for a lip land change or lip land change procedures are too time-consuming, processors will often struggle with sheet quality. This is especially true at the thinner and thicker extremes of their product range, where a medium-sized lip land is less appropriate. Improvements in Sheet Quality and Consistency Provided by SmartGap’ System In addition to avoiding extended shutdowns and broadening the available thickness range, SmartGap technology provides these advantages: • Avoiding excessive sheet shrinkage. Since it is now convenient to set smaller lips gaps, processors do not need to draw down as much to achieve target gauge. As a result, there is less orientation of the sheet and, subsequently, fewer problems with shrinkage. • Tighter tolerances and better lay-flat sheet. Now that more appropriate lip land lengths are available for small and large lip gaps, use of the flexible lip to fine tune the
effective. In addition, a proper lip land to lip gap ratio prevents excessive extrudate swell, which causes visible corrugation defects. Improved lip geometry also yields a more fully developed flow, which results in more uniform orientation and less warpage. • Better appearance. Reduction in extrudate swell helps to avoid streaks and reduces the tendency of lip faces to become contaminated. Defects from running with a die gap that is too small, such as ‘shark-skin,î can be avoided by using systems that provide good thickness control at larger die gaps. • Improved external deckle performance. Since the SmartGap system slides the lip components, instead of flexing them through an arc, the lip lands will remain parallel and the lip faces remain flush and normal. This keeps the lip geometry ideal for use with external deckles since the deckle seals do not need to conform to irregular lip faces. The result is that external deckles seal better and require less maintenance.
38 | March-April 2015 | Plastics & Rubber Review
Nordson Corporation engineers, manufactures and markets differentiated products and systems used for the precision dispensing of adhesives, coatings, sealants, biomaterials, polymers, plastics and other materials, fluid
management, test and inspection, UV curing and plasma surface treatment, all supported by application expertise and direct global sales and service. Nordson serves a wide variety of consumer non-durable, durable and technology end markets including packaging, nonwovens, electronics, medical, appliances, energy, transportation, construction, and general product assembly and finishing. Founded in 1954 and headquartered in Westlake, Ohio, the company has operations and support offices in more than 30 countries. Visit Nordson on the web at http://www. nordson.com, @Nordson_Corp, or www.facebook.com/nordson. Nordson Polymer Processing Systems provides customers with engineered components to melt, homogenize,
filter, meter, and give shape to plastic and fluid coating materials. Nordson Corporation leverages the collective plastics industry experience from a series of strategic acquisitions to offer a uniquely broad portfolio of industry-leading technologies. Nordson delivers a full range of precision melt stream products ó from screws and barrels for extrusion and injection molding ó to filtration systems, pumps, and valves ó to the extrusion dies and pelletizing systems to meet the constantly evolving needs of the polymer
industry. Nordson Corporation provides customers with local technical sales, service and remanufacturing capabilities through sales organizations and regional manufacturing facilities in over 30 countries. To learn more visit us at http://www. nordsonpolymerprocessing.com.
Sacmi to showcase 4 technological winners at Fruit Logistica The best Sacmi tray-forming technology played a central role at Fruit Logistica in Berlin, the international exhibition of fruit and vegetable processing technology that, from 4 to 6 February, attracted a record 65,000 visitors from 130 countries. The first new product was the industrial version of the automatic TF 70 modular tray forming machine, presented at the Sacmi stand (a 102-square-metre exhibition area) complete with the TS 60 stacker. Launched on the market back in 2013 as a prototype, this is now the flagship model of a series that has won widespread market acclaim on account of outstanding productivity, reliability and flexibility. A key feature of the machine is, of course, its modularity, which allows, starting from the different base modules – magazine, press and corner – manufacturers to obtain a standard tray former (TF 50) and the new TF 70 forming machine, currently the market’s most competitive, highest-performing solution for corner-post trays. In addition to remarkable productivity (up to 50 pieces per minute thanks to the double feed chain and other technical devices), the strong points of the machine include its ability to operate together with the new TS 60 stacker, which Sacmi has redesigned to cope with the high output of the new former; this allows parallel production of two trays, up to a maximum length of 800 mm, and stacking without any upper height limit.
Sacmi Packaging will be displaying 4 new products in Berlin: the “compact” TF 80 for the manufacture of small stackable trays and the modular TF 70, the newest model in a series that has enjoyed widespread market success on account of productivity, reliability and flexibility. Also on show was the fast, compact GD 25, specially kitted out to form boxes with corner posts in the hopper, plus the new Multibox for the manufacture of RSC or telescopic boxes.
Low maintenance requirements, ease of use, quick size changeovers: these are just some of the advantages offered by new Sacmi solutions for the fruit and vegetable sector, advantages that have, in recent years, put us ahead of the competition. Just consider, for example, the distinctive qualities of the latest Sacmi proposal, the new Multibox, capable of forming up to 15 RSC or telescopic cases per minute, with fast, practical size adjustments and a highcapacity magazine. Flexibility, productivity and - once again - extreme compactness were the key features of another solution showcased by Sacmi in Berlin, the TF 80, an automatic tray forming machine that can simultaneously cope with two different sizes and offers output rates in the order of 120 pcs/minute. Similar characteristics were also seen on the GD 25, the last machine to be presented on the Sacmi stand: compact and fast, the version presented at the fair featured the special kit for forming boxes with corner posts in the hopper. A not-to-be-missed event, then, for Sacmi, which decided to attend what is the most important European fresh produce packaging and processing fair with no less than four new high-tech solutions: the best possible way of leaving a positive impression and to continue playing a lead role in an industry characterised by growing international competition. This increasing competitiveness is evident in the rise in the number of exhibitors at Fruit Logistica: this year there were 2,785 (200 more than last year) from 83 countries, more than 90% of them foreign. Plastics & Rubber Review | March-April 2015 | 39
Ferrarini & Benelli Innovation at Plast 2015 At Plast 2015, Ferrarini & Benelli will showcase its new solutions for corona treatment, plasma treatment and a line of digital generators. The company, based in Romanengo (CR), Italy, which celebrates its 50th anniversary this year, is growing (especially abroad) thanks to its constant technological innovation, the know-how acquired and its ability to produce surface treatments that are effective also on the most innovative materials used in the packaging sector. The solutions offered by Ferrarini & Benelli stem from a long-standing collaboration with the world’s leading manufacturers of production lines for extrusion and the processing of flexible packaging, as well as from a design process developed in-house by specialised staff. There are more than 10,000 corona treatment stations produced by Ferrarini & Benelli installed around the world. WHAT YOU’LL SEE AT PLAST 2015 (Pad. 15 – Stand C51)
orona treatment stations • Bikappa Rotary - High-technology double-sided treatment station, particularly suitable for mounting on high-performance blown film extruders (that require the use of high power coefficients for high working speed and/or for
particularly slippery materials) or on flexographic presses in line with extruders. • Polimetal - High-performance universal treatment (up to 600 m/min) equipped with special electrodes and ceramic rollers. Designed for applications of extrusion coating, flexographic and rotogravure printing, laminating and coating machines. • Mini Bikappa - Corona treatment station double-sided with small size, suitable for mounting on laboratory blown film extruders. • Corona Quality Control is a software for the monitoring and certification of production that allows to import Corona Treatment data to one’s own PC from an SD card mounted on the generator.
