Plastics & Rubber Review (November-December 2014) by Worldwide Publications

Business & Shopping... Dubai calls you... Dubai Shopping Festival to add excitement to ARABPLAST 2015 ARAB PLAST 2015 GETS BIGGER AND BETTER.....

Now is the time to............ • expand the borders of your business…… • push your sales….. • build your brand image …. • showcase your products & services ….. • mark your 2015 calendar….. Unveiling the LARGEST plastics, petrochemicals and rubber industry trade show in MENA region – ARABPLAST 2015 ARABPLAST 2015- the FASTEST way to enter the vast

MENA region’s plastics, petrochemicals and rubber industry. ArabPlast 2015 is envisioned to make better business sense to the participants who are giving shape to a better world. The captains of the plastics and rubber industry would be here to unveil products solutions, cutting-edge technology, and revolutionary innovations and forge international alliances. Yes, it’s an event that would provide a greater leverage to international exhibitors and trade visitors with decisionmaking authority. Seize this opportunity as a manufacturer or service provider at ArabPlast 2015. It’s the perfect venue to showcase your products and innovations, develop contacts and sign profitable partnerships.

‘A Million Reasons To Shop’ during 20th anniversary of Dubai Shopping Festival • Latest campaign to offer a total of One Million Dirhams in prizes • Promotion to run from January 1st to February 1st , 2015 • Shoppers who spend AED 200 and above at any of the participating malls stand a chance to win prizes in cash and shopping vouchers instantly In celebration of the milestone 20th Anniversary of Dubai Shopping Festival, the Dubai Festivals and Retail Establishment (DFRE) and the Dubai Shopping Malls Group (DSMG) have announced the ‘A Million Reasons To Shop’ promotion, offering shoppers, who spend a minimum of AED 200 the chance to win up to AED 1 million in prizes, from January 1st to February 1st. The One Million Dirhams being given away in the ‘A Million Reasons To Shop’ promotion, will be in the form of cash prizes and shopping vouchers, providing residents and visitors another incentive to celebrate during the shopping extravaganza. The campaign will have raffle draws taking place on January 9th, 16th, 23rd and February 1st. It will also see AED 20,000 in cash awarded to 5 winners each week and a Mega Bumper Cash Prize worth AED 100,000 won by one person every week.

Vol.2 No.6 | November-December 2014 | New Delhi, India

ANNUAL SUBSCRIPTION: INDIA: RS.2000 | OVERSEAS: US$150

PRR wishes a very happy new year to its readers!

I n T h e P a g e s 4 6 8 12 16 18 22 23 27 30 32 40 42 46 47 50 53

HITEMA - Improved energy efficiency of air cooled chillers PLAST INDIA 2015: THE “LIGHT DUTY LINE” SERIES RIGID FILM EXTRUSION LINE Arburg at the Arabplast 2015 in Dubai New Perspectives For In-Line Thermoforming Technolgies The interplastica and UPAKOVKA / UPAK ITALIA K 2016 invites exhibitors from all over the world Plastika Skaza and Cablex Plastik win “Golden and Bronze Gazelle 2014” BOY strikes a new path in India Smallest BOY insert moulding machine in big Russia Laser melting with metals in Aircraft manufacturing New methods for process-oriented design of additive components CHINAPLAS: High booth booking rate reflects the optimism of industry outlook Micro-drip irrigation tube – Rapid Rupture Response Euromold moves to Düsseldorf Metal caps, the global players meet up in Sacmi Versatile & Functional Solution for Complex Packaging Applications

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 | November-December 2014 | 3

Improved energy efficiency of air cooled chillers 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.

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 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. 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.

New ENR/ENRF SERIES from 1 to 480 kW

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

International business

Hitema is a leading manufacturer of highly customized refrigeration units. The company’s global presence has ensured the development of a technologically advanced, efficient, economical and environmentally friendly product range. Figure 9 illustrates how Hitema is widely present in the international market. Today there are many applications

4 | November-December 2014 | Plastics & Rubber Review

New SBS/SBSF SERIES from 240 to 1000 kW

Big Evolution Chiller SERIES EET and ITC up to 1.5MW

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. Improved energy efficiency of air cooled chillers HITEMA

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. The 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 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 ECWH SERIES from 260 to 1500 kW

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. International business

product range. Figure 9 illustrates how Hitema is widely present in the international market. 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. v

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,

AHA SERIES with turbocor compressors from 245 to 1140 kW Plastics & Rubber Review | November-December 2014 | 5

PLAST INDIA 2015: The Biggest Business Opportunity of 2015 Opens its Doors Plastindia Foundation, the apex body for plastics in India and the federation of the most significant plastics industry bodies from the Indian subcontinent has formally announced the next edition of the Plastindia Exhibition to be held from 5-10 February 2015 (PI 2015) with the rousing tagline of ‘Expanding Horizons’.

eld every three years, the Plastindia exhibitions have acquired the stature of a huge global platform. They are arguably the most significant Plastics related events that showcase the opportunities in developing nations and therefore the future of plastics. This simply massive exhibition will showcase the latest in technology, innovation, processes, products, responsible plastics management, recycling and a whole host of related aspects of plastics. In its 9th edition, Plastindia 2015 will be the biggest one till date and is expected to consolidate its position as one of the largest pure Plastics exhibitions on the global plastics scene. Expected to bring together about 150,000 business visitors and 2000 top class exhibitors from across 40 nations at a showcase extending across 125,000 sq. mts, this will truly be a staggering platform and opportunity for Indian plastics. Not just the main exhibition itself, there will be a stunning bouquet of associated offerings that make Plastindia exhibitions a ‘must not miss’ affair for global plastics honchos. PI 2015 will also host the 4th PROPLAST Exhibition, which shows off the ever enhancing global standard capabilities of India’s plastics processing fraternity and is a magnet for OEMs and retail chains. Also being held concurrently would be the 9th International Conference on Plastics, the 24th ASEAN Plastics Forum, the 6th Plasticon Awards, the Wiintech Technology Transfer initiative as well as numerous B2B meets on investment, finance, knowledge sharing etc. Describing PI 2015 as the largest single business opportunity of 2015, Mr. Subhash Kadakia, President Plastindia Foundation said that the exhibition would significantly expand the business horizons of all those who participate, regardless of their origin and business

6 | November-December 2014 | Plastics & Rubber Review

size, due to the sheer volume of opportunity that it would showcase and the quantum of learnings that would be available to one and all. All in all, PI 2015 promises opportunities for growth and success to anyone associated with or willing to associate with the wonderful world of plastics. India - Poised to become the next Global Hub for Plastics

Backed by a huge workforce of economical yet skilled manpower; a high emphasis on quality as well as value for money; and a favourable regulatory environment, India’s plastic processing sector is surging. The industry has surplus processing capability to cater to more business and is constantly upgrading itself on technology and automization front to keep pace with the developed nations. The intent is simple - to become one of the world’s preferred processing hubs over next few years. India is welcoming, ready and waiting. Exhibitors and visitors from over 40 countries across the globe to attend PLASTINDIA 2015

INDIA - The globe’s most lucrative business destination is growing bigger by the day. Plastics – as the key material for man’s progress today – will be a key beneficiary of this tremendous growth surge. PLASTINDIA 2015 will be the gateway to this profusion of unlimited possibilities. Companies from every corner of the globe will gather to convert opportunities to business reality.

INDIA - THE KEY DRIVER FOR THE FUTURE

• India’s Per capita GDP set to double by 2020 • India’s household income to almost triple by 2020 • At present, India’s total merchandise trade is US $ 792 Bn - more than 50% of GDP • A productive and growing work force of 467 million people; expected to add 100 million more by 2020 • India has a surging, upwardly mobile, middle class of 400 million people; 60% of which is under 35 years of age • A productive and growing work force of 467 million people; expected to add 100 million more by 2020 • India has a surging, upwardly mobile, middle class of 400 million people; 60% of which is under 35 years of age • India has a surging, upwardly mobile, middle class of 400 million people; 60% of which is under 35 years of age • A productive and growing work force of 467 million people; expected to add 100 million more by 2020 • India has a surging, upwardly mobile, middle class of 400 million people; 60% of which is under 35 years of age • India’s plastics processing industry will deploy more than 180,000 machines by 2020 from the current 110,000 – to cater to booming demands For more information, please contact: PlastIndia Foundation 401, Landmark B, Suren Road, Off Andheri Kurla Road, Andheri (East), Mumbai -400093, India. Tel:+91-22 26832911 – 14 Fax: +91-22-26845861

BANDERA SHOWS IN PREVIEW THE NEW 2015 REVISED AND AUTOMATED VERSION OF

THE “LIGHT DUTY LINE” SERIES RIGID FILM EXTRUSION LINE

he “Light Duty Line” series new extrusion line will be shown at the new Bandera R&D facility in the historic Busto Arsizio factory. This extrusion line, sized for an output of 700 Kg/h PET rigid film, with a net width of 1100 mm, was recently acquired by an important thermoforming company operating in the Middle East. The main components of this rigid film extrusion line are:

- - - - - - - - -

“Loss in weight” gravimetric dosing system Main, co-rotating twin screw extruder, 2C 70mm 52 L/D, with efficient venting system Superfiltration screen changer with filtering plates automatic cleaning system Single screw co-extruder, TR 65 mm 35 L/D Single channel flat die with external deckles Rigid film thickness control system In-line silicone unit complete with drying system 4-position manual winding system complete with accumulator Centralized control system

8 | November-December 2014 | Plastics & Rubber Review

The numerous benefits of the “light duty line” are :

- - - -

Maximum flexibility in processing various types of raw materials Quick delivery timing thanks to its modular design Extremely compact line ensuring a quick installation process Possibility of easy in-line placement with thermoforming machines.

Application area of the NORPLAST® PUR 385 SE AS extended

Flame retardant and anti-static The more abrasion-resistant and anti-static NORPLAST® PUR 385 SE AS suction and transport hose (NORRES Schlauchtechnik) now has enhanced hose properties.

he NORPLAST® PUR 385 SE AS convinces through its improved and enhanced product properties: The leading NORPLAST® manufacturer NORRES has now made the NORPLAST® PUR 385 SE AS flame retardant in accordance with DIN 4102-B1. With this innovation NORRES has expanded the areas of application for customers of its all-plastic range of these tried and tested hoses. Its permanently anti-static walls with a surface resistance < 109 Ω makes it optimally suited to the transport of abrasive solids such as dusts, powder, fibre, chips and granulate. It has highly distinguished itself in application in dedusting and suction plants, industrial 10 | November-December 2014 | Plastics & Rubber Review

vacuum cleaners as well as in the suction of paper and textile fibres. The walls exhibit approx 2.5 to 5 times better wear resistance than the majority of rubber materials and in addition is approx. 3 to 4 times more abrasion resistant than most soft PVC. Also the NORPLAST® PUR 385 SE AS is gas and liquid-tight – a property that makes it suitable for transporting gaseous media.

The hose is especially suitable for external uses through its good UV and ozone resistance. The NORPLAST® PUR 385 SE AS, in lightweight design, is smooth and highly abrasion resistant inside and can be deployed in a temperature range from about -20 °C to approx. +70 °C. At the same time it has good resistance to chemicals. In daily use the hose is flexible and demonstrates the smallest bending radii. v

Arburg at the Arabplast 2015 in Dubai • Presentation of the product and service range • Focus on individual consulting • Best local support from Arburg subsidiary and Alldrive high-performance machine series. These machines combine high productivity with reduced energy consumption and are characterised by a wellbalanced combination of distance between tie-bars, clamping force and opening stroke. Moreover, they provide fast, precise, energysaving mould movements (through servo-electric toggle-type clamping units), high plasticising flow rate (through barrier screws and servoelectric dosage drives), dynamic position-regulated screws and effective injection volume flows. Medical technology concepts for all requirements “The transfer of knowledge plays a very important role,” says subsidiary manager Joachim Branz (2nd from right). Arburg therefore holds on-site seminars and training courses, e.g. at the “Higher Institute for Plastics Fabrication” (HIPF) in Riad, Saudi Arabia.

Arburg will be exhibiting at the Arabplast in Dubai from 10 to 13 January 2015. At exhibition stand 5C124 in Hall 5, trade visitors will have the opportunity to find out all about the range of Arburg products and services and receive individual consulting from the Arburg experts.

Arburg

has been represented with its own subsidiary in the United Arab Emirates since 2009. Customers in the Arabian countries receive intensive support from the Ras Al Khaimah site. “We offer them both a comprehensive on-site pre and aftersales service as well as application technology consulting on all areas of injection moulding,” explains the subsidiary’s Managing Director Joachim Branz. “With our hightech modular hydraulic, hybrid and electric injection moulding machines, we are ideally positioned to implement customised injection moulding solutions and to fully meet the high demands of the Arabian market. For the dominant packaging and medical technology industries we offer specially equipped machines, for example. This is complemented by specific productions cells. Responsibility for each turnkey solution, in which upstream and downstream steps can be integrated, rests completely with Arburg – from consulting and planning through to implementation and commissioning.” "Packaging" version: high performance and speed

For the packaging industry, the Arburg range includes a “Packaging” (P) version of the hybrid and electric Hidrive 12 | November-December 2014 | Plastics & Rubber Review

In the field of medical technology, the requirements set by the OEMs and users must be precisely met. Thanks to the modular product range from Arburg, production solutions can be configured, which are very precisely adapted to the production requirements of the customers. The equipment options range from a stainless steel clamping unit, clean room modules with air ionisation through to the clamping unit and corrosion-

resistant, coated mounting platens. A variety of clean room concepts can also be implemented. These extend from machines and production cells with modular clean room equipment, which are docked to a clean room, through to injection moulding solutions which are fully contained in the clean room. Consulting at the Arabplast

At the Arabplast 2015, the focus will be on individual customer consulting. “This is not limited to the machine and application technology, but also includes the overarching topic of production efficiency,” explains Joachim Branz. “This is because, in order to achieve cost-effective moulded part production, the entire valueadded chain must also be taken into account.” In this context, he also mentions the know-how of the employees, which should be invested in on an ongoing basis. For this purpose, Arburg offers comprehensive training offerings, including individually tailored courses on the customers’ premises.