tmospheric lasma treatment FB PLASMA 3D, works under conditions of atmospheric pressure, assures excellent wetting properties of polymeric materials and metals and improves the bonding of inks, glues, coatings and adhesives. Suitable for treating: 3D objects, small areas of plastic parts, profiles and sections, cables and pipes, strips of plastic film. The system is composed of a high frequency generator and a dedicated
40 | March-April 2015 | Plastics & Rubber Review
nozzle. The treatment width of a single nozzle is 10 mm. Applications: Pad printing, Silk-screening, Ink-jet printing, Laminating and application of glue on folding cartons.
enerators Ferrarini & Benelli designs and produces digital generators to be used in combination with corona and plasma systems. Corona treatment three-phase generators, with integrated digital control system can reach high powers necessary for treating the most difficult materials at maximum line speed.
The software of the generator is able to independently manage the power circuit regulating power automatically according to the speed of the line. The corona treatment system can be integrated with the customer’s line control PLC through fibre-optic or communication protocols such as RS 485, Profibus, Profinet, Canbus and Ethernet etc. From a single exit, thanks to these new languages, it is possible to give all the information to the central processor. The operator thus controls the whole process with a single control panel. For more info: www.ferben.com
BARRY SHEPHERD OF SHEPHERD THERMOFORMING & PACKAGING IS NAMED SPE 2015 THERMOFORMER OF THE YEAR
T
he Society of Plastics Engineers (SPE) Thermoforming Division has named Barry Shepherd as Thermoformer of the Year. The award will be presented during SPEís Thermoforming Awards Dinner, held in conjunction with the 24th SPE Thermoforming ConferenceÆ. The conference will take place August 31-September 2, 2015 in Atlanta, GA, at the Renaissance Atlanta Waverly Hotel. The Awards Dinner will be held on Tuesday, September 1.
Throughout the 1960s, Barry Shepherd worked for several different packaging companies in sample making and design. He joined Kodak Canada in 1970 and began designing packaging for cameras, film, and related products. While at Kodak he was involved in the development of packaging for Kodachrome slides, an early ground-breaking use of thin-wall injection molding. During the mid 70s and early 80s, Barry Shepherd worked for several corrugated packaging companies in positions ranging from sales to president of a small box company. He always stayed involved in his passion: design and development. In 1984, Barry was introduced to the Alloyd Company, which specialized in thermoforming medical, consumer packaging, and sealing equipment, and he was intrigued by plastics and blister packaging. In 1985, Barry Shepherd launched Shepherd Packaging, selling plastic blisters, trays, clamshells, sealing equipment, and other packaging materials. Shepherd Packaging expanded its manufacturing business and in 1997 entered the heavy gauge thermoforming market by developing a custom thermoformed plastic pallet for Lear. Under Barry Shepherdís leadership in 2006, Shepherd Thermoforming & Packaging Inc. opened its 43,000 square foot custom thermoforming facility near Toronto, Canada, where the company operates seven thermoforming and two CNC milling machines. Now retired, Barry Shepherd remains active on the Board of Advisors for the company he founded. Barry Shepherd joined the SPE Thermoforming Division Board of Directors in 1997 and worked on several committees, including the
Executive Committee, before retiring from the Board in 2010. During his tenure, Barry Shepherd also served as technical editor of the Thermoforming Divisionís award-winning publication, SPE Thermoforming QuarterlyÆ magazine. Past recipients of the Thermoformer of the Year Award may be found on the SPE Thermoforming Division website, http:// thermoformingdivision.com/awardsrecognitions/thermoformer-of-theyear/past-winners/. More information is available at http://thermoformingdivision. com or by contacting Lesley Kyle at 1-914-671-9524 or lesley@ openmindworks.com. S C
AS CS
RS
(SPE) is the premier source of peerreviewed technical information for plastics professionals. Founded in 1942, SPE takes action every day to help companies in the plastics industry succeed by spreading knowledge, strengthening skills, and promoting plastics. Employing these vital strategies, SPE has helped the plastics industry thrive for over 70 years. SPE has become the recognized medium of communication among scientists, engineers, and technical personnel engaged in the development, conversion, and application of plastics. For more information, please visit http://www.4spe.org.
Plastics & Rubber Review | March-April 2015 | 41
SMART from the start Equipped with sophisticated features, Starlinger’s newly introduced recoSTAR dynamic recycling line makes plastics recycling more ecological, economical and energy-efficient. innovative machine design that improves the energy efficiency of Starlinger recycling lines. Energy savings are achieved using the new extruder drive concept as well as the use of motors classified IE3 or NEMA Premium (highest efficiency standard according to the U.S. National Electrical Manufacturers Association), as well as the use of infrared heaters on the extruder barrel. The use of the radiant heat of the extruder for material processing helps to recover additional energy.
T
here were several key factors taken into account while pioneering the design of the new recoSTAR dynamic line recently unveiled by Starlinger recycling technology. The high degree of automation completes the design elements of a very energy-efficient production platform that ensures reliable and constant operation, higher outputs, and extraordinary flexibility in regard to types of input materials. Highly automated operation and continuous process adjustments are now possible using the Dynamic Automation Package. This allows to increase the machine uptime and productivity of the recoSTAR dynamic while reducing the overall energy consumption by up to 10 %. The recycling line automatically starts up and shuts down via the SmartStart feature, and when the material feeding is stopped, the SMART feeder switches into stand-by mode without requiring
A recoSTAR dynamic recycling line was exhibited during the NPE in Orlando, USA, from March 23 – 27, 2015 at the Starlinger’s booth. operator interaction. The automatic temperature controller allows the processing of input materials with different moisture levels and varying bulk density, all the while maintaining consistent product quality. “This makes it possible to process, for example, postconsumer regrind or fluff that has varying moisture levels”, explains Elfriede Hell, General Manager of Starlinger recycling technology. “Under unfavourable storage conditions the moisture content in the input material can easily increase from 2 % to 6 %. The recycling line automatically adapts to the requirements of the input material and can even process material with a moisture content of up to 10 % with additional equipment. The speed, and consequently the friction, in the SMART feeder are increased until the required material temperature is reached. This saves the operator a lot of process adjustments and cuts down machine downtime.”
42 | March-April 2015 | Plastics & Rubber Review
In addition, the increased capacity of the large SMART feeder results in a much larger operating window, while the self-regulating material feeder allows the extruder to process a wider range of input materials, giving recyclers greater flexibility in the marketplace. Additionally, upcycling is realized by compounding during the recycling process. Additives can be fed directly into the extruder through a side feeding unit while the output feedback loop ensures total process control.
Increased energy efficiency r Increasing awareness of energy consumption and CO2 emissions has a strong impact on modern machine engineering and construction. In the “green industry” of recycling, a small carbon footprint and reduced energy consumption not only present an attractive marketing tool, they translate into direct cost benefits for those recycling plastics. The “rECO” stamp indicates the
About Starlin er recyclin technolo y Starlinger recycling technology is a division of Austrian-based Starlinger & Co GmbH, world market leader in the field of machinery and complete lines for woven plastic packaging production. For more than 25 years Starlinger recycling technology has been providing machinery solutions for the recycling and refining of a wide scope of plastics such as PE, PP, PA, PS, BOPP and PET. Starlinger PET recycling systems produce food-safe rPET and are approved for use in food applications by many brand owners as well as various national and international authorities. The worldwide sales and service support network and technical consulting service help customers to achieve optimum results in the manufacturing process. Further information: Starlinger & Co. Ges.m.b.H. www.recycling.starlinger.com -NEMA remium is a registered trademark of the National Electrical Manufacturers Association. -recoSTAR is a registered trademark of Starlinger & Co. GmbH.
i hly ef cient pro uction unit with l xis S hi h spee in ection moul in machine
Producing IML decorated containers by the second e pectations
A
t Plastpol, which will take place from 26 until 29 May in Kielce/Poland, Demag Plastics Group SP. z.o.o will present a highly impressive exhibit: an El-Exis SP 200 for the production of IML decorated food containers will be on show as a system solution in hall G, stand 15.
and intuitive machine operation. Numerous software features and adjustment options specially developed for packaging producers facilitate process optimisation.
At Plastpol, Demag Plastics Group SP. z.o.o, a subsidiary of Sumitomo (SHI) Demag Plastics Machinery GmbH, Germany, will prove its expertise in packaging by exhibiting an El-Exis SP 200-920 with a clamping force of 2,000 kN, which will be producing and IML-decorating food containers. The injection moulding machine will be combined with handling equipment from Polymac Robotics b.v. to form a compact production unit, which allows the production of containers within less than 3.5 seconds. The polypropylene (PP) cups will be produced in a 4-cavity mould manufactured by Otto Hofstetter AG with a shot weight of about 6.2 grams.
The El-Exis SP exhibited at Plastpol is also equipped with different Sumitomo (SHI) Demag active features. In addition to the standard technology modules activeQ/Q+, activeCool&Clean and activeAdjust, the machine runs with optional features such as activeMotionControl, activeScrewDrive, activePowerLink and activeEcon. They improve the machine’s adaptation to the application at hand and help operators tap into the available efficiency potential.
The El-Exis SP’s clamping unit with its decentralized electric drive provides high-speed, careful mould opening and closing in order to achieve a highly precise mould-stop position. This way, the labels are accurately placed and the cups are removed correctly. An NC5 plus control guarantees easy, uncluttered
l- is
- ature concept for high
El-Exis SP injection moulding machines offer premium technological performance for the production of thin-wall packaging applications. Thanks to the combination of electric and hydraulic drives, El-Exis SP machines deliver maximum speeds and dynamics. These machines are the result of Sumitomo (SHI) Demag’s extensive market intelligence gathered over many years in the packaging segment. Thanks to a total of 20 years of market expertise and 15 years of experience with the El-Exis machine range, we have achieved very high process stability, which makes the El-Exis SP one of the best packaging machines in the world. When we developed the El-Exis range, the aspect of cost-efficiency was always at the top of our agenda. Parallel hybrid drives and virtually loss-free force transmission ensure that this machines combines maximum performance with low energy consumption. Aside from material costs, energy costs are the second most important parameter of cost-efficient production. Thanks to tried-and-tested, reliable machine technology, the El-Exis SP also offers high availability and a long service life. For more information, please visit: www.demag.pl Plastics & Rubber Review | March-April 2015 | 43
TECHNOLOGY
Improved energy efficiency of air cooled chillers independent refrigeration circuits (mod. 130÷480). The SBS/SBSF models are all equipped with shell & tube evaporator, modular aluminum finned copper coil condensers, mounted in V configuration, axial fans and scroll compressors (up to 6 compressors) installed on two or on request, three independent refrigeration circuits.
New ENR/ENRF SERIES from 1 to 480 kW
In the last 10 years awareness in energy saving has continuously increased in both industrial and HVAC applications, at Hitema we strive to reduce the electrical consumption of cooling equipment using the most effective, innovative and efficient techniques. In the refrigeration and heat pump sectors European standards and directives are now applied to increase the standard of materials used, increase innovation and in the application of new technologies to improve refrigeration system efficiencies.