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 developed in-house was added to the plastic processing range in 2013. In keeping with its motto “Arburg for efficient injection moulding”, 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 optimal 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.

A R A B P L A S T | 2 0 1 5 | F E A T U R E

4D119/ Booth 5 ST 201 A L P B A AR

TOMRA SORTING HIGHLIGHTS COMMERCIAL OPPORTUNITIES IN POLYMER RECYCLING

Stand: Hall 5 - Stand 5C1113

EGE PROSES has been the leading company in the EPS machinery manufacturing industry in Turkey and has been meeting all expectations and requirements of customers by providing tailor-made services at a holistic level. EGE PROSES which was established in 1992, completed its first 10 years only with process engineering and as of 2002, completed its 12st year in manufacturing of EPS machinery with its two juxtaposed factories under a single roof in İzmir, Aegean Region with its motto; “Engineered for better quality EPS products” and “Our EPS Process background indicates our power” and it completed its 22nd year in engineering, contracting and process works. EGE PROSES family produces all EPS machinery and equipment under its own roof with its stuff as a community of businesses which • Produces machinery and moulds for EPS packaging and building & insulation sector • Establishes Turn-key facilities and EPS plants all over the world • Renders engineering service in this field • Provides EPS resin and consultancy service for its customers. These services and products of EGE PROSES are the highest quality and yield a profit for customers under the most appropriate conditions, make business productive and environment-friendly. These EPS main machinery and equipment can be listed (but not limited) as follows • Pre-Expander Machine ( Batch / Continuous ) • Block Moulding Machine ( Vertical / Vacuumed / Movable Wall ) • Shape Moulding ( Fast Change Mould System, Servo Geared ) • Centralised Vacuum Unit • Steam Accumulator • Aging Silos ( Full Automated ) • Continuous Sheet Cutting Line • Compact Block Cutting Machine • Recycling System ( Mixing/Crushing/De-Dusting ) • Aluminium Mould for all kind of EPS applications • Pneumatic Feeding Guns For more information www.egeproses.com 14 | November-December 2014 | Plastics & Rubber Review

International recycling specialists, TOMRA Sorting Recycling, will be exhibiting at Arabplast - the largest plastics, petrochemicals and rubber industry trade show in MENA region (10 – 13 January 2015, Dubai International Convention & Exhibition Centre). Experts from TOMRA Sorting Recycling will highlight the very latest innovations in sensor-based sorting technology, with a strong focus on polymer recycling including PET bottle sorting and PET flake sorting. Visitors to TOMRA’s stand (Hall 5 - Stand 5C1113) will be able to find out about the company’s industry-leading TITECH autosort technology, which enables automated separation of different types of polymers, recovering greater than ever before volumes of high quality, high purity end polymer fractions and increasing the overall recovery rate of valuable materials. Tasos Bereketidis, Regional Director Middle East and Africa at TOMRA Sorting Recycling, comments: “Arabplast provides an excellent opportunity for us to meet face to face with bottle producers and other companies within the region that are involved in the processing and manufacturing of different polymer types. Technology is advancing all the time and polymer recycling is a major growth area in the region, with many recognising the strong commercial opportunities on offer. We are delighted to be attending the event and highlighting the latest advances in sensor-based sorting technology for this material stream.” TOMRA Sorting Recycling has established a strong presence in the Middle East and the region remains a key growth area for the company, which has installed more than 4,000 sensor-based sorting machines to the waste and metal recycling industry in over 40 markets internationally. v

One Stop Solution For MACHINES

(for all sizes of PVC / PE Pipes)

New Generation High Speed Automatic Slotting Machine

Jockey Extruder

Perforating Machine

Twin Screw Barrel

Scrap Grinder

Threading Lathe Machine

Products Being Exported to: FRANCE, USA, POLAND, UAE, MADAGASCAR, MOROCCO, SAUDI ARABIA, IRAN, BANGLADESH, KENYA, TANZANIA, UGANDA, AUSTRALIA, NIGERIA, BURKINA FASO, LIBERIA, LATVIA, NAMIBIA & ZAMBIA.

New Perspectives For In-Line Thermoforming Technolgies AMUT has successfully tested and delivered to a large North American producer a completeb in-line thermoforming plant for the production of disposable cups (size required by the USA and Canadian markets).

The request of the customer presented some very demanding features: - production of disposable cups both in PS and in PP, - use of the same lid for the cups produced in PS and PP, after the rimming, assuring a perfect seal to the liquids, - same cut diameter of 94 mm but with different weight, from 9 to 16 g/ piece, for all 3 products 12 Oz -16 Oz e 22 Oz.

AMUT

has found the solution to satisfy the requirements of the customer realizing an integrated in-line machine where all the operations are in-line, automatic and continuous, from the raw material dosing unit to the packaging of the finished product, with an in-line total recovery of the thermoforming skeleton. 16 | November-December 2014 | Plastics & Rubber Review

The necessity to produce both materials with the same machine resulted in the selection of a thermoforming machine with an in-mould forming and punching technology and tilting platen: the AMP 850 GP model from the AMUT COMI range. Being one of the largest and fastest machines on the market nowadays, the AMP 850 GP assures to get high outputs, over 63.000 cups/h, and permits to assembly a mould with 33 cavities for cups with a diameter of 94 mm. The production speed achieves the 32 cycles/min. The plant is equipped with a conveying system designed to handle up to 2,3 mm thick sheet and with a heating oven optimised with a management and control

system, properly developed for the characteristics of the PS and PP materials. The performances of the mould and forming thermoregulation circuit have been bettered and powered, and the management of the thermoforming thermodynamic cycle has been as well integrated and improved with a new control system. The movement is direct, with hightorque motor of the plug assist unit. The extrusion section becomes very important because, in particular, is required a foil output of 1300 kg/h when cups of 20 Oz are in production. The line is composed by:

- feeding and dosing system of the raw materials (dosing at 4 components, one of them, the skeleton grinded material, is run in close loop); - main single screw extruder, AMUT model EA 130, complete of inscrew dosing system driven by a specific software, with a plasticizing capacity up to 1200 kg/h and a vacuum venting unit complete of water management in close loop; - single screw co-extruder AMUT model EA 75 for the external layers; - continuous screen changers and

melt gear pump unit both for the main extruder and coextruder; - feed block suitable to get foil with different layers configuration A/B, BA, A/B/A without stopping the production; - extrusion die with completely automatic regulation and control of the thicknesses; - calibration/cooling vertical calender with rolls of 1000 mm for a homogeneous and efficient cooling of the foil, even at the maximum output (without inner tensions); - gauging thickness unit and related automatic control systems of the extrusion die. The thermoforming unit achieves a speed of 40 cycles/min also with the maximum size of the mould (850 x 560 mm) and it is equipped with an advanced mechanical system of the platen movement which reduces at the minimum level the inertias and the problems related. An automated stacker unit

is provided and using vacuum to pick the product which facilitates the start-up operations and permits a continuous and great efficiency in the production as well as with items pretty heavy. The cups produced are discharged and automatically conveyed to the rimming unit that shapes the edge and calibrate accurately the outer diameter to joint perfectly together the lid. This operation is extremely difficult and needs strict quality checks in running conditions. The rimming machine is developed to treat both polymers, PS and PP, with special screws of rim: the 4 screws have an adjustable position with the possibility to change the diameter of the rim in inlet and in outlet. The plant terminates with a packaging unit: the cups can be packed in rows of 20-100 pieces, or in Twin Pack (pair rows of 50100 pieces). v

Plastics & Rubber Review | November-December 2014 | 17

Steady demand despite difficult conditions

The interplastica and UPAKOVKA / UPAK ITALIA trade fairs are expecting around 1,000 exhibitors in January 2015 in Moscow interplastica and UPAKOVKA / UPAK ITALIA 2015, the two leading Russian trade fairs for plastics and rubber and for the packaging and processing technology industry, are recording steady demand from international exhibitors. From 27 - 30 January almost 1,000 companies will present their new products and services over a net area of around 16,000 square metres.

erner Matthias Dornscheidt, Chairman and CEO of Messe Düsseldorf, takes a cautiously optimistic view of the market chances, in spite of the tense trade relations with Russia and the current economic difficulties, caused, among other things, by the weak rouble. “Even if the situation at the moment is not exactly easy, I am convinced, that the prospects for the plastics and packaging industries in the Russian market are positive in the long term. We have been organising trade fairs in Russia since 1963 and there have always been highs and lows. Past crises have shown us that those who maintain a market presence in difficult times are among the winners when business picks up again.” Messe Düsseldorf organises both trade fairs jointly with its subsidiary OOO Messe 18 | November-December 2014 | Plastics & Rubber Review

Düsseldorf Moscow and, in the case of UPAKOVKA / UPAK ITALIA, in collaboration with the Italian exhibitors’ organizer, Centrexpo. The exhibitors who have already registered for interplastica and UPAKOVKA / UPAK ITALIA come from more than 20 different nations. They include the large suppliers from the plastics and packaging industries as well as smaller specialists, regular participants and a remarkable number of new exhibitors. Suppliers from Germany, Italy and France, and also the host nation Russia, are particularly well represented at both trade fairs. Austria, Portugal, Turkey and Taiwan also have many companies exhibiting at interplastica and, for the first time ever, there is a joint contingency of Swiss exhibitors at UPAKOVKA / UPAK ITALIA. There is a good chance that once again around 20,000 trade visitors will come to Moscow for the upcoming trade fair duo. Werner M. Dornscheidt says, “Events held in Russia are benefiting from the fact that it has become more difficult for Russian experts to visit trade fairs abroad.” The topic of recycling is being particularly showcased at both trade fairs. At interplastica this is being done within the “Meeting Point Raw Materials”. In this special show with open exhibitor seminars in Hall 1, innovative developments in the production, use and recycling of raw materials will be presented. The main focus of the supporting

programme at UPAKOVKA / UPAK ITALIA is the special show “Future Forum – Trends for the Russian Market”. In this trend show, selected exhibitors will present and explain in detail their technological innovations, with a particular focus on one day on the disposal and recycling of packaging and packaging materials. Trade visitors will have the opportunity to talk directly to suppliers to discuss market needs and solutions. The hall layout at the Moscow trade fair centre EXPOCENTRE in Krasnaya Presnya will continue with the successful concept from 2014: interplastica will be held in halls 1, 3, 8 and the forum. Hall 3 will once again be the centrepiece of the heavy machinery range; here numerous innovative plants will attract interest from trade visitors. UPAKOVKA / UPAK ITALIA will once again be located in halls 2.1, 2.2 and 2.3 and will thus be in the immediate vicinity. For more details on interplastica, please contact : Mr Hannes Niemann at NiemannH@messeduesseldorf.de or Ms Claudia Wolfgram at WolfgramC@messeduesseldorf, Tel. +49 (0)211/45 60-7768 and -7712). Website: www.interplastica.de For more details on UPAKOVKA / UPAK ITALIA, please contact: Mr Thomas Franken at FrankenT@ messe-duesseldorf.de or Ms MarieLuise Schläfke at SchlaefkeM@ messe-duesseldorf. Tel. +49 (0)211/4560-7739 and-7741. Website: www.upakovka-upakitalia. de. v

Hudson-Sharp co-exhibits Starlinger at ARABPLAST 2015 at Arabplast in Dubai

t is our pleasure to announce that Hudson-Sharp will co-exhibit at Arabplast in Dubai from January 10th to January 13th, 2015. HudsonSharp welcomes and invites visitors at stand 7B 145 for a discussion about existing or future projects. Hudson-Sharp is excited to share the newest developments of the complete product lines and the latest version of Hudson-Sharp’s successful model 5750 W. This model includes several new standard and optional features designed to help customers reaching efficient production, save energy, reducing waste levels and down time of the machinery, while keeping operators away from strain injuries. For certain applications and under optimum conditions, the machine can run consistently in a production environment at cycle speeds of 450 per minute. The use of new materials for key components combined with the latest servo technology has significantly contributed to the increase in running speed. Attention has also been focused on reducing energy costs. Both the new standard airless anti-static system and servo driven wicket punches improve running costs. Downtime is reduced and production quality enhanced with HudsonSharp’s automatic seal bar cleaner. The machine can be programmed to stop at pre-programmed intervals for the seal bar to be cleaned automatically of any accumulated debris. This cleaning cycle lasts less than 12 seconds compared with minutes for a manual clean. A seal bar free of debris helps to ensure stronger seals. Hudson-Sharp also proposes different options to ease the handling of finished stacks of bags. Ranging from a simple stack processor to a robotized system for automatic boxing, solutions can be customized for individual requirements. Automation includes insertion of wicket wire, boards and grommets and insertion of finished stacks into boxes. The WASP or Wicket Automation Stack Processor has been ergonomically designed to reduce repetitive strain injuries for the machine operator. At Arabplast, Hudson-Sharp will also unveil the new generation of tools helping existing and potential customers changing over from one job to another at amazing speed rates. Do not miss the opportunity to visit our stand and learn more about our tailored offerings in upgrades and attachments. As a leader in Bag Converting Equipment, Hudson-Sharp is a member of Thiele Technologies, a global leader in cartoning and robotics, case erecting, palletizing, bagging and bag converting equipment and has its European headquarter in Brussels (Belgium). Thiele Technologies is a member of the Barry-Wehmiller family of companies. v

tarlinger leads the world market in the field of machinery and process technology for woven plastic sack production shall be participating at the upcoming ARABPLAST 2015 at the Austrian Pavilion 5G 100 & 101.

Key features of Starlinger products:

- - - - - -

the widest range of woven sack plant machinery machinery for the most comprehensive scope of processes in connection with woven sack production worldwide presence 45 years of global market experience the largest number of customers the biggest range of possible end products

The Starlinger product range covers all types of machinery for the production of modern woven polypropylene sacks. Starlinger recycling technology

Starlinger recycling technology offers a spectrum of innovative machinery solutions for the efficient recycling of a variety of plastics, such as PE, PP, PA, PS, PET, and many more. Starlinger’s Recycling Division, founded in 2000, is the company’s youngest field of endeavour. Yet thanks to entirely new recycling technologies and proven machine concepts, Starlinger’s product line recoSTAR quickly asserted its place in the market and has become a global player in the field of plastics recycling. Starlinger Group is an Austrian family-owned globally active machinery corporation. The group consists of the independent company Starlinger & Co. GmbH, and the affiliated companies Georg Sahm GmbH & Co. KG and XMesh Technology GmbH. Associated companies are SML Maschinengesellschaft mbH, Maplan GmbH, unistrap GmbH, and UNIMAS GmbH. - - -

Starlinger & Co. GmbH: complete plants for woven plastic sack production and recycling lines Georg Sahm GmbH & Co. KG: Precision winding machines XMesh Technology GmbH: Production of sealed netting. Plastics & Rubber Review | November-December 2014 | 19

Gilles Mazzolini becomes new General Manager of Sumitomo (SHI) Demag Plastics Machinery (France) S.A.S. Gilles Mazzolini, currently Head of Sales at Sumitomo (SHI) Demag France, will take over as General Manager of the Lognes-based French subsidiary of Japanese-German injection moulding company Sumitomo (SHI) Demag with effect from 1 January 2015.

azzolini (40) studied polymer engineering and marketing at Metz University and joined the former Demag Ergotech in France as sales engineer in 2008. In 2013, he took over as Head of Sales.

Effective 1 January 2015, Gilles Mazzolini will take over as General Manager of Sumitomo (SHI) Demag Plastics Machinery (France) S.A.S. from Christian Lozé, who will leave the company for his well-deserved retirement. Dr Tetsuya Okamura, CEO of Sumitomo (SHI) Demag and Senior Vice President of Sumitomo Heavy Industries (SHI) congratulated Christian Lozé on his retirement and thanked him for his services to the company. Throughout his work, Lozé was well respected and trusted by all employees. Dr Okamura expressed his gratitude for Lozé’s untiring dedication during more than twenty years with the company. Sumitomo (SHI) Demag Plastics Machinery GmbH Sumitomo (SHI) Demag has shaped the development of the plastics industry from its very beginning. As a specialist for injection moulding machines for plastics processing, Sumitomo (SHI) Demag and its Japanese parent company are leading the industry.

forces in the small to medium range. Nearly 95 % of all delivered machines are equipped with an all-electric drive concept. The Germany-based facilities in Schwaig and Wiehe specialise in the production of Systec Servo machines with hybrid drive concept and hybrid highperformance and high-speed El-Exis SP and Systec SP machines. IntElect machines with electric drives for the international market are also being produced in Germany. Sumitomo (SHI) Demag will continue operations at the former Demag facility in Ningbo/China, which came on-stream in 1998. The Chinese subsidiary of Demag Plastics Machinery (Ningbo) Co., Ltd. has been operating a local facility with a production area of 11,000 sqm since 2007. Demag Plastics Machinery (Ningbo) Co., Ltd. is planning to expand its production capacities in Ningbo

(Zhejian province). By mid-2015, the production will be stepped up from the current rate of about 650 to 1,000 injection moulding machines per year. The injection moulding portfolio is comprised of the hydraulic Systec C series with clamping forces of between 500 and 10,000 kN for the Asian market. In addition to injection moulding machines, Sumitomo (SHI) Demag offers customised and standardised systems for the part handling automation, technical and process solutions for special applications, tailored services and service concepts as well as a range of financial options to support investment in injection moulding machines. With its comprehensive sales and service network of subsidiaries and agencies, Sumitomo (SHI) Demag is present in all major markets. France.sumitomo-shi-demag.eu

The global development and production network of Sumitomo Heavy Industries and Sumitomo (SHI) Demag is comprised of four facilities in Japan, Germany and China with more than 3,000 employees. The product portfolio includes all-electric, hydraulic and hybrid injection moulding machines with clamping forces of between 180 and 20.000 kN. With more than 115,000 installed machines, Sumitomo (SHI) Demag is present in important global markets.

‘Plastics & Rubber Review’

More than 5,000 machines sold per year make Sumitomo Heavy Industries and its plastics machinery division one of the largest manufacturers of injection moulding machines in the world.

ARABPLAST 2015,

At Sumitomo’s headquarters in China, Japan, the company manufactures machines with clamping 20 | November-December 2014 | Plastics & Rubber Review

meet

at Booth 3ZB - 234 10-13 January, Dubai World Trade Centre, U.A.E.

K 2016 invites exhibitors from all over the world Registration documents available from the beginning of 2015

ot long to go now: the registration documents for the world’s premier trade fair for the plastics and rubber industry will be available from January 2015. That is when the printed exhibitor invitations will be sent out and the digital registration form can be used at www.k-online.com. For all companies wishing to participate in K 2016, the closing date for registration is 31 May 2015. Werner Matthias Dornscheidt, President and CEO of Messe Düsseldorf, and his team are looking forward to the exhibitor response: “After busy months of preparation, we are now shifting into the ‘active’ phase. We are again expecting a very big turnout, as K in Düsseldorf is the industry’s platform for premieres. Every three years, companies from all over the world come here to present their innovations and their

current and visionary solutions. Thanks to their unparalleled breadth of offering and the unmatched internationality of exhibitors and visitors, the fair is in a class of its own worldwide.”

and the PEPSO pavilion:

The presentations of exhibiting companies at K 2016 will be supplemented by a special show illustrating the possible uses of plastics and their diversified properties well beyond the present day. Health and nutrition, quality of life, communication and global networking, energy efficiency and climate protection, and safety and mobility are just some of the topics spotlighted. The special show is being organised by the German plastics industry under the auspices of PlasticsEurope Deutschland and Messe Düsseldorf.

establishments are presenting their latest scientific findings on the complex overall theme of plastics and rubber.

Other highlights of the accompanying programme of K 2016 will be the Science Campus, the field of additive manufacturing

22 | November-December 2014 | Plastics & Rubber Review

The Science Campus is the forum for research and teaching. In this special zone, institutes, universities and other higher education

Under the 3D fab+print banner, special prominence will be given to the diversity of generative production techniques known as 3D printing. At the Printed Electronics Products and Solutions (PEPSO) pavilion, suppliers from the printed electronics sector can exhibit their latest developments in a dedicated area. Numerous useful features on the Internet will be making it easier for exhibitors to register for K 2016 and organise their trade fair participation. For instance,

companies that exhibited in 2013 can log in with their existing access data. All they have to enter on the registration form are any changes to the 2013 details. First-time exhibitors are asked to choose the type and size of exhibition stand and enter what they will be exhibiting on the basis of product categories. Then they simply add a personal contact and the relevant company details, and their original registration is complete. Anyone who needs help is welcome to contact the teams in Düsseldorf and of any of the 72 foreign representatives and subsidiaries around the globe. With its impressive product innovations and the multitude of business transactions concluded in October last year, K 2013 surpassed even the highest expectations. 3,220 exhibiting companies and 218,000 trade visitors came together in Düsseldorf. v

Two customers of Sumitomo (SHI) Demag’s win highly coveted awards

Plastika Skaza and Cablex Plastik win “Golden and Bronze Gazelle 2014”

Tanja Skaza (middle), Managing Director of Plastika Skaza, accepted the “Golden Gazelle 2014” during the award presentation ceremony. IIgor Jarc (right), Managing Director of Cablex Plastik is proud of his “Bronze Gazelle”.

n 22 October 2014, Slovenian plastics processor Plastika Skaza d.o.o. was presented with the “Zlata Gazela 2014”, the “Golden Gazelle”. Established in 2001 by Dnevnik, one of the largest Slovenian daily newspapers, the economic awards in gold, silver and bronze are presented to domestic companies with the highest growth rates. Cablex Plastik, also a customer of Sumitomo (SHI) Demag’s, came third and was presented with the “Bronze Gazelle 2014”. Award-winning companies neither applied for the “Gazela” nor were they nominated or selected by a jury. Every year, up-and-coming Slovenian companies are assessed according to defined criteria such as growth, economic viability, creation of jobs and sustainability. Due to this independent assessment, the award is one of the most coveted economic prizes in Slovenia. In October 2014 Tanja Skaza, Managing Director of Skaza d.o.o., accepted the prestigious national award, the “Golden Gazelle”, on behalf of her company at the award-

winning celebration in Ljubljana. Plastika Skaza is a long-standing customer of Sumitomo (SHI) Demag’s. In 2000, when Igor Skaza, son of the company’s founder, joined the Board of Managers, the company’s workforce rose from 42 to 180 employees. The company with headquarters in Velenje, manufactures furniture, white good components, semi-finished products for the automotive industry and covers for electronic devices. The company product ranges of lifestyle articles for tables and kitchens as well as organic waste disposal containers display the specialist’s rich creativity and innovative power. The use of environmentally friendly high-quality, sustainable plastic products is at the top of the company’s agenda. Already, Plastika Skaza manufactures 50 % of its products from recycled plastic. Often, these innovative articles pose a significant challenge for the company’s production equipment. Injection moulding machines are part of this equipment. They are supplied by the JapaneseGerman company Sumitomo (SHI) Demag. Sumitomo (SHI) Demag’s management congratulated both Managing Directors Igor and Tanja Skaza on behalf of all employees on this major achievement. Cablex Plastik d.o.o., a member of the Cablex Group, received the “Bronze Gazelle 2014”. Cablex Plastik is a system developer and

provider of ready-made cable sets, plastic and silicone parts and mechanical modules. The company with more than 1,500 employees and eight production sites in Europe is continuously expanding and has responded to the challenges of the global market with an exemplary strategy. Top Teh d.o.o.

Top Teh d.o.o. has represented injection moulding machinery manufacturer Sumitomo (SHI) Demag of Schwaig/Germany in the Slovenian market since the beginning of 2009. Over many years, the company with headquarters in Skofljica has become established and renowned for its technical services. Top Teh offers an extensive sales and service package including maintenance and repair. With this approach, Sumitomo (SHI) Demag has acquired about 25% of the Slovenian market – a large step towards market leadership in Slovenia. Consolidated by its strong position in the Slovenian market, Sumitomo (SHI) Demag and Top Teh started their partnership in 2009 and extended their sales activities to the entire region of former Yugoslavia - Serbia, Croatia, Bosnia-Herzegovina, Montenegro and Macedonia (FYROM) at the beginning of 2012. More information: www.topteh.si

Plastics & Rubber Review | November-December 2014 | 23

Welex Sheet Line Lets Processor Bypass Drying And Crystallizing While Running Ingeo® Pla At 25-50 °C Lower Temperatures NatureWorks Cites ‘Virtually No Loss of Molecular Weight’ in PLA Processed with Welex Converge CTS™ Line; System Yields Energy Savings and Enhanced Product Quality molecular weight degradation, which in turn results not only in higher quality first-pass parts but also in sustained quality with post-industrial regrind,” said Mr. Nangeroni. “Processing with conventional technology, even under ideal conditions, you can expect 4% molecular weight loss per pass, comparable to polystyrene, but in our trial of the Welex system there was virtually no loss of molecular weight through eight passes, which is remarkable. This technology, combined with Ingeo pricing of $0.80-$1/lb. for standard extrusion/thermoforming grades, makes for a very competitive package.”

“Melt temperature is pure energy, so a lower melt temperature saves the delta required to both heat and cool the polymer, in addition to that saved by eliminating the drying system,” said Mr. Nissel.“Altogether, this could amount to 25% less energy demand. At the same time, higher melt strength makes it easier to process the material, with less sagging at the nip and fewer surface blemishes.

he first Welex Converge CTS™ sheet line is in production with a leading manufacturer of food service disposable ware, it was announced today by Graham Engineering, owner of the Welex brand. The sheet line directly feeds an inline thermoforming process. The processor, a leading manufacturer of food service disposables, runs Ingeo® PLA resin from NatureWorks LLC at a rate of 3,500 lb. (1,590 kg) per hour and a temperature of 200 °C. “Welex Converge CTS runs at a temperature 25 to 50 °C less than we have experienced with Ingeo at these outputs with other processing technologies,” according to Jim Nangeroni, senior applications development engineer for NatureWorks. “The lower temperatures possible with the Welex Converge CTS system lead to a reduction in

24 | November-December 2014 | Plastics & Rubber Review

Based on co-rotating conical twin screw technology, the Welex Converge CTS sheet line processes PET and PLA with moisture content up to 2,500 ppm while eliminating need to crystallize or pre-dry the material. Surface moisture is removed by means of a low vacuum applied at the feed area. After the material is plasticized in the first stage of the extruder, there is a decompression section where a high vacuum is applied through a large vent to complete moisture removal. Large thrust bearings enable Welex Converge CTS system to produce higher pressure, and a large screw diameter generates greater torque. As a result, the Converge CTS line processes PET and PLA effectively at the lowest possible melt temperature, according to Jim Nissel, Welex sales director. Benefits of a lower melt temperature include energy savings, higher melt strength, less

monomer reformation, and color preservation. “Melt temperature is pure energy, so a lower melt temperature saves the delta required to both heat and cool the polymer, in addition to that saved by eliminating the drying system,” said Mr. Nissel. “Altogether, this could amount to 25% less energy demand. At the same time, higher melt strength makes it easier to process the material, with less sagging at the nip and fewer surface blemishes. Less reformation of monomer minimizes plate-out on the polishing rolls. And lower temperature preserves color. Less yellowing due to heat history eliminates the need for blue-tone masterbatch to compensate for color degradation.” In addition to the processing benefits, mechanical and operating advantages cited by the company for the Welex Converge CTS system include: reduction of overall line length by about 20%, chiefly because the screws are half the length and weight of conventional parallel twin screws; faster screw removal, with almost no added clearance required, made possible by a pivoting barrel; and a large feed throat opening, providing the ability to add fillers without the added cost and complexity of side feeders. Welex Converge CTS systems are available to process from 1,100 to 4,000 lb. (500 to 1,815 kg) per hour, handling bulk densities as low as 150 g/l. For information on NatureWorks and Ingeo materials, visit http://www.natureworksllc. com.