T
he ENR/ENRF and SBS/SBSF are chillers from our Cooling Plus Energy series with air cooled condensers operating on R-410A, which can also come with complete “Free-cooling” sections (only for models ENRF and SBSF) to guarantee energy savings. The ENR/ENRF units are equipped with either stainless steel plate type, self-cleaning coaxial or shell & tube evaporator, aluminum finned copper condenser, axial fans and rotary compressor (mod. 001÷005) or scroll compressors (mod. 008 ÷480, up to 4 compressors) installed on one refrigeration circuit (mod. 001÷100) or two
44 | March-April 2015 | Plastics & Rubber Review
HVAC designs for Data Centre – Total Load 1.5 MW
In the refrigeration and air conditioning sector continuous attempts are made to reduce the energy consumption of all systems by improving the management of cooling power, optimizing the flow paths of water-glycol and providing greater temperature accuracy. Recent research has developed the use of environmentally friendly refrigerants with lower environmental impact and excellent thermal performances. However, large refrigerant equipment still have very high power requirements, especially those demanded from very large air or water cooled chillers with screw compressors. The utilization of screw compressors is traditionally very high amongst larger capacity chillers (>300 kW) and therefore the optimization of partial load performance, which is a condition present in almost all refrigeration plants at various stages throughout the year, is deemed as the goal by Hitema. A modern and intelligent technology is to control the large power demands of screw compressors by inverter driven
electronic devices.
Advantages offered with the Inverter Technology
An inverter (VDF) is an electrical device acting on the variation of voltage and frequency. The inverter uses the line alternate voltage (a.c.) to produce a direct voltage (Diode Bridge - d.c.). From this direct voltage an alternate voltage is regenerated (PWM technique) with a frequency f between 0 and fmax (maximum frequency) and voltage V<Vnet (electric net voltage). Inverters are widely used in filmpolyester capacitor configuration, which is similar technique used on photovoltaic plants. The absence of electrolytic materials avoids the early aging due to the temperature, currents and stocking periods. The current distortion THDI is much lower than is electrolytic capacitors since the equivalent electrical capacity is lower. Moreover the compactness and longevity of inverters above film capacitors is also a consequence of superior effectiveness of cooling directly with liquid refrigerant line. With this technology, the partialization of cooling capacity is achived by reducing the number of revolutions of the motor that drives the compressor or in other terms reducing its power supply frequency. The rotation speed of the screw is adjusted according to the instantaneous thermal load to be disposed. High thermal loads requiring high flow rates of refrigerant gas, so high rotational speeds and low thermal loads
• Cooling power can increase up to 20% above the optimal cooling power at 50 Hz, this is because the screw compressors can rotate with higher gears reaching higher frequencies up to 130 Hz. • Higher operating flexibility due to large envelope of control (from 16% to 100%, widest modulation range on the market) and higher power density. • Reduced electrical consumption at partial load between 30 Hz and 50 Hz compared to a standard screw compressor with a slide valve capacity control system. This results in a measured absorbed power being reduced by up to 15%.
• Reduced mechanical compressors wear, as the screw will rotate for most of year with reduced r.p.m. (higher MTBF). • Inverter technology with screw compressor variable Vi, using automatic control of Vi the performances of chiller increase.
High-efficiency chillers with magnetic oil-free compressors
Not only screw compressors can use the inverter technology. Another solution recently adopted from Hitema in collaboration with Arctic Cool Chillers Limited, are the Danfoss Turbocor compressors. The Turbocor compressors are centrifugal oil free compressors with magnetic bearings. This
New SBS/SBSF SERIES from 240 to 1000 kW
allow you to work at lower speeds. Going to intervene on the rotation speed of the motor, the absorbed power by compressors is reduced and thus the energy consumption, as opposed to a machine with screw compressor without inverter that operates at constant speed. The application frequency range was widened between 30 Hz to 130 Hz. Main advantages are: • The starting current is effectively equal to 0, as the current is directly proportional to frequency, the inverter starts the screw compressor with no frequency and it causes an absorption equal to 0, as opposed to a machine with a standard screw compressor without inverter, that would have a typical inrush current when they are started.
Figure 1 – Soft start characteristic
Figure 2 – Comparison at typical ESEER conditions for air cooled chillers
• Reduced CO2 emissions by cutting electrical consumption at partial load. • Superior control of water outlet temperature exhibiting less fluctuation around the set point temperature. Typically tolerances of around +/- 0.5°C are possible.
type of compressors has all the advantages of inverter technology and need less maintenance because they are oil-free. Friction-free magnetic bearings reduce the maintenance costs associated with oil service. One moving part (motor rotor shaft and impeller assembly) is levitated
Figure 3 – On left, a semi-hermetic compact screw compressor with integrated frequency inverter mounted in a Hitema chiller. On right diagram of necessary components for inverter technology: line reactor filter (2) and RFI filter (1), this last only required in residential areas according to EU EMC directive (2004/108/EC) and EN 61008-3. Plastics & Rubber Review | March-April 2015 | 45
E.E.C.C.A.C. proposal (Energy Efficiency and Certification of Central Air Conditioner). The formula used to calculated this is: ESEER= 0.03 x EER(100%) + 0.33 x EER(75%) + 0.41 x EER(50%) + 0.23 x EER(25%) The EER value (%) is the efficiency of chiller at 100%, 75%, 50%, 25% of load under various conditions in accordance with Table 2: Figure 4 – On left, a cross section of Turbocor compressor. On right, the diagram of shaft with the magnetic bearing.
during rotation by a digitally controlled magnetic bearing system, consisting of one axial and two radial bearings, which completely eliminates any metalto-metal contact and wear surfaces. Sensors at each magnetic bearing monitor the shaft location 100,000 times per second ensuring precise positioning of the shaft.
The advantages of inverter technology in numbers
Table 1 shows a comparison between three compressors that having the same capacity under the same operating conditions, working at full load.
Table 2 - Weighting factors of part load efficiencies for calculating European Seasonal Energy Efficiency Ratio.
Figure 5 and Figure 6 show the advantage of inverter technology in two practical cases: Figure 5 shows the EER how varies as the load varies and the ESEER for three air-cooled chillers product by Hitema with about the same cooling capacity; Figure 6 show the same thing but for three watercooled chillers.
BRAND
BITZER
BITZER
DANFOSS
Model
CSH8583-125Y-40P
CSVH24-125Y-40A
TT300-H6-1-ST-E-O-CE
semi-hermetic screw compressor
semi-hermetic screw compressor with integrated frequency inverter
centrifugal compressor with integrated frequency inverter
1540 691 712 860 64,1
1434 664 652 735 66,1
788 518 487 120 53,5
Description
Length [mm] Width [mm] Height [mm] Weight [kg] *Sound Pressure Level [dB(A)]
Table 1 – Comparison between compressors that having a cooling capacity of about 290kW for the 100% of load, condensing temperature of 40°C and evaporating temperature of 3°C. *Sound pressure level referred to measures according to normative ISO3744, pressure level at distance of 10m, referred to free field on reflecting surface.
This simple comparison shows another interesting aspect in the use of compressors that use inverter technology compared to compressors that do not: the dimensions and weights are much lower, this is especially true for the Turbocor due to the fact that they are centrifugal compressors instead of volumetric compressors. Finally, in terms of noise again the Turbocor compressors have a sound pressure level measured at 10m well below the most classic screw compressors. In the European market the adopted index to classify chiller performance is E.S.E.E.R. (European Seasonal Energy Efficiency Ratio) and this is in accordance with 46 | March-April 2015 | Plastics & Rubber Review
Figure 5 – Comparison between three air-cooled chillers: Hitema model EET.750 with twin semihermetic screw compressors; Hitema model ITC.770 with twin semi-hermetic screw inverter driven compressors; Hitema model AHA.760 with Turbocor compressors. Each models are equipped with economizer and condenser with cooper tubes and aluminum finned core. The models EET.750 and ITC.770 have fitted shell & tube evaporator and AC fans regulated with fan speed regulator (cut phase). The model AHA.760 have fitted flooded evaporator and EC fans. The refrigerant for all models is R134a. ÅÅ
Figure 6 – Comparison between three water-cooled chillers: Hitema model ECWH.630 with twin semi-hermetic screw compressors; Hitema model ECWH.630 with twin semi-hermetic screw inverter driven compressors; Hitema model AHW.630 with Turbocor compressors. Each models are equipped with shell & tube condenser. The models ECWH.630 have fitted shell & tube evaporator and the model AHA.760 have fitted flooded evaporator. The refrigerant for all models is R134a.
act in this method, we can consider the operating curve of a centrifugal pump. (Figure 7).
AHA SERIES from 245 to 1140 kW
Big Evolution Chiller SERIES like EET and ITC up to 1.5MW
From these two figures it can be seen that the use of compressors with inverter technology leads to an increase in the efficiency of chillers especially at partial loads with a consequent reduction in power consumption. This is especially true for models fitted with Turbocor compressors. Also you can see a higher EER for the water cooled chillers in comparison of aircooled chillers due to the lower condensing temperature and the absence of energy consumption by the fans mounted in the air-cooled models.
inverters, and chillers that have Turbocor compressors, Hitema also offer the use of inverters applicable to the standard axial fans. To control the volume of air circulated through the condenser in the air cooled chillers simple fan speed regulators to cut the phase applied to the fan motor are currently widely used. With this method, it is possible to decrease the rotation of the motor intervening directly on the supply voltage. However, with the use of inverters, which modulate the frequency from 20 to 50 Hz it is possible to reduce steadily the air flow and achieve improved condensing control.
For chillers with screw compressors installed with inverter control and variable Vi compressors, the increase achieved in ESEER is around 14% for air cooled chillers and 17% for water cooled chillers. For chillers with Turbocor compressors and EC condenser fans, compared with chillers that have fitted standard screw compressors without inverter and AC fans, the increase achieved in ESEER is around 36% for air cooled chillers and 63% for water cooled chillers. If we compare chillers with inverter driven screw compressors and chillers with Turbocor compressors, the increase achieved in ESEER is around 20% for air cooled chillers and 40% for water cooled chillers.
Axial Fans for Condenser with inverter
To reduce the yield gap that exists between the chillers that have screw compressors, with or without
Benefits obtained by the use of frequency variation with respect to voltage variation are the following: • Lower energy consumption For low-medium speed (rpm) the frequency variation allows reduced power consumption. However the motor efficiency is completely utilized with all cooling load. A cut phase adjustable fan-motor has an efficiency ratio between 72−74% whereas the same motor with frequency driver has a performance ratio of 80%.
installed with fans operating from a variable frequency drive, significant noise reductions up to 6 dBA for the same chiller unit are possible (ISO3744). Hitema also uses another innovative application around the air fans, by the use of a special diffuser on top of the fans, that allows: • Energy Saving of 22%. • Noise reduction of 6 dB(A).
Centrifugal process pump (2-4 poles) with Inverter
Hitema has continued the use of inverters to their circulating pumps in order to obtain a non-dissipative regulation of power with variation of the pump speed, depending on the heat load required. Agin we obtain significant results in energy savings as you trace the actual load energy requirements without any effect on the process. To understand how the nondissipative adjustment is able to
The intersection of the characteristic operating range for centrifugal pump with the typical flow-pressure curve can be used to identify the point of working regime (point A for 100% of load). If the load in the system requires a flow of 75% of the maximum by the regulation by the classic choke valve installed after the pump then an additional pressure drop is artificially introduces and the system must overcame a higher pressure drop (kPa or m.w.c.) than is actually required by load (point B). Furthermore by moving the operating flow point, the pump efficiency is also changed, which then introduces a further efficiency loss. By adjusting inverter frequency instead, it follows the real load demand by altering the pump curve. (Figure 8). Varying the speed of the pump changes its actual operating curve, which will move vertically downwards and thus we reach into the new operating point (point C) without any adjustment valve introduction. This results in a real energy saving of 30%. The process pumps when installed with an inverter can effectively have zero starting current if the water flow can be gradually increased up to the maximum
• Reduced noise levels This is a key point when using axial fans for refrigeration in the air conditioning sector, as air cooled chillers are widely used in residential applications; when
Figure 7 - Operating curve of a centrifugal pump. Plastics & Rubber Review | March-April 2015 | 47
Figure 8 - Operating curve with speed pump variation.
New ECWH SERIES from 260 to 1500 KW
New AHW SERIES from 260 to 1560 kW
flow, which again avoids potential water hammer. The correct management of the inverter location completes the full system optimization.