Arburg expands service technician training in China • • •

Premiere: Jason Ding appointed as trainer for service technicians in China at headquarters Expansion of service: decentralised training for service team members Breaking the language barrier: training in local languages in Asia Objective: the same training standards worldwide

If the necessary technical infrastructure is unavailable at the subsidiaries, Jason Ding also has the option of bringing his service technicians to Lossburg, where the relevant course content can be communicated to optimum effect. This also strengthens the personal bond between the Chinese workforce and their contacts at headquarters in Lossburg – bringing an important social dimension to international cooperation and promoting the employees’ loyalty to “their” company.

Arburg Managing Partner Renate Keinath (left) and Uwe Klumpp (right), Product Training Manager in Lossburg, present Jason Ding from ARBURG Shanghai with his certificate marking successful completion of the training course for trainers.

Arburg is taking another decisive step in customer support by extending its high standard of service worldwide. In future, international service technicians can benefit from the same high standard of training whether they attend a training course at the company headquarters in Lossburg or receive decentralised training in their own local language. The program has started with Jason Ding, most recently Head of Service at Arburg’s subsidiary in Shanghai. He received basic training at headquarters from September to November 2014 and will be the first trainer at a subsidiary to train service technicians at local level. In future, this model will become a regular feature at Arburg, enabling native speakers to cover training course content with staff and customers in a professional way without language barriers.

“

You are the first employee from a subsidiary to be trained as a trainer,” said Arburg Managing Partner Renate Keinath when she presented Jason Ding with his new trainer certificate on 18 November 2014. “We are very pleased that you will be able to share the experience and expertise you have gained here in Lossburg with our service technicians in China in future.” Jason Ding is very well equipped for his new task. He has already been working for Arburg in China for 18 years, mainly in the service area. In organisational terms,

26 | November-December 2014 | Plastics & Rubber Review

he is now part of the Product Training department and thus has access to the relevant documents at headquarters, enabling him to provide expert training for the technical team in China and, later, in other Asian countries.

Training as a trainer at Arburg headquarters During his time in Lossburg, Jason Ding learned methods and structures that he will use to train service technicians at local level. These include, for example, the use of guidelines and training schedules, the issuing of confirmations and certificates for customers and the use of specific PC programs when training technicians. In addition, Jason Ding also had the opportunity to familiarise himself with the various departments at headquarters, including Technical Documentation.

Jason Ding believes it makes very good sense to train Chinese service technicians in their native language: “In China, it’s still difficult to find suitable employees with good English skills. That’s why training in the local language is better suited for communicating all the content in detail.” Now that he has received basic training as a trainer, Jason Ding will pay regular visits to the company’s German headquarters to see the latest interesting developments at first hand, so that he can incorporate these into his training courses in China.

Excellent contacts to the Black Forest

Because he has worked for Arburg for so many years, Jason Ding feels quite at home in the Black Forest. As well as his native language, he also speaks very good English, which facilitates communication. He rented a holiday home during his time in Lossburg and went on several excursions around the region at weekends. He quickly integrated into the trainer group and spent many social evenings with them. Moreover, a number of his Chinese colleagues visited Lossburg during his time there, so that he was able to act as their personal “tour guide” for the area. v

I N J E C T I O N | M O U L D I N G | M A C H I N E S

BOY strikes a new path in India and torsion resistant two-platen clamping system and the high capability of the injection unit, this injection moulding machine is especially suitable for the production close tolerance, precision moulded parts. The fourtie bar BOY 35 E injection moulding machine with a clamping force of 350kN and only a 1,94 m² footprint is very convincing. In addition to a high machine efficiency (efficiency class 7+ according to Euromap 60.1; depending on the configuration) its low machine hour rates are second to done. The E-Series servo drive and the optionally available EconPlast technology are also impressive machine features. When the user combines both, the energy consumption is reduced by up to 70 percent when compared to injection moulding machines with conventional components. Besides the BOY injection moulding machine, the presentation of peripheral devices will complete the exhibition performance of the Indian BOY distributor.

BOY 35 E with energy classification 7+ according to Euromap 60

t the Plastindia plastics trade fair (February 5 – 10, 2015), which will take place in Gujarat / India for the first time, a BOY 35 E will be exhibited. In the German corporate booth in hall 8 / booth D 09, a BOY injection moulding machine will produce a technically formed part. The tolerance range of the plastic part, which is filled with 33 % glass fiber, has some dimensional tolerances of only 0,002 mm. Karan Engineering Co. - the BOY distributor responsible for India - is already confident in the run-up to the event: “We will impress a number of visitors with an interesting application and also the new location of the Plastindia.

The innovative developments of BOY injection moulding machines have led to much better efficiency. EconPlast, the servo-motor pump drive and the Procan ALPHA ® 2 control with the “smart“ operating interface, set new standards in the clamping force range up to 1,000 kN.“ It does not surprise us that the BOY 35 E is used for such precise applications. Due to the compact

About BOY 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/.

Plastics & Rubber Review | November-December 2014 | 27

Most successful Fakuma of all time: More attendees than ever visited BOY “Over 60 percent increase in visitors to our booth – we did not expect this”. This is the enthusiastic conclusion by Klaus Geimer, BOY Deputy Managing Director, concerning Fakuma 2014. The six interesting applications in the BOY booth and the seven additional machines in the booths of partner companies impressed a number of exhibition visitors. 28 | November-December 2014 | Plastics & Rubber Review

Individually tailored automation solutions

The compact and simple integration of individual perfectly tailored automations was the focus of the visitors. A compact integrated handling unit at the rear side of the BOY XS removed the sprue from an eight-cavity protective cap – all done without any additional required footprint. (Picture of compact removal handling at the rear side of the BOY XS) A pneumatically driven swivel arm on the BOY 35 E, designed for the removal of the business cards, worked just as reliably as the handling device on the BOY 25 E VV insert moulding machine.

The linear handling guarantees the precise positioning of the blanks and removal of the multi tools, which are then over-moulded with liquid silicone. The right mix makes the difference The machine technology as well as the applications scored points with the visitors. Extremely thin-walled parts were produced on a BOY 35 E and a BOY 100 E, which could not be produced without the use of the new differential injection unit. The business cards with long flow paths and many openings were fed and perfectly filled from one side in the mould. The individual printing with previously scanned data was the icing on the cake for this application.

fast cycling application on the BOY 60 E. The production of pipettes in a 32-cavitiy mould with a 4.8 seconds cycle time was a visitor favorite. The seven other BOY injection moulding machines in the booths of partner companies were also very impressive.

he BOY 100 E produced thin-walled ICE model railway housings. The parts were removed via the BOY SL 30 handling system and the typical ICE red band was added with a special printer. An ICE model, which was ready mounted for comparison, made its rounds during the entire exhibition â&#x20AC;&#x201C; nearly without interruption. The impressive applications in the BOY booth were capped off by a

The technological developments, which BOY introduced to the market in the previous years, has clearly paid off. The enormous increase in efficiency and the nearly 70% reduction in energy consumption have their foundation through the development and market launch of the servo-motor pump drive (2008) and the EconPlast technology (2013). Thus, the platform for more efficient part production was created for users.

users to identify more efficient injection moulding machines from other machines â&#x20AC;&#x201C; some of which partially use other conventional technologies. Although the energy label does not cover all applications, it provides some conclusions about the machine efficiency. BOY will soon mark all machines with the new energy label prior to delivery.

According to Euromap 60.1, the combination of both technologies enables the BOY 60 E and BOY 100 E to achieve an energy classification of up to 9+. The Euromap 60.1 comparison evaluation permits Plastics & Rubber Review | November-December 2014 | 29

Smallest BOY insert moulding machine in big Russia

Plastindia 2015: Destination Gandhinagar, Plastics Industry To Benefit At Gandhinagar, PLASTINDIA 2015 is most certainly going to get bigger and better…be a part of this mega event as it’s time to expand your horizon! The PLASTINDIA 2015 is all set to create new milestones, and scale newer heights as has been the tradition of every PLASTINDIA exhibition. The strong growth that the plastics industry has witnessed in the recent past and continues to do so today will only help in making this PLASTINDIA, a resounding success. PLASTINDIA exhibitions have always been the cornerstone of the exponential growth that this sunrise industry has witnessed. The sheer numbers are overwhelming. Between 2013 and 2020, in India, plastics consumption is set to increase from 12 MMTA to 20 MMTA; exports from USD 6 billion to 8 billion as well as direct and indirect employment from 1.2 million to 2 million. So surely, 150,000 visitors would congregate at Plastindia 2015 to visit the world’s finest 2000 exhibitors spread over a sprawling 125,000 sq. mts. at Gandhinagar, Gujarat. Gandhinagar as a destination will further catalyse this growth story. Gandhinagar is home to one of the most elaborate exhibiting infrastructure and the internationally acclaimed Mahatma Mandir Convention Centre. The exhibitors of Plastindia 2015 will witness this expansive infrastructure and the convenience it brings to them and to their visiting customers. This ultra-modern venue has air-conditioned halls that are roomy and come with a convenient layout, created for ease of crowd movement. Ample parking space will be another plus.

At Interplastica in Moscow (January 27 – 30, 2015), the BOY distributor BIM Engineering, which is responsible for the Russian market, will show a BOY XS V in hall 3 / booth 3 A 21. The smallest of the BOY insert moulding machines with a vertical injection unit has a maximum clamping force of 100 kN. With a footprint of only 0,64 m², the BOY XS V offers a maximum injection volume of 8,0 cm³ with its largest 16mm screw. “Achieving greater performance in the very small BOY XS V footprint is simply not possible“ says BOY Export Manager Wolfgang Schmidt. During the four days of the fair, blanks of a small nail file will be overmoulded with a grab handle on the BOY XS V. This will demonstrate the advantages of the vertical design. As with all BOY insert moulding machines, the lower clamping platen is fixed, so that shifting of the inserts during closing is impossible. The clamping unit of the BOY XS V has two diagonal tie bars. This ensures good accessibility to the mould. The show visitors will be able to be actively involved by inserting the metal parts in the open mould on their own. By activating the start button, everyone can produce its own nail file. BOY goes smart

The compact BOY XS will be equipped with the Procan ALPHA ® 2 control. The main difference of the new system is the multi-touch capability. Like with modern communication devices, operating functions like scrolling or page changes are now achieved by wiping. Compared with previous foil-touch systems, the new Procan ALPHA ® 2 PCT touch technology guarantees considerably longerlasting functionality. A recalibration of the screen is no longer required and the touch-surface has been protected against damage with a stable single safety glass cover.

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Locational convenience will surely act as a strong motivator for an unprecedented visitor footfall, especially when Gujarat and its near surroundings itself constitute a significant 60% of the Indian plastics industry. This fact will singularly ensure both, quality and quantity of visitors resulting in sheer exhibitor delight. Gandhinagar, located just 16 kms from Ahmedabad, is one of the most modern and well planned cities in India with wide avenues and ample greenery and is designed by a well known French architect. It comes with convenient road, rail and air connections for ease of access. With one of the best port facilities in the country, it will ensure smooth movement of cargo as well. Pleasant weather and a tourist destination will only enhance the pleasure of visitors to Gujarat, a truly vibrant state. PLASTINDIA 2015 concurrent events include: PROPLAST: This 4th edition event is the final word in processed plastics, the heart of India’s plastics industry. PROPLAST is a showcase of India’s burgeoning plastics processing capability. It demonstrates the high standards that are consistently delivered by Indian processors across the globe.

Conference: The 9th International Conference will host some of the most renowned experts on plastics. World leaders in plastics are looking forward to sharing their experience, knowledge, expertise and share views with international audience through this conference. Plasticon Awards: The 7th Plasticon Awards will be held, where the

best and brightest from the Indian plastics industry will be felicitated for their accomplishments and excellence across 23 categories. At Gandhinagar, PLASTINDIA 2015 is most certainly going to get bigger and better…be a part of this mega event as it’s time to expand your horizon.

Aviation industry: Laser melting with metals (LaserCUSING)

Expert panel: Prof. Dr.-Ing. Claus Emmelmann, CEO, Laser Zentrum Nord GmbH, Hamburg

Peter Sander, Head of Emerging Technologies & Concepts, Airbus, Hamburg

Frank Herzog, CEO, Concept Laser GmbH, Lichtenfels

Laser melting with metals in Aircraft manufacturing: 3D printing enables “bionic” aircraft designs • A component used in the Airbus A350 XWB was a finalist in the running for the “2014 German Industry Innovation Award” • A first: the first titanium component produced using 3D printing onboard the Airbus A350 XWB

Laser melting with metals gains importance in aircraft manufacturing: quicker throughput times, more cost-effective components and heretofore unimaginable freedom of design are often-cited advantages of this technology. However, a range of new benefits are now becoming apparent, such as lightweight construction, bionics and a new approach to design. A bracket connector used in the Airbus A350 XWB was honored as a finalist in the running for the “2014 German Industry Innovation Award.” 32 | November-December 2014 | Plastics & Rubber Review

reviously the component was a milled part made of aluminum (Al); now it is a printed part made of titanium (Ti). Naturally it is significantly lighter than it used to be. But what does the change in manufacturing strategy mean for aircraft manufacturing in the future, in terms of prospects and technology? It should also be mentioned that industry insiders expect global aircraft manufacturing capacity to double over the next 20 years. We spoke with the project partners: Editor: Recently we have been hearing about “composite aircraft” and now additive manufacturing

Cabin bracket for the Airbus A350 XWB made of Ti, manufactured using LaserCUSING

technologies, such as laser melting with metals and laser sintering of polymers, are being employed in aircraft manufacturing. How does this change the design of structural elements used in aircraft? Peter Sander: Our primary objective is to reduce weight. This approach helps our customers, the airlines, operate their aircraft more economically. Additive layer manufacturing or laser melting with metals, also known simply as 3D printing, allows us to design completely new structures. They are actually more than 30% lighter than conventional designs realized using casting or milling processes. Another factor is that we can proceed directly from 3D designs to the printer, that is, the laser melting system. Usually tools are required to manufacture aircraft parts – this is now no longer the case for us. This saves money and shortens the time until the component is available for use by up to 75%. To cite an impressive statistic: previously we budgeted around six months to develop a component – now, it’s down to one month. Claus Emmelmann: The advantages for structural elements used in aircraft are obvious. The high degree of geometrical freedom of design enables more effective lightweight construction solutions compared to conventional approaches. For the brackets we’re currently focusing on, this means a considerable weight reduction, which in turn translates into lower fuel consumption and the potential to increase the load capacity of aircraft. These represent important steps

toward more sustainable solutions. Editor: How does the additive process change project processes? Claus Emmelmann: That’s a good question, since it’s not only the weight of the component that has changed. Project processes can also benefit from the characteristics of laser additive manufacturing. Since tools are not required in the process, it’s now possible at an early stage to produce functional samples of components that are very close to being ready for series production without incurring the high cost of tools or other pre-production expenses. This means that sources of error can be identified in the early stages of the design process, which allows for optimization of processes within the project as a whole. Editor: What are some of the effects that result from transitioning from milled or cast components to printed components?