Conclusion
Today there are many applications that require effective and innovative solutions to reduce the absorbed power requirements of the refrigeration hardware in process cooling industries, commercial air conditioning and data centres facilities. The optimum operation of the refrigeration equipment at partial loads is especially significant when average annual ambient air temperatures are between +5°C and +20°C, typical for the vast majority of European countries. For even lower ambient temperatures, the combination of inverter technology coupled with that of free-cooling, whereby chilled water can be produce by using fan energy only, can also be effectively used to produce chiller units with even greater efficiencies than previously considered possible. 48 | March-April 2015 | Plastics & Rubber Review
Figure 9 – Electrical panel for Big Evolution chillers product by Hitema
For more information, please contact:
HITEMA SRL Via Mons. G. Babolin 14, Z.I. San Gabriele 35024 Bovolenta (Padua) Tel. 049 5386344 R.a. 12 linee, Fax. 049 5386300, info@hitema.it, www.hitema.it
CHINAPLAS, Shanghai, 20-23 May 2015
EREMA: Live Demonstration of the TVEplus® technology for heavily printed materials years of innovations from With over 30 years of success, more than 4,000 systems in operation throughout the world and a notable list of references, EREMA has been regarded as the global market and innovation leader in plastic recycling systems for years. In the year of the company’s 30th anniversary EREMA launched a plant system with new core technology and additional innovations at K 2013 in Düsseldorf: INTAREMA®. The groundbreaking new feature of INTAREMA® can be seen in its name which comes from INverse + TAngential + eREMA® and is based on the newly developed and globally patented Counter Current technology. The result of this innovation: INTAREMA® brings together in an unparalleled way top productivity, flexibility and extremely easy operation with considerably lower energy consumption. EREMA technologies are regarded as the leading global standard for a wide variety of recycling jobs in the applications inhouse recycling of production waste
EREMA’s focus at Chinaplas 2015 will be on its top-selling hit, the new INTAREMA® generation of systems featuring the core technology Counter Current. The global market leader in plastics recycling system engineering has already been able to sell 150 new systems worldwide after only a year since sales began in 2013. As the trend is continuing in Asia, too, EREMA will present an INTAREMA® 1007 TVEplus® system with an EREMA melt filter SW4/104 RTF as an exhibit at Chinaplas 2015 (Booth No. 9.2A41) from 20 to 23 May 2015. The system with a throughput of 300-350 kg/h will live demonstrate the high efficient recycling of heavily printed LDPE materials.
and severely contaminated post consumer waste.
ounter urrent technology sets new standards With the patented Counter Current system EREMA sets another milestone in plastic recycling system engineering. The innovation takes place in the interface area of the cutter/compactor and extruder. To date the worldwide technical standard has been a system in which the material in the cutter/ compactor moved in the direction of the extruder. The difference with the Counter Current system is that the material spout in the cutter/ compactor is now reversed and thus moves against the direction of the extruder. The result of this inverse-tangential configuration is increased process stability and, at the same time, considerably higher throughput. With this new innovation EREMA confirms once again its position as global market leader in plastic recycling systems.
ngineering ecycling aschinen und nlagen es.m. .H. is the world s mar et leader in the development and production of plastics recycling systems and components of the finest quality. he company is headquartered in nsfelden near in in ustria. ver national representatives and the su sidiaries ensure that our customers throughout the world can rely on service relia ility and support. acts and figures - nnual group turnover million - patent families granted worldwide - employees in total in the group produce several hundred systems each year ver systems around the glo e now produce more than million tonnes of plastic pellets every year. is an international pioneer and one of the most innovative companies in the plastics recycling industry. eview ince it was founded in has never stopped developing. any ground rea ing inventions and patents in the field of plastics recycling together with permanent growth and entering new mar ets spea for themselves. Plastics & Rubber Review | March-April 2015 | 49
Went down well – BOY at Plastindia 2015 The Procan ALPHA ® 2 control is supported through its modern “smart” operability. Well-arranged screen pages with less text and memorable symbols allow a fast and intuitive handling via a multitouch display. Like with modern communication devices, operating strategies like scrolling of screen pages or page changes by wiping are available. The machine manual, which is integrated in the control, has made browsing much easier.
- eries goes down well increasingly in India
T
he organizer of Plastindia wasn’t the only one to make a big step forward with the new fair grounds in Ahmedabad. Even BOY impressed the visitors with its technical solutions. In previous years, “cheap injection moulding machines” were demanded almost exclusively. Today, technique is more and more in the foreground. “We were surprised by the high number of visitors during PLASTINDIA”. This is the exhibition conclusion. “BOY has had a very good reputation in India for many years. Numerous customers who have used BOY injection moulding machines for years, have been further impressed just like our new promising business partners.” BOY 35 E – predestined for technical mouldings As one of few exhibitors from Germany, the specialist for injection moulding machines with clamping forces up to 1.000 kN demonstrated its BOY 35 E (350 kN clamping force). It was surrounded by visitors nearly all the time. (Picture: BOY booth) S. Sunderam, Managing Partner from the Indian distributor Karan Engineering Co., was very satisfied with the high number and quality of conversations in the BOY booth. The BOY 35 E, a four-tie bar machine with a two-platen clamping unit and swivel-out injection unit, is the most compact machine in its range (1,9 m² footprint). Its cost/ performance ratio is unbeatable. Due to the efficient and torsion resistant clamping system and the high capability of the injection unit, this injection moulding machine is particularly suitable for the production of close tolerance precision parts.
50 | March-April 2015 | Plastics & Rubber Review
With its E-Series, BOY responds to the ever-expanding demands for precise and efficient injection moulding machines. Equipped with a servo-motor pump drive and optionally available EconPlast plasticizing technology, BOY has set standards in terms of machine efficiency. Supplemented with costefficient automation equipment, which is adapted to each application, a compact production system is available. This was a common subject in many conversations that the Indian BOY distributor had during the six day exhibition. “We are more than satisfied with the course of the exhibition and the
contacts. Especially in the processing of elastomer and silicone, BOY has had a good reputation in India for many years. More and more of our Indian customers count on the flexibility and the advantages of the E-Series“, says Michael Kleinebrahm, BOY Manager Process Engineering. Concerning Plastindia, he states, “the exhibition at the new fair grounds and particularly the hall with the European machine manufacturers was well-attended just like the previous exhibitions in Mumbai or Delhi.“ Company profile Dr. Boy GmbH & Co. KG is one of the leading worldwide manufacturers of injection moulding machines with clamping forces up to 1,000 kN. The very compact, durable machines work precise, energy-saving and therefore highly economical. BOY continually sets new standards in our industry with innovative concepts and solutions. Since the company was founded in 1968, over 40,000 injection moulding machines have been delivered worldwide. The privately owned company continues to put special emphasis on engineered performance and high-class “made in Germany” workmanship.