Peter Sander: Milling of aircraft parts in particular results in up to 95% recyclable waste. With laser melting, we produce components with “near-final contours,” which are associated with waste of only around 5%. This makes the process especially attractive when valuable and expensive aircraft materials, such as titanium, are being used. Compared to casting, we have the additional advantage of not requiring any foundry tools. This is tangibly reflected in saved time and improved cost structures. Furthermore, additional safety considerations are associated with cast parts, such as cavities. Last but not least, they are heavier than printed components. Frank Herzog: In addition to reduced resource consumption, the freedom of design enjoyed by aircraft engineers is also quite attractive. The ability to economically keep component density under control and determine the microstructure quality are additional aspects.

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Airbus A350

Another fundamental quality feature is the ability to define the force distribution within the component, which is often impossible with conventional parts or is considerably more difficult to achieve. This is an important argument when it comes to safety-related components. Our QM modules integrated into the system technology allows users to take advantage of real-time, inline quality control. Process mapping is a key tool for ensuring quality. This makes reverse engineering possible and serves to seamlessly document the process. Let’s also consider the environmental aspects. Reduced energy and resource consumption are features of the laser melting process. LaserCUSING is a green technology and improves the often discussed environmental footprint of production. Claus Emmelmann: The process generally results in positive effects for manufacturing costs for small to medium-sized unit quantities. For instance, the comparatively higher relative investment costs for casting molds are eliminated, as well as any costs for tools that may be required. Furthermore, laser additive manufacturing offers greater freedom of design, since undercuts and interior channels, e.g. for cooling, can be implemented during manufacturing. Previously unimaginable geometries can be combined with functionalities. Moreover, the material properties are slightly different. Materials produced using laser additive 34 | November-December 2014 | Plastics & Rubber Review

manufacturing have greater rigidity while at the same time, less ductility; this can be enhanced with the right heat treatment, however. Editor: What potential applications do 3D printing techniques offer for aircraft manufacturing and structural elements used in aircraft? Peter Sander: Two areas need to be considered in this connection: process optimization, on one hand and product design, on the other. For us, process optimization means that we no longer require any foundry, injection molding or pre-production tools. We can print components directly from the 3D design system. This reduces our throughput time by up to 75%, with considerably lower one-off expenses. It’s easy to imagine how attractive this is for us, especially for series with few and very few units. Lot size considerations are more significant in aircraft manufacturing than for high-

volume production, as is familiar in the automotive and consumer sectors. For example, we installed several tons of test equipment in the first test aircraft. This required thousands of Flight Test Installation (FTI) brackets, to be produced in very small unit quantities. Spare parts are an additional, exciting area. In the future we will be able to manufacture them close to where they’re needed, without tools and on an “on demand” basis – instead of having to finance large warehouses to store rarely needed spare parts all around the world. This reduces capital commitment while providing huge flexibility. And now, regarding the second point, component or product design: since with laser melting we can manufacture very fine – even bone-like – porous structures, the aircraft parts of the future will look “bionic.” Nature has optimized functional and lightweight construction principles over millions of years, minimizing

“Inline Process Monitoring” with the QMmeltpool QM module: The system uses a camera and photo diode to monitor the process within a very small area of 1x1 mm². The process is then documented.

the amount of resources required in clever ways. We are currently investigating and analyzing these solutions found in nature with regard to their applicability. Initial prototypes indicate great potential in this approach. The process is expected to launch a sort of paradigm shift in design and production. Frank Herzog: From the perspective of system manufacturers and process developers, the process enables users to significantly augment productivity while offering numerous options for automation. The size of components has also been significantly increased thanks to the qualification of the 1000W laser technology. The use of multiple lasers will play a role in the future. By relying on “intelligent exposure strategies,” the laser can apply layers to a component in a strategic manner in order to produce custom characteristics in terms of structure, rigidity and surface quality. The quality and speed in this area offer considerable potential to aircraft manufacturers. Editor: In terms of lightweight construction and bionics, the weight reduction appears to be a clear advantage. Nevertheless, at what point does the technology reach its limits for safety-relevant components?

Peter Sander: Generally speaking, there are no compromises in aircraft construction, since safety is the prime concern. Especially when one considers that our products remain in the skies for up to 30 years. When it comes to metals in aircraft construction, welding is the most common process. Aircraft manufacturers have long been familiar with it. From experience, we know how welded components must be handled to satisfy the high safety requirements. However, we still have to learn how best to take advantage of implementing the new geometrical freedom in component design. Toward that end, we will have to perform many structural tests and trials over the coming years. The result will be a novel “bionic” aircraft design, I’m sure of it. Claus Emmelmann: Currently, certain limits are definitely reached in terms of compromises in surface quality. These are comparable to those evident in cast components, however. These phenomena result in considerably reduced fatigue strength, especially with titanium. Yet precisely this parameter is essential for structural components in aircraft manufacturing, which are exposed to high stress. Nevertheless, downstream surface treatments, such as those using microwave radiation, can significantly increase fatigue strength when combined with proper heat treatment. Ultimately, values comparable to those of rolled material can be achieved when necessary. Editor: What physical loads or stresses are aircraft exposed to?

Active quality assurance using QMmeltpool: although the human eye is incapable of detecting defects, QMmeltpool nevertheless identifies deviations in component quality

Peter Sander: In addition to basic static stresses, aircraft are exposed to extreme temperature fluctuations during ground and flight operations, for example. The most significant, however, are the

permanent loads that demand the maximum from the affected parts. These include takeoffs and landings, as well as flight operation with permanent turbulence which can lead to several meters of deflection at the wing tips. In short, aircraft are exposed to stresses that can be extreme in nature, and which must always be withstood. Claus Emmelmann: I would like to add something. While aircraft are indeed exposed to a wide range of extremely complex load spectrums, only static loads are relevant when it comes to designing support structures, such as brackets. This facilitates implementation of this technology, which is still in its infancy, in aircraft manufacturing. Editor: What methods or instruments do you use to monitor and/or validate processes with the LaserCUSING? Peter Sander: As an aircraft manufacturer, monitoring during the component’s construction phase is one of the most important aspects for industrial applications. In practice, the “Inline Process Monitoring” provided by the QMmeltpool QM Module from Concept Laser means that the system uses a camera and photo diode to monitor the process within a very small area of 1x1 mm². The process is then documented. Frank Herzog: Mr. Sander has referred to a very important aspect here. QMmeltpool, QMcoating, QMpowder and QMlaser modules are the fundamental instruments we rely on for active quality assurance while the component is being manufactured. They measure laser output, the melt bath, the layer structure of the metal powder and monitor and document the entire manufacturing process seamlessly. An additional aspect

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such improvements. Applicationspecific approvals represent additional quality features that we are working on in a strategic manner. Editor: Does the additive manufacturing approach change the thinking around design in aircraft manufacturing? If yes, how is this evident? Demonstration of a series construction job with deviating QMmeltpool signals: reducing laser output (purple line), dosing factor deviations (blue line) and series construction job (rest of the lines – in red and green)

is the capability to work in a closed system, which guarantees that the process remains free of particles and contamination. The decisive factor is that all disruptive influences that could negatively influence the process can be eliminated. It’s accurate to call this a regulated manufacturing process that provides repetition accuracy and process reliability. As mechanical engineers and system manufacturers, our task is to deliver seamless validation of the systems and peripherals. Claus Emmelmann: We use the QMmeltpool and QMatmosphere quality management software in our M2 cusing system from Concept Laser. This now enables us to monitor and document key data, such as laser parameters, melt pool parameters, as well as the composition of the inert gas atmosphere. This effectively eliminates disruptions due to contamination. Furthermore, as part of a research project we are developing our own quality management concept based on optical coherence tomography. Editor: Can you describe the approaches to quality management in more detail? Frank Herzog: We are constantly improving our Quality Management Modules, “QM Modules” for short, in order to set the standard in terms of prediction quality and operability, as well as influencing the ongoing construction process. There are currently 25 development engineers working in the laboratory at our new development center, where they analyze the microstructures of components, and test for rigidity and density distribution. They use microscopy to understand what is happening at the atomic level. Materials expertise is an essential tool to offer users security and safety. As a pioneer in this technology, we have decisively improved the quality of technology over the past 15 years. Penetration of the aviation, aerospace and medical technology industries has only been possible thanks to 36 | November-December 2014 | Plastics & Rubber Review

Peter Sander: To me, the “freedom of design” stands out: the degree of design freedom with which we can determine the force distribution in the component with great precision at the Laser Zentrum Nord thanks to CAD design. The next generation of aircraft engineers will understand 3D printing and all the opportunities it brings in greater depth. Thinking around design and production is currently changing. I would also call it a paradigm shift, as Mr. Sander has already indicated. We should also remember that resistance to new things is only slowly overcome. Our production engineers are currently well-trained in casting and milling, so we need new insight and experience. Last but not least, some advocacy work has to be done in the form of practical examples we can point to in aircraft manufacturing. In general, laser melting technology is capable of developing safety-related components that are even better, lighter and more durable than the components available today. Claus Emmelmann: Within the scope of various projects already completed for Airbus, we have been able to determine that the opportunities presented by laser additive manufacturing have fundamentally led to new ways of thinking and lightweight construction solutions. Especially with regard to structurally optimized components, which generally have a high degree of geometrical complexity, it is possible to implement the form in

a very direct way to achieve a high degree of lightweight construction. In the past, compromises with lightweight construction have been necessary due to the restrictions of conventional manufacturing – restrictions we are now able to elegantly avoid. Editor: Spare parts for civil aviation aircraft are considered costintensive and a logistical challenge due to their long lifecycles. Spare parts experts have to meet the challenges of global availability, warehouse stock, lifecycle and time pressure. How can additive manufacturing improve this situation? Peter Sander: Since February of this year, Air Transat in Montreal has been flying with the first spare part printed and delivered by Airbus. The former manufacturer of the injection-molded part for a Cabin Attendant Seat in an A300/310 was no longer available; the tools had been scrapped. At that time, the question we faced was whether to invest in new tools, at a cost of US 36,000, or to take advantage of 3D printing. By using the laser melting process, we were able to offer the part at a cheaper price from the outset, without tool costs. As a result, we no longer store hundreds of parts in warehouses, but instead, going forward we will operate decentralized spare parts printing centers and only manufacture plastic spare parts when they are requested. A similar strategy is being pursued for metal components. Frank Herzog: The example given by Mr. Sander is analogous to the situation for laser melting with metals. Additive manufacturing is generally characterized by various aspects: decentralized, rapid turnaround, quick time from implementation to the finished component. It allows for lower logistics and warehousing costs. It

Without QMcoating

QMcoating

QMcoating: without QMcoating, the layer may be insufficiently coated (the red areas indicate a lack of powder material); with the QMcoating approach, however, the powder dosing factor is adjusted within the tolerance range.

uses fewer resources than conventional manufacturing methods, which makes it a green technology. Even production-on-demand is possible, as was discussed. We also have to consider the small lot sizes common in aircraft manufacturing, which are another factor in favor of an additive process. With regard to the safety aspects of components, engineers are discovering that 3D printing offers many answers to problems posed by force absorption, the required durability, high quality standards and bionic design. Claus Emmelmann: I also regard supplying spare parts for aircraft construction as a high-potential area. It will be possible to hugely improve materials and warehousing costs. I would say that the decentralized factor addressed by Mr. Herzog is the real key advantage. In case of a component failure, the spare part can be produced directly where it is needed. This minimizes transport distances and above all, delivery times, leading to shortened aircraft overhaul times. Editor: What is the perspective of aircraft manufacturers on resource protection and green technologies? Claus Emmelmann: I can only underscore the importance of those topics. In conventional manufacturing using milling processes, the blanks are produced from plate material. In extreme cases, this can produce up to 95 % recyclable waste. In laser melting, the process produces parts with near-final contours, which means we only produce around 5 % waste. But even this waste can be reused after undergoing a screen sorting process. In aircraft manufacturing, we work with the “buy to fly” ratio, and 90 % is a fantastic figure. Naturally, this figure is also reflected in the energy balance sheet. Editor: What general changes have 3D strategies produced in aircraft manufacturing, in your opinion? Peter Sander: Initial studies show that the number of manufacturing steps necessary has been cut in half, since the process yields blanks with near-final contours.