SUSTAINABLE INNOVATION
Rajiv Plastics Brings New OMFI launches the first BioBased TPE suspension for bed slats Additive Masterbatches to CHINAPLAS 2015 Rajiv Plastics Limited will participate in CHINAPLAS 2015, the 29th International Exhibition on Plastics and Rubber Industries, which will be held on May 20-23, 2015 at China Import & Export Fair Complex, Pazhou, Guangzhou, PR China.
O
MFI srl, run by Pietro
Bio-based MEGOL BIO which was
from the selection of raw materials
Frigerio, is a company
developed by API Spa.
used in production until its full and
of excellence in high
technology plastic injection molding. The company has recently designed and created an innovative “green” alternative in bed slat suspensions.
Not only is this innovative suspension 100% recyclable thanks
The MEGOL BIO family of
to its being made of thermoplastic
compounds is based on raw materials
resin of the TPE-SEBS family, but
from renewable sources and
it also maintains a series of technical
vegetable crops thus contributing to
Founded over 40 years ago by Isaia
and functional advantages such as
Frigerio and still run by the Frigerio
resistance to aging and good and
family, OMFI srl has distinguished
constant elastic qualities.
itself within the Italian context with its great expertise both in designing molds and producing technical articles of quality particularly for the home furnishing industry. Always attentive to quality and innovation, with the strength of decades-long experience in molding technical articles, OMFI srl has developed and produced the first suspension for bed slats produced in Bioplastics using the new TPE
final disposal.
In addition, the MEGOL BIO used contains up to 25% of renewable resources which is of clear benefit to the environment.
the reduction of CO2 emissions and greenhouse gases, the saving of fossil resources and the efficient use of agricultural resources. This project confirms OMFI srl’s historical orientation towards innovation that since 1963 has designed and manufactured
This factor results in a benefit that
technologically advanced solutions
can be measured by the Life Cycle
and this further strengthens the
Assessment (LCA) according to
partnership between OMFI srl and
the ISO 14040-14044 standards,
API Spa in finding solutions with a
a method that analyzes the
low environmental impact.
environmental impact of a product throughout its entire life cycle, right
For more information: www.omfi.it
Rajiv Plastics Limited has recently launched the following Additive Masterbatches – 1) Freshness Plus & Agri Fresh Masterbatches for enhanced shelf life of fruits and vegetables (Blown Film) 2) Photo-Oxo Biodegradable Masterbatches for Blown Film 3) Anti-Rodent Masterbatches for Pipes, Wire & Cable Industry 4) VCI (Anti Corrosive) Masterbatches for Blown Film 5) Anti-Microbial Masterbatches for all polymers Established in 1978, Rajiv Plastics Limited is one of Asia’s leading Masterbatch manufacturers with the capability of manufacturing color and additive masterbatches for over 32 different polymers. The company has 2 manufacturing locations and serves more than 1500 customers in more than 55 different countries. 40% of their business is exports. Rajiv is a Government of India registered Export House and Export Award Winner. For more information on their products and services, please contact Rajiv Plastics Limited A-9 Nand Bhuvan Indl. Est.,Mahakali Caves Road, Andheri East,Mumbai – 400093, India. Phone: +91-22-66929701 Fax: + 91-22-66929705 E-Mail: info@rajivplastics.com Web: www.rajivplastics.com
Plastics & Rubber Review | March-April 2015 | 51
SHOW REPORT - interplastica and UPAKOVKA/UPAK ITALIA,
Crisis does not deter international suppliers to the Russian market Both Moscow trade shows, interplastica and UPAKOVKA/UPAK ITALIA, record steady visitor flow
were regular visitors, there were also numerous company representatives, who attended the fairs because they expected the current market changes to improve their sales opportunities. About 950 exhibitors from 35 countries presented their products at Moscow’s EXPOCENTRE in Krasnaya Presnya.