Welded components composed of multiple parts are also attractive, as they can now be manufactured “in a single process” without welding equipment. Additive 3D printing is enabling new, more rapid speeds for component development and the construction process, drastically shortening previous development timelines. The cost structure of our projects is also changing significantly. The new approach has also allowed lightweight construction to develop further. And it is leading to new design perspectives, which will be evident in the different geometries used. Claus Emmelmann: Since we do not require any special tools or clamps for the additive manufacturing process, we can produce the component directly from the 3D CAD data. This time factor ensures that in many cases we can work considerably faster than with conventional manufacturing processes. Speaking of production costs: if the direct cost of manufacturing a milled component is compared with the cost of manufacturing the same component using laser additive manufacturing, the additive process is usually found to be less costeffective. However, when the components are redesigned and improved thanks to the new design possibilities, e.g. by making them lighter or with higher functional performance characteristics, there are already many examples of circumstances in which the use of additive manufacturing processes offers cost advantages. Editor: What opportunities do you see for integrating various functions, such as cooling functions, into the components of the future? Peter Sander: Similar to aircraft structures, we are currently rethinking the entirety of aircraft systems. We are facing a new

continent of opportunities and options, so to speak. We need maps of the unknown terrain before us, as it were; in other words, experience and production strategies. We already have all of that for conventional processes. But here we are entering new territory, one with fascinating opportunities on the horizon. Initial prototypes produced in our development work show significant potential in terms of reducing costs and weight. Functional integration is one of the possible new options. I am convinced that we will make good progress toward producing safetyrelated components in better and more cost-effective ways. Frank Herzog: Laser melting is synonymous with functional integration and added value. Added value is evident in superior component quality. Close contour cooling in tool construction for injection molding is one such application that we’ve initiated over the past decade. In aviation, these cooled elements can be used for electronic systems or hydraulic components. In terms of aircraft design, future components can strategically accommodate the force vectors. Claus Emmelmann: The capability of producing entire assemblies as a single piece and of integrating additional functions into a component are among the major advantages of laser additive manufacturing. Laser additive manufacturing will therefore continue to increase in importance, especially in areas in which we exploit the geometric freedom of design and functional integration capability. Yet the options enabled by this freedom of design should be taken into account early on in the design process in order to differentiate it from conventional production strategies. Currently design and development often fail due to lack of knowledge of the

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the cost advantages. Editor: Critics say that the restrictions in terms of assembly space size curtail the opportunities. On the other hand, proponents say that conventional assembly and joining techniques mean that this in and of itself is not a real limitation. How do you assess this discussion?

QMcoating: Use of QMcoating can save up to 25% of the powder quantity required compared to manual operation (potential savings = shaded area)

capabilities of this production process on the part of engineers and production experts. Editor: Aircraft manufacturing is characterized by very long lifecycles and comparatively low batch sizes. What effects does this have on additive manufacturing strategies? Claus Emmelmann: The comparatively small unit quantities involved in aircraft manufacturing favor laser additive manufacturing techniques. The additive manufacturing process does not allow us to take advantage of any economies of scale, as is the case for other production methods. In concrete terms, this means that the unit costs change only very slightly as production volume increases. Conversely, conventional production methods, such as pressure casting, are more cost-efficient for producing large unit quantities. Frank Herzog: I agree. The lot size aspect, along with safety considerations and durability constitute a special profile of requirements for aircraft manufacturing. The strengths of laser melting also lie here: no tools required, production-on-demand, rapid, cost-effective, high quality. Peter Sander: Let’s consider two aspects, namely quality, which is ensured through inline process monitoring, as well as geometrical freedom, which is achieved through being able to dispense with the aids that form the contours of parts; these make aircraft components produced using 3D printing with metals better, lighter, more rapidly available and most importantly, safer – not to mention 38 | November-December 2014 | Plastics & Rubber Review

Peter Sander: Only the future will tell. Yet one thing is already clear to us at this early stage: the material in question can be welded. This opens up the possibility of welding together various components, which in turn means that joining techniques will be employed to good effect. Frank Herzog: I would agree, as this topic is still in flux. In the past, we have managed to increase the assembly space by up to 700 %. Laser output has been increased to 1000 W while the assembly speed for aluminum parts has been accelerated by a factor of 10 to 15, to cite only a few key figures. In my view, which is shared by many users, this represents fantastic progress. With very large components, the internal stresses in the part increase due to the nature of the process. This tendency to warp sets certain limits. Ultimately it’s not the assembly spaces that set the limits, but rather the task is to explore the physical limits. The limits can be expanded further with an intelligent joining technique, I’m convinced of it. In this sense, assembly techniques could play an important role for large components that are to be manufactured cost-effectively. This makes it possible to develop components with large volumes and extremely long components that extend beyond the assembly space sizes offered by laser melting systems themselves. Claus Emmelmann: In general,

development of systems toward larger assembly spaces is to be endorsed. Joining of individually produced substructures to form larger components is technically possible, however this means that additional production restrictions have to be taken into account for the component as a whole. In my view, this restricts the design freedom of laser additive manufacturing. We should also note that production costs are essentially determined by component production volume. Therefore, from a cost-effectiveness standpoint, smaller components that can be manufactured with the systems already available on the market are more worthwhile. But that’s the perspective of today; it can change in the future, of course. Editor: What components produced using additive manufacturing are conceivable in aircraft manufacturing over the next decade? Peter Sander: If development continues in a similar manner, I see no technical restrictions. The decision will then ultimately be based on cost-effectiveness and on the industrial availability of metal powders and high-speed machines. Claus Emmelmann: We won’t be printing complete aircraft, even in ten years. But I’m confident that in the future laser additive manufacturing will be capable of producing increasingly larger and more complex components in a cost-effective manner. This will be possible thanks to the rapid pace at which the system technology is being further developed, and the increased productivity associated with such advances. I see great potential in particular for structural components with dimensions of up to one meter, as well as for engine components. v

Smart Consumer – More Energy Efficiency through Intelligent Coupling of Energy Fluxes in Industrial Companies Start of the largest IdE research project to date, with strong Hessian participation At the IdE Institut dezentrale Energietechnologien (Institute for Decentralized Energy Technologies), the starting pistol for the project Smart Consumer has been fired. For this large-scale project with a budget of 10 million Euro, the experts of the IdE Institut dezentrale Energietechnologien, together with those of Arburg, Imtech and Limón, implement and test measures for increasing industrial energy efficiency at Ferrero and Junghans Kunststoffwarenfabrik (Junghans Plastic Ware Factory). Ferrero and Junghans Kunststoffwarenfabrik, both of which are located in Hessen, Germany, are making their manufacturing plants available for this research work. The project will be supported over the next three and a half years by the Federal Ministry of Economics and Energy. A central goal of the project is the implementation of intelligent solutions for the control and reduction of energy needs within a real-life production environment. ‘In pursuing this goal, it is important to us that the solutions we work out can also be implemented in other companies’, says Prof. Hesselbach, head of the scientific department at IdE. The project Smart Consumer consists of two subprojects. In the sub-project Smart CHP, the focal point is the optimization of the power supply of factories that are processing plastic. Using the company Junghans as a test case, the primary energy need and the energy costs are supposed to be lowered by fifty percent. ‘Sustainable economizing has always been an essential part of our company. This research project offers us the opportunity to become the most energy efficient plastic injection moulding company in Europe. The future reduction of our energy need by fifty percent is a milestone in our company’s history and our contribution to the energy turnaround’, says CEO Klaus Junghans. To achieve this, however, the current electrical heating of the production machines has to be changed to thermal oil heating. This creates greater flexibility in being able to run the machines either through heat from CHP processes, through burning of gas or through electrical energy. The main idea is to make greater use of the heat that is being generated. This makes it necessary to, among other things, rebuild the injection moulding machines as well as the building technology and the heat grids in the plastic factory. At the confectioner Ferrero, the focus lies on energy saving in the area of refrigeration and air-conditioning.

On the one hand, there will be a change to alternative, more efficient cooling technology; on the other hand, cooling will only take place where cool temperatures are actually necessary. For the production this means that, for example, only a small part of the production line will be cooled instead of the entire production hall. The goal is to make the cooling as precise as possible by making constructive changes in controlling the air. ‘We expect to be able to save up to fifty percent of thermal energy in this way’, explains Prof. Hesselbach. In addition to the reconstruction, it is important for both sub-projects that energy fluxes can be measured, evaluated and controlled. That is why Junghans as well as Ferrero will have an energy monitoring system installed, which is fundamental for an intelligent control of energy fluxes and helps predict future energy needs. Such predictions about future energy needs make it possible to optimize electricity costs and, at the same time, contribute to a less strained energy grid. In this way, the consumer becomes a Smart Consumer and thus an essential building block of a future Smart Grid. Using simulation, the intelligent control systems of the energy fluxes of both sub-projects will be developed together by Imtech und Limón. Limón integrates the production technology and Imtech is responsible for the energy flow of the power supply and the technical building equipment.

About IdE: The IdE Institut dezentrale Energietechnologien (IdE Institute of Decentralized Energy Technologies) was founded as a nonprofit limited company in 2011. The institute develops concepts, strategies, products and services for the growing market of decentralized energy management. The focus of the company is application-oriented research and development as well as energy transfer in the areas of renewable energy and energy efficiency. Its projects draw on the scientific expertise of Kassel University, which is also the chief partner of IdE Ltd. The close cooperation of IdE between business, science and politics strengthens northern Hessen as a location for decentralized energy technologies. Partner involved in IdE are: Kassel University, the commercial enterprises EAM Beteiligungen GmbH, Städtische Werke AG, SMA Solar Technology AG, Viessmann Werke GmbH & Co. KG and Wingas GmbH as well as the city of Kassel, the municipality of Niestetal and deENet Kompetenznetzwerk dezentrale Energietechnologien e.V.. Through a cooperation agreement, the Volkswagen AG is closely integrated into the structures of IdE. For more information, visit www. ide-kassel.de. Plastics & Rubber Review | November-December 2014 | 39

Component design for laser melting with metals (LaserCUSING)

New methods for process-oriented design of additive components Partnership between Concept Laser and RSC Engineering for additive design Concept Laser and RSC Engineering GmbH (Cologne, Germany) have announced a strategic partnership for engineering of laser-fused components. Frank Herzog, President & CEO of Concept Laser:“We are pleased to partner with RSC Engineering and Tim Richter. Our users will benefit from our partnership with a design firm that can create process-oriented component designs using LaserCUSING for complex components. RSC Engineering’s list of references and expertise will give us a strong foundation for maximizing the potential of LaserCUSING.”

Tim Richter, RSC Engineering (CEO): “Lightweight constructions are often used for component structures that cannot be adequately produced with traditional processes, whereas functional integration improves the quality of a component.”

he new partnership with a highly specialized design firm follows a current market trend: In the past, there was a demand for designs that replaced cast or milled components. Today, more and more designers and engineers are realizing that additive manufacturing can open up entirely new approaches to design. “LaserCUSING-oriented” design is ideal for bionic or lightweight construction approaches that produce components with optimized geometries and new possibilities in areas such as functionality or resilience. 40 | November-December 2014 | Plastics & Rubber Review

RSC Engineering is one of today’s design pioneers that know how to incorporate the benefits of laserfused metals into the component development process.

Advantages of LaserCUSINGoriented design Process-oriented design means leaving behind the traditional approach of substituting a milled or cast component. In an additive design context, the advantages of LaserCUSING can be maximized: optimized design, better performance and increased added value. There are many reasons for this, says Tim Richter: “Additional functions are now possible, such as cooling, production of moving parts in a one-shot process without assemblies, or lightweight structures that can withstand heavy stresses. Hybrid manufacturing solutions (combination of conventional processes and LaserCUSING) can bring together the best of both worlds. It’s all about understanding new possibilities and using them in a targeted way. Additive design eliminates the need for substitution and produces completely new solutions.”

Spectrum of additive design RSC Engineering’s design activities are primarily in the areas of rapid prototyping, rapid tooling and rapid manufacturing. Reference components include solutions for lightweight design and functional integration. “Lightweight

constructions are often used for component structures that cannot be adequately produced using traditional processes,” says Tim Richter, “whereas functional integration improves the quality of a component.” These approaches involve a range of strategies that RSC Engineering determines according to the each component requirement: Reduction or avoidance of support geometries, integration of cooling channels, elasticity or increased rigidity through integrated lattice structures. Tim Richter: “We focus on the component’s ultimate function right at the beginning of the design process. ‘Virtual prototyping’ is an important concept. Going from a virtual prototype to the actual product is no longer a big process thanks to LaserCUSING. This means that we can often shorten the development process significantly.”

Exhaust gas probe with intelligent functional integration An exhaust gas probe developed by RSC Engineering is an excellent example of intelligent additive design. The probe is used to determine the composition of engine exhaust gases in a test system. The exhaust gas is up to 2100°C and under high pressure. Because of these high temperatures, the exhaust gas probe also features cooling channels for coolant flow, in addition to six pipes for collecting the exhaust gas. Conventional exhaust gas probes are typically welded, which is a

Exhaust gas probe: single-stage production combined with integrated cooling in one extremely compact component

Frank Herzog, Concept Laser (President & CEO) and Tim Richter, RSC Engineering (CEO) (left to right): RSC Engineering’s references and expertise will give us a strong foundation for maximizing the potential of LaserCUSING.”

time-consuming process. By contrast, the exhaust gas probe by RSC Engineering GmbH was manufactured in one step, including all flow-optimized channels, using LaserCUSING. “Such highly effective functions can be very compactly integrated into an intelligently designed additive component,” says Tim Richter. “But the problem was in the costs. The product costing analysis for the exhaust gas probe showed that we reduced manufacturing costs by almost 60%. This demonstrates the incredible cost-cutting potential of this technology.”

Project phases of LaserCUSING design The additive design process is based on a coordinated analysis and component design by RSC Engineering. During the first phase of the project, the potential of

the component is systematically evaluated. What will it do? What were the advantages and disadvantages of previous solutions? Are there special objectives, such as cost reduction or lightweight construction? In addition to these criteria, the possible advantages of the LaserCUSING process are defined. In the second phase, precise specifications are created. This involves drafting binding functional requirements, determining the timeframe and defining batch sizes. The third project phase is the actual design process. Tim Richter: “The key words here are design or redesign and simulation.” This involves evaluating and comparing alternative geometries as part of a virtual prototyping process. Physical functions then go through the various levels of simulation using DMU (digital mock-up), FEM (mechanical/thermal simulation) and CFD (thermal simulation). The final conclusions are also examined with respect to the consequences for manufacturing. In the last stage, implementation in the production environment is analyzed as a QA measure.

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. Procedures 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.

Plastics & Rubber Review | November-December 2014 | 41

Many global renowned firms such as Toray, Mitsubishi Chemical, Engel, Haitian, Milacron, Hasco, Yudo, Conair and ACS have confirmed their booth booking.`

CHINAPLAS: High booth booking rate reflects the optimism of industry outlook Sign of optimism in the outlook of plastics and rubber industries was found as exhibitors begin making their stand reservations for CHINAPLAS 2015, leading the show scale to break its past records. Apart from showcasing a perfect blend of International and China’s latest innovations covering the entire manufacturing processes essential to different sectors, a variety of concurrent activities addressing industries’ hottest topics such as automation, design for sustainability and medical plastics are also dedicated to the visitors. 42 | November-December 2014 | Plastics & Rubber Review

ver 3,100 companies from over 39 countries and regions are expected to participate in CHINAPLAS 2015. Being Asia’s largest and the world’s second plastics and rubber trade fair, the show will be held on 20-23 May, 2015 at China Import & Export Fair Complex, Pazhou, Guangzhou, PR China. Occupying 25 exhibition halls, CHINAPLAS 2015’s gross exhibition area will exceed 230,000sqm, making it the biggest of its history. This highly internationalized show will gain the support from 13

international pavilions coming from Austria, Canada, France, Germany, Hong Kong, Italy, Japan, Korea, Switzerland, the UK, USA, PR China & Taiwan and on-site demonstration of their latest technologies is expected. Ada Leung, Assistant General Manager of Adsale Exhibition Services Ltd., the organizer of CHINAPLAS, said, “CHINAPLAS is one of the very few trade fairs to cover all of the manufacturing processes, from materials, technologies to services that are

The extraordinary diverse and versatile nature of modern plastics fuel designer’s boundless imaginations to create countless products that help society to meet many challenges and improve our quality of life.

essential to the plastics and rubber industries and their downstream sectors. The exhibition, serving as the one-stop platform, has appealed to both international and local buyers alike to source raw materials, machinery as well as the solutions for their entire processing lines, from high-end and sophisticated products to costeffective and volume production ones.” The next edition of CHINAPLAS will exhibit innovative plastics and rubber technologies and a wide array of raw materials in line with policies and regulations and the latest trends under 11 theme zones, namely Extrusion Machinery zone, Injection Molding Machinery zone, Chemicals & Raw Materials zone, Auxiliary & Testing Equipment zone, Die & Mold zone, Film Technology zone, Plastic Packaging & Blow Molding Machinery zone, Rubber Machinery & Equipment zone, Chinese Export Machinery & Materials hall, Bioplastics zone and Semifinished Products zone.

Exhibitors reflect their optimism of industry’s future Ada Leung continued, “The booth booking for CHINAPLAS 2015 is overwhelming. We have already

recorded over booking of certain theme zones such as film technology and packaging. Increased booking is also seen in extrusion machinery and auxiliary equipment zones. Besides several hundreds of new exhibitors, many of past exhibitors have requested for booth expansion. The reservation status somewhat reflects the market trends in the plastics and rubber industries.” According to the study from Freedonia, packaging will remain the largest single market for plastics processing machinery. Equipment utilized in the production of plastic packaging products will expand at the fastest pace through 2017, accounting for one-third of total sales revenue of plastics processing machinery, thanks to the growing demand for packaging products

and increasing food and beverage manufacturing activities due to rising living standards in developing countries. Consumer products and construction sectors will occupy the second and third places of sales revenue of plastics processing machinery. Injection molding equipment will continue to be the most popular product type of plastics processing machinery, accounting for close to two-fifths of global sales revenue in 2017, followed by extrusion machinery that is spurred by an increase in the global construction activities. Film and sheet technology is another evolving area as domestic players are rallying their R&D efforts to develop their proprietary technology which was dominant by the developed countries. For examples, Jinming Machinery, a

Plastics & Rubber Review | November-December 2014 | 43

successful China’s extruder maker, has partnered with BASF to jointly develop solutions for the coextrusion film industry for local market. The company also aligned with Xian Jiaotong University in China to co-develop an intelligent controller based on System on Chip, a core technology of the blow molding industry which has long been monopolized by a few advanced countries. At the same time, the auxiliary equipment market is gaining momentum, with the world’s regulations in place to promote the “circular economy” and the “zero waste” policy for end-ofthe life products. In CHINAPLAS 2015, it is expected to see more recycling solutions at the fairground provided by global leaders and Chinese companies. Meanwhile, machine vision inspection system also enjoys benefit from the growth of automation market to underscore a huge potential in China. Being used in conjunction with the robots, the system is widely applied in automotive, electronics, telecommunications, aerospace and military for processing tasks that need high precision. Frost and Sullivan’s research indicates that the global market for industrial machine vision inspection systems generated revenue of US$4.37 billion in 2011 at a compound annual growth rate (CAGR) of 9.1% from 2011 to 2016. China’s market alone will reach to US$618million (CNY 3.8billion) of sale in 2016. Ada Leung added, “Apart from the expanded Machinery Zone, the Chemical Zone will also house around 800 chemical exhibitors, making it the world’s biggest of its kind. There are some new joiners from Middle East countries such as

UAE and Saudi Arabia to exhibit in the zone for the first time.”

Concurrent events move with the new trends, focusing on automation, design and innovation and medical plastics With the great success of last year’s concurrent activities, namely ‘The City of Tomorrow’ and ‘Green Conference’, the next edition will carry forward the same theme “Greenovation – Solution to Sustainability” through a variety of activities organized at the fairground. Known to shade insights of the industries, CHINAPLAS 2015 will bring the hottest topics such as processing line automation, applications of medical plastics and design for sustainability into the fairground in shaping a new era of manufacturing. A host of activities such as the showcase, demonstrations and conferences will be organized around these themes in concert with the new trends to help visitors staying at the forefront of the sectors. BASF, the world’s leading chemical company, will join hands with CHINAPLAS to showcase a range of innovations by highlighting how plastics enables good product designs and innovation to improve our life at the show. Modern plastics not only have helped us meet many of society’s challenges from lifesaving technologies to sustainable living, but also empower designers with infinite imaginations to consistently create innovative products that shape a better world. Industrial automation will be the area worth the industries’ attention. The perils of rising labor costs, shortage of skilled labour and increasing competition from other emerging Asian countries have

44 | November-December 2014 | Plastics & Rubber Review

given the Chinese enterprises a nudge in switching the labour intensive operations to automated manufacturing. According to the latest findings released by International Federation of Robotics (IFR), China was the largest destination for industrial robots in 2013, purchasing 36,560, a fifth of the world’s total robots, with the annual growth rate of 60%. Many big corporations in China have already benefited from the move. For example, Haier, the home appliances giant, has recently laid off around 10,000 workers this year to give way to robots for boosting their efficiency and productivity. Midea, an air conditioning equipment maker, has been widely using robots in its assembly line since 2010. The company said automation has cut their labor cost by US$1.28 million in 2013. Medical plastics will be another area to experience an exponential growth, thanks to the aging population and the high demands of low cost access to the medical system in Asia countries and the developing worlds. According to the analyst firm NanoMarkets, the global medical polymer market will grow from US$2.3 billion in 2013 to over US$3.5 billion in 2018. Healthcare spending in Asia Pacific

is expected to grow at a CAGR of 10.5% over the next five years to reach US$2.21 trillion in 2018, says from another healthcare report by Frost & Sullivan. Ada Leung added, “We are hoping the visitors can benefit not only from meeting the international exhibitors and their latest products in our show, but also the variety of concurrent events and activities that embrace the latest development and visions of plastics and rubber industry we bring into the fair”. The entry tickets have two types, namely one-day pass (RMB 30) and four-day pass (RMB 50). Visitors who successfully pre-registered at www.ChinaplasOnline.com/prereg on or before 11 March, 2015 will enjoy free admission and receive visitor badge in advance. Besides, pre-registered visitors can also enjoy the function of “My Exhibitor” through official website and CHINAPLAS’ app. It helps visitors to select their own exhibitors from the exhibitor list and take note of each. The exhibitor list and app will be launched soon. For more details, please visit the official show website at www.ChinaplasOnline.com.

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.

In-house Recycling: International visitors flock to EREMA’s “Discovery Day 2014”

EREMA “Discovery Day 2014” In-house Recycling

Recently, over 130 existing and potential international customers and guests invited by EREMA were at the company’s headquarters in Ansfelden near Linz in Austria for “Discovery Day 2014”. The focus of the EREMA’s series of events this year was on in-house recycling, one of the global market leader’s core competencies. With first-class talks given by experts representing the entire value chain and live demonstrations on several types of INTAREMA® systems, EREMA demonstrated how the quality of the end products can be kept constant with intelligent in-house recycling solutions while saving production and labour costs at the same time.

lexible packaging accounts for a quarter of the world’s plastic applications. Special polyethylene (PE) film applications such as shrink and stretch films and biaxially oriented PP (BOPP) dominate the field here with annual growth rates of 3-5% in the market. As material costs account for a majority (over three quarters) of the production costs, less production “waste” also means lower costs for raw material and disposal. With “Don’t waste your waste” as the motto, EREMA showed how you can use intelligent in-house recycling solutions to return up to 100% of the plastic “waste” to the production process and thus save production and labour costs. Over 130 existing and potential customers and guests of EREMA came from the whole of Europe, Russia, Israel, Thailand and Senegal to benefit from the first-class information about the latest trends and product news in this sector. Experts from the well-known companies Borealis, SML, OCS, Polifilm Extrusion

Experts from the entire value chain gave high-class talks

and EREMA provided valuable insights in their presentations. The live demonstrations took place in the EREMA Customer Centre which, together with a plastics analysis lab, features worldwide state-of-the-art engineering. Intelligent in-house recycling solutions

In-house recycling solutions for flexible plastic packaging are a core competency at EREMA – some 2,000 of the over 4,000 EREMA systems sold around the world operate in this application field. The new INTAREMA® plant generation offers users an additional boost in efficiency: the new, patented Counter Current technology means even higher output capacity, the Smart Start system makes operation extremely easy with a remarkably high degree of automation and enhanced EcoSave® technology reduces energy costs even further. Existing and potential customers who want to integrate recycling in production benefit from EREMA being able to provide concrete solutions to individual challenges, especially in terms of quality and personnel costs. The perfect preconditioning of the plastic

material prior to extrusion is crucial for the quality of the recyclate. EREMA fulfils these requirements with its systems through the combination of a preconditioning unit with the recycling extruder. The Counter Current technology also ensures remarkable recycling process stability despite varying characteristics and conditions of the input material. Thanks to the Smart Start system, however, the personnel required for the recycling process is kept to a minimum, which is important as inhouse recycling systems often only run “on the side” compared to the actual film production plant. Inline & offline

EREMA presented both inline and offline systems at “Discovery Day 2014”. The recycling systems can thus be integrated not only in the production lines but also installed externally. For flexible and highly efficient offline applications EREMA presented to attendees the brand new EFS Crocodile system with a technical conveyor belt for the dosing of endless edge trim. This innovation enables the constant feeding of tangled edge trim without pre-cutting for the first time. v

Plastics & Rubber Review | November-December 2014 | 45

Micro-drip irrigation tube – Rapid Rupture Response With its most recent micro-drip irrigation extrusion line, PIL // Explore, Maillefer continues to build-in innovative solutions that improve ease of use and augment performance. Our Rapid Rupture Response (triple-R) feature addresses quality and performance issues that occasionally arise during production – complete tube breaks and smaller wall tears. When they do happen, the aim is to minimize down time and rapidly return to full quality production.

complete tube break unfortunately results in a full line stop. How to avoid polymer bleeding into the calibration trough and dripper melting onto insertion equipment? It’s a time consuming and tedious clean-up job that awaits the operator. Meanwhile, finished product no longer flows from the line. Fortunately, the triple-R feature includes detection of tube breaks and a fast reaction in consequence. The area around the head is immediately freed, 46 | November-December 2014 | Plastics & Rubber Review

which leaves polymer bleeding on the floor rather than into equipment. The tube downstream is stopped with minimum distance from the breakage point. At this point, all the advantages of the PIL // Explore line are brought into play. The fixed chassis of the insertion and calibration sections give the operator the ease of returning retracted equipment back to preset alignment positions, without complicated adjustments. With the tube’s break point is only an arm’s reach away, the operator easily joins the tube at the extrusion head and returns to full quality production within minutes. Scrap is limited, identified, and isolated from quality product. Soon finished product can rapidly flow from the line again. The second rapid response

feature is detection of tears and fracture points along the tube wall. Maillefer’s patent pending technology immediately identifies the faults in real-time during production. Response is configurable according the fault degree. Tube lengths can be automatically treated according to the scrap management strategy in vigor. For over thirty years, Maillefer has been helping manufacturers respond to the world’s growing demand for micro-drip irrigation tube. Our PIL extrusion lines are suited to a variety of needs. Whether you are looking for an all-in-one solution to develop the business or expanding your worldwide operations with a highly optimized line, we have a configuration that is right for you.

moves to Düsseldorf

trade fair portfolio. With its line-up it offers the ideal bridging link to our plastics fair as well as to the events in our metal trade fair quartet GIFA, METEC, THERMPROCESS and NEWCAST and with its concept it closes the gap between industry designers, product developers, processors, suppliers and users. For EuroMold the Düsseldorf location means not just stability but also added impulses thanks to the synergies for exhibitors and visitors.”

At Exhibition Centre on the Rhine from 6 to 9 October 2015 EuroMold, World Fair for Moldmaking and Tooling, Design and Application Development, is moving from Frankfurt to Düsseldorf. For the first time now the event running from 6 to 9 October 2015 will be held at the exhibition centre on the Rhine.This news was announced recently by Managing Directors of the organiser DEMAT GmbH, Diana Schnabel and Dr.-Ing. Eberhard Döring. Annually, the trade fair brings together over 1,000 exhibitors and some 55,000 visitors from throughout the world. One key reason for the switch in location is the new direction and more flexible approach of EuroMold at one of Germany’s most important and state-of-the-art exhibition centres. Düsseldorf is also located centrally in one of the strongest economic metropolitan regions in Europe; its importance as the regional capital of Germany’s most populous federal state North Rhine-Westphalia and, not least, the great exhibition expertise of Messe Düsseldorf have convinced us to hold EuroMold at Düsseldorf Exhibition Centre. Commenting on this move Diana Schnabel said: “Messe Düsseldorf is one of the most successful trade fair companies with an excellent reputation, especially in the field of plant, machinery and equipment trade fairs. Particularly in terms of the international spread of exhibitors and visitors Messe Düsseldorf leads. I am certain that EuroMold customers can greatly benefit from the knowhow and the well-known quality service of our new partner.” Werner M. Dornscheidt, CEO at Messe Düsseldorf GmbH, adds: “As a guest event EuroMold is the perfect complement to our

A large proportion of EuroMold trade visitors come from the automobile industry (34%), mechanical engineering (26%), the electrical and electronics industry (11 %) as well as medical technology (10%) – sectors that are at home in North Rhine-Westphalia (NRW). At EUR 599.8 b NRW generated 21.9% of German GDP in 2013 ranking it very much top among all German federal states. North Rhine-Westphalian plant and machinery construction alone occupies national pole position – almost one in four German machines is produced here between the Rhine and the Weser. Over 1,600 mechanical engineering operations in the state employ just under 200,000 people. With some 800 firms and over 200,000 employees the automobile industry and its upstream suppliers is one of the strongest sectors in North RhineWestphalia. The electrical industry is also represented in the state of NRW across the entire spectrum and forms an indispensable part of the value added chain. Many of its 1,100 companies employing 155,000 people lead on the world market with their innovative products. When it comes to the international spread of exhibitors and visitors at investment goods fairs, Messe Düsseldorf GmbH ranks N°1 worldwide. At its own events in the expert fields of plant, machinery and equipment some 70% of exhibitors and 60% of

trade visitors come to the Rhineland from abroad and customers from a total of 162 countries attend trade fairs in Düsseldorf. Representations in 135 countries (72 foreign representations and subsidiaries) form the global network of the corporate group. The central location of Düsseldorf in the most densely populated region of Europe (the catchment area is home to 150 m people within a 500 km radius), its good traffic connections and comprehensive range of hotels and restaurants make travelling to and from the city and staying here very pleasant. DEMAT GmbH

DEMAT GmbH is one of the highest profile private trade fair organisers in Germany. EuroMold is the world’s leading fair for moldmaking and tooling, design and application development and as the international meeting point it presents the entire process chain. The Messe Düsseldorf Group:

With turnover of EUR 323 m in 2013 the Messe Düsseldorf Group was able to maintain its position as one of the most successful German trade fair companies. At the events in Düsseldorf 25,126 exhibitors presented their products to some 1.2 m trade visitors in this trade fair year. Added to this were about half a million congress visitors. With some 50 trade fairs (24 of which are N°1 events in the Düsseldorf location’s five areas of expertise – plant, machinery and equipment; retail, skilled crafts and services, medical systems and healthcare; fashion and lifestyle; leisure) and some 80 to 100 of our own events, participations and commissioned events abroad the Messe Düsseldorf Group is one of the world’s leading export platforms. Here Messe Düsseldorf GmbH ranks as the N°1 organiser of international investment goods trade fairs. Customers from a total of 160 countries attend trade fairs in Düsseldorf.

Plastics & Rubber Review | November-December 2014 | 47

“Cure Time Reduction” project at the University of Leoben, Austria

Potential for cure time reduction in rubber injection moulding

Investigation of shear and extensional heating using conical dies for cure time reduction in rubber injection moulding In using calculating models to ascertain curing times and bulk temperatures, possible potential to reduce cure times may be estimated. This enables manufacturers working with elastomers to systematically optimise their processes as well as to improve tools and injection die concepts.

The cure time as a main part of the total process of rubber injection moulding is a key factor with significant potential for optimisation. Within the framework of the research project “Cure Time Reduction” at the Montanuniversitaet Leoben, Austria, influencing factors for the injection and heating process were systematically investigated and optimisation strategies were derived. The understanding of flow and thermodynamic processes during the injection phase was considerably improved as part of the experimental investigations. A new calculation programme for the estimation of bulk temperature attained in the injection process, as well as the cure time reduction (cure time calculator) are of practical significance since they can be systematically deployed by manufacturers processing elastomers for optimisation purposes.

Project leader Dr. Leonhard Perko created an empirically

verified programme to calculate increases in temperature of rubber compounds during the injection moulding process. An additional model enables users to estimate potential cure time reduction even before process optimisation has been carried out. A software assisted cure time reduction ensuring complete cross-linking enables significantly shorter cycles,

minimising energy requirements. Additionally, the potential for increasing bulk temperature by means of superposed shear and extensional heating in a conical die was practically recorded and predicted using the programme. Furthermore, compression heating in rubber compounds was scientifically investigated for the first time within the framework of this project. Calculation model for superposed shear and extensional heating in conical dies

The basis for observations of shear and extensional heating in conical dies are the analytical models developed by Cogswell and Binding. For practical verification, the flow field in the inlet area of the die was investigated experimentally. The investigations showed that die angles of >45° resulted in “dead areas” with almost no material flow. The 48 | November-December 2014 | Plastics & Rubber Review

dies could be described by means of a new calculation model, as already mentioned. Using an experimental mould, (Figure 2) injection moulding experiments were carried out under different process conditions. The parts produced were tested as follows: a) hardness, b) compression set and c) tensile test. Above all, the compression set in the middle of the injection moulded parts proved to be a good indicator for the critical cross-linking of parts.

Figure 1: Melt temperature as a function of die angle: comparison of measured and calculated values (NBR test compound)

The practical experiments showed that the injection work is the main influencing factor on the temperature increase of the rubber compound also having a major influence on the curing time. Further optimisation of the conical die geometries resulted in no additional technological improvements. Cure time reduction by means of compression heating

Figure 2: Experimental mould for the investigation of shear and extensional heating for cure time reduction purposes

bulk temperature measurements downstream of each conical die were used to verify the calculation model. Figure 1 shows the measured temperature increase as a function of the die angle for differing injection speeds (continuous lines). The intermittent lines show values derived using the new Perko calculation model. The maximum temperature increase achieved was 70 °C. An interdependency of the bulk temperature and die angle was witnessed in a range of 20° to 45°C. A further increase in die angle had no additional effect. Investigation of cure time reduction by means of conical dies The combined shear and extensional heating in conical

In addition, the potential of compression heating in rubber compounds for the reduction of heating times was investigated. The measured values for the compression heating induced by pressure increase of 1,800 bars were 10 °C. The systematic deployment of a compression phase in the cycle however

did not lead to any noticeable improvements in part quality or cure time reduction. Conclusion: compression heating is not suitable for cure time reduction. The reasons are the relatively small temperature increase attained (approx. 10 °C at 1,800 bar pressure increase) and the fact that the vast majority of the generated heat is lost through the cooler walls of the injection unit. Calculation programme to estimate cure time reduction (cure time calculator)

Investigations of the calculated potential for cure time reduction depending on the thickness of the moulded part were carried out. The experiments showed that the heating time of moulded parts with a thickness of less than 4 mm could hardly be reduced at all. The potential grows with rising mould temperature TW and increasing part thickness. Project leader Dr. Leonard Perko: “The cure time calculator is a new programme that can be used for valid estimates of the possible cure time reduction. Manufacturers of elastomer parts can now systematically optimise their processes as well as mould and die concepts”. The cure time calculator has been made available to rubber processing companies by the project partners.

meet

‘Plastics & Rubber Review’ at Booth 3ZB - 234 ARABPLAST 2015,

10-13 January, Dubai World Trade Centre, U.A.E. Plastics & Rubber Review | November-December 2014 | 49

Metal caps, the global players meet up in Sacmi Metal Cap Day – the workshop that focuses on industry-related technology, scenarios and prospects – had no trouble attracting participants. This essential event saw the presentation of, among other machines, the all-new PTC 600 and a line for ‘deep’ aluminium caps developed with Friuli-based firm BortolinKemo. In the afternoon there was a visit to the Closures plant and lab and a demonstration of working machines, such as the revolutionary PMA 24 L that makes fully PVC-free annular seals No less than 123 specialised operators from 27 countries took part in Metal Cap Day, the workshop that examines the new technology, latest scenarios and future outlook of the metal cap industry, jointly organised by Sacmi Imola and Friuli-based firm BortolinKemo. “The high number of participants”, pointed out Giuseppe Lesce, “ manager of Sacmi’s Closures & Containers Division, “shows the keen interest in the topic. This year we’re celebrating the 95th anniversary of Sacmi’s founding and want to show everyone just how committed we are to customer satisfaction in the metal cap industry, where we’ve been doing business for over 50 years”. It was way back in 1952, in fact, that the first Sacmi press for the manufacture of crown caps was built: today. 50 | November-December 2014 | Plastics & Rubber Review

it’s a market in which the Imolabased Group is the world leader in terms of installed machines (over 1000 on five continents). And it’s a project that continues to evolve – as Massimo Gani, sales manager of Sacmi Closures, explained to the audience of international operators – with the launch of the all-new PTC 600, a solution that “incorporates all the advantages of the previous range in terms of power and reliability but also boosts performance and flexibility thanks to exceptional

design features and cutting-edge technology”. Some statistics? Output up by 20% compared to the previous range, with the machine capable of achieving 231 pressing cycles per minute (about 6,000 caps/minute), and vibration down by 37%, meaning less stress on materials and key machine parts. A more compact design, 30% less compressed air consumption and halved sound pressure (noise levels) complete the picture.

Further advantages include a metal sheet loading system that is fully automated and managed by dedicated servomotors and integration of the press with the CVS 3000 (a vision system with high definition video cameras produced by Sacmi’s Automation & Inspection System Division). More specifically, on the new PTC600, integration with the CVS means that the metal sheet picked from the magazine is repositioned correctly in the press and decoration alignment is executed within a minimal margin of error. The machineuser interface has also been completely renewed with a platform common to all Sacmi solutions: this combines userfriendliness, interoperability and comprehensive control of the production process. The crown cap enamel can be completed with a promotional code inkjet marker (integrated on the PCM 500 that makes the seals on the caps) and, lastly, there is the CCD 300, an innovative closure embossing solution where integration with the CVS3000 vision system ensures perfect embossing-decoration synchrony. From crown caps to metal caps, the industry is a vast one in which Sacmi plays a leading role together with Friuli-based firm BortolinKemo. Together, they offer a comprehensive solution of special interest for manufacturers of so-called ‘deep ROPP caps’: these are aluminium caps up to 60 mm high that are, in several countries – from Germany to South Africa – highly important on the alcoholic drinks market, especially wine. Hence the showcasing of Sacmi’s new PMH 120, an innovative system for forming the seal directly inside the cap using a compression process: the advantages of this machine, specially designed for this sector – observed

Iacopo Bianconcini, marketing manager of the Sacmi Closures Division – include outstanding productivity and flexibility with respect to insertion of traditional discs, plus the possibility of making a range of profiles and defining the most suitable solution together with the customer and the assistance of the Sacmi technological lab. “Teamwork with Sacmi”, highlights Mr. Sain, Managing Director of BortolinKemo, “is a consequence of having the same values and goals and a shared vision of the future”. The future, in fact, was the focus of Metal Cap Day, which, after a morning dedicated to presenting various solutions in the packed Sacmi meeting hall, continued with a visit to the plant. Here, participants enjoyed an opportunity to see machines in action, from the all-new PTC 600 to the vision systems (including the CAT 300 for crown caps, the MVS for metal caps and lids and the innovative CHS 360-3D, specially developed for ‘total inspection’ of ‘deep ROPP’ caps) and the

revolutionary PMA 24 L. The latter is designed to make seals inside caps in the 33 - 82 mm size range; it stands out on account of a special annular pellet extrusion system and its use of PVC-free materials. This gives advantages in terms of both energy and material savings and also improves product ‘healthiness’ by lowering contamination with respect to the more commonly used PVC-based substances. In short, then, technical developments for a future that is, for Sacmi, built on constant R&D investment – 47 million Euros in 2013 at Group level, point out Giuseppe Lesce. With regard to caps, a central role is played by the Closures laboratory, which this year obtained prestigious Pepsi certification. It is here, in fact – as visitors to Metal Cap Day saw for themselves – that solutions are assessed right from the design stage via lab tests performed according to protocols approved and certified by the industry’s leading players.

Plastics & Rubber Review | November-December 2014 | 51

Labellers by Kube Labelling for highquality still and sparkling wines Flexible and highly automated, this solution can apply up to 9,000 labels per hour. Quality is guaranteed by an optical alignment unit with a movement tracking system.

producer of complete solutions for cold and hotmelt self-adhesive labelling systems, with a strong focus on medium-to-high quality still and sparkling wines, Kube Labelling presented its Kube K30 9T rotary labeller at the Vinitech 2014 fair in Bordeaux (2-4 December 2014, stand 1E2305). This model, capable of achieving output rates of up to 9,000 applications an hour, has been designed for the parallel application of three labels on cylindrical and shaped containers. Equipped with an electronic-cam plate movement system, the labeller features a universal screw feeder powered by a brushless motor for the flexible and efficient handling of variable diameters. Equipped with three gluing stations – 2 self-adhesive, 1 with glue – the labeller stands out on account of its optical alignment system, which ensures

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proper application of the label. The prime requirement, in fact, is to ensure correct orientation of the bottle with respect to the label: unlike traditional solutions (mechanical orientation) the Kube Labelling-developed “intermittent tracking” system allows correct label positioning under all output conditions and makes size changeover