W
hile Russia’s weak rouble, the dramatically declining oil prices and the challenging political situation are affecting the Russian market for plastics, rubber, packaging and process technology, business has by no means come to a grinding halt. Russia and its neighbours still have a substantial demand for investment and an unbroken interest in advanced machinery, production and process technology and high-tech materials. The domestic consumer goods and packaging industry is under pressure to improve its competitive edge so as to substitute the decline in imports. Hence, business owners and industrialists are keen to find out more about innovative technologies and maintain or establish business contacts with suppliers, even if business projects cannot be rolled out immediately. Accordingly, there was a keen interest in the two major trade fairs for plastics and rubber, processing, packaging and printing, interplastica and UPAKOVKA/UPAK ITALIA 2015. Between 27 January and 30 January 2015, some 19,000 visitors from Russia, CIS and neighbouring countries attended both events. While many of them 52 | March-April 2015 | Plastics & Rubber Review
“Considering the current conditions, we are very happy with these results,“ Werner Matthias Dornscheidt, Chairman and CEO of Messe Düsseldorf stated. “The fact that so many international exhibitors attended the interplastica and UPAKOVKA/UPAK ITALIA trade shows speaks of great confidence in the Russian market. And their commitment was rewarded by an unexpectedly high number of visitors. This success confirms the significance of both events for their respective industries. In times of challenging political conditions and difficult business relationships, we hosted two major trade shows to ensure that business relations will remain unaffected.” Messe Düsseldorf and its subsidiary Messe Düsseldorf Moskau OOO co-host both trade shows. UPAKOVKA/ UPAK ITALIA is hosted in cooperation with the Italian organiser Centrexpo. Visitors used the four-day event to gather comprehensive information on the current range of international products. They unanimously provided positive feedback on the
undeterred attendance of global businesses. In turn, exhibitors were delighted by the keen interest of the trade show visitors who did not seem discouraged by the fact that many Russian businesses are currently dealing with major challenges. Project financing was identified as one of the most detrimental challenges, particularly for mediumsized and small companies. Despite the drop in orders, Germany has not lost its rank as the most important supplier to the Russian plastics and rubber processing market by far and has retained a market share of 35.5%, followed by China with 14.9% and Italy with 14.7% (2013). The current figures reflect the challenging situation facing the Russian consumer industries: over the first eleven months of 2014, Germany sold plastics and rubber machines worth EUR 141.9 million, down 30.7% on the previous year’s results. In 2013, the global export of plastics and rubber machines to Russia only dropped by 4.7 % compared to the previous year, totalling EUR 615.7 million. Bernd Nötel from the VDMA Association for Plastics and Rubber Machinery knows that the Russian market is and remains to be important for German machine manufacturers: “Experts are convinced that Russia’s per-capita consumption of plastics products will rise steadily over the next few
years. This is a major opportunity for suppliers of highend processing machines. Investments are planned and necessary, but many projects have been delayed because of the financial uncertainties resulting from the fast-changing exchange rate. However, German suppliers are well aware of the importance of their commitment at this particular point in time and they are willing to attend interplastica in order to personally present new products and maintain good customer relations in these difficult times. Both sides would like to see more diplomatic efforts to defuse the current political conflict and they are unwilling to jeopardize the traditionally good relations between German companies and Russian business partners. Russia still needs to enhance its value-added chain. The raw material processing segment has seen first developments, all be it at a low level.“ Mario Maggiani, CEO of Assocomaplast, the Association of Italian Machine Manufacturers confirms the essential importance of the Russian market. “Despite the fact that our exports to Russia have dropped by about one fifth, Russia is and remains to be one of the five most important markets for Italian manufacturers of plastics and rubber machinery. Even though we must anticipate similar results in 2015, none of the Italian companies active in this market intends to withdraw from it. The market has major long-term potential. The current problems are caused by the weak rouble and the massive interest on borrowings for those few companies that were fortunate enough to qualify for loans in the first place.“ Among the Italian
exhibitors at interplastica were many companies with long-standing business relations in Russia, and they are keen to maintain their personal contacts, which still play a major role in the Russian business world. Also attending the event were many visitors from other CIS nations such as Armenia, Kazakhstan, Belarus, Ukraine and Uzbekistan. The wide range of international products and services presented by the exhibitors was enhanced by a support programme that met with a keen interest from visitors of the interplastica 2015. Complementary presentations and discussions with a focus on plastics recycling and bioplastics were hosted at Polimer Plaza in Hall 1. In addition to this, open seminars for exhibitors provided insights into current developments in raw material production and application. Exhibitors’ comments on interplastica 2015:
ntonio appadona eneral irector of r urg s representation ranstechni a-
osto
oscow ussia
We have been active in the Russian market for many years and we have dealt with our share of crises. At present, investment is at a minimum and this caused a 50% drop in our business volume in 2014 compared with the previous years. We sincerely hope that the situation will improve because many projects are currently on hold. Eventually, this investment lag will come to an end. The automotive segment has been affected particularly badly. Food and beverage is doing a bit better, as there are many international companies with representatives in Russia. These days, our customer service representatives are particularly busy.
udith Hic s enior usiness ommunication anager ow urope m H Hor en wit erland We want to emphasize our commitment to the Russian market especially in these hard times. Our company has been active in this market for more than forty years and we have experienced many ups
Plastics & Rubber Review | March-April 2015 | 53
and downs. Most of our customers are working in the food industry and in industrial packaging. By helping them to grow, we increase our share in this market. At our exhibition stand, we provided information on numerous subjects with activities such as “Pack Talk“ and received very positive feedback. Our two meeting rooms were occupied at all times. Most of our visitors were from Russia, mostly from Moscow and its vicinity, but we also welcomed customers from neighbouring countries such as Kazakhstan or Poland. For the first time, we also operated a small stand at the UPAKOVKA/UPAK ITALIA, in order to target customers from the packaging segment.
am i ir arimi ommercial anager ene o. . . . ehran Iran
am olypropyl-
Business relation between Russia and Iran are growing with institutions such as the Iran-Russia Joint Chamber of Commerce becoming an increasingly important platform for information exchange, mutual consultancy, initiation of partnerships, networking and marketing activities. Our participation in the interplastica, the most important trade show for plastics and rubber in Russia, is also an important part of our promotion strategy for our products. We offer high-tech materials for applications in the fibre, automotive, domestic goods and other industries. This is a good time for Iranian companies to step up their business activities in Russia. An easing of customs restrictions and the direct route of transport across the Caspian Sea are also beneficial. We are very happy with the feedback we received at this trade show and with the high number of specialists who visited our stand. We welcomed guests from all over Russia, Armenia, Turkey, the Ukraine, Uzbekistan and Belarus and had many interesting meetings.
einhard lting ales irector astern urope indm ller 54 | March-April 2015 | Plastics & Rubber Review
H lscher engerich ermany Many customers attend this trade show even if they can’t acquire any products at the moment. The current situation is really far from rosy, but there is still some satisfying business to conduct with customers that still have financial options to draw on. The weak currency is a major drawback, particularly because some customers are now running into difficulties covering their debts. There are leasing companies, which are now offering financial restructuring measures for customers to alleviate the most pressing problems. We also offer safe financing models to our longstanding business partners. Many customers from the packaging segment have told us about their dilemma: while they have an urgent need for more capacities and wish to
extend them, they have no feasible borrowing options. Although we would like to see swift improvements in this situation, we remain sceptical, as we are dealing with a political problem and not with a purely economic crisis. The next interplastica will take place from 26 until 29 January 2016 in Moscow, again in tandem with UPAKOVKA/UPAK ITALIA. For more information, please visit www.interplastica.de or contact Messe Düsseldorf GmbH, Hannes Niemann, Phone +49-211.4560.7768, Email: NiemannH@messe-duesseldorf.de, and Claudia Wolfgram, Phone +49211.4560.7712, Email WolfgramC@ messe-duesseldorf.de
Y
Government of India RNI Regn. No. DELENG/2013/56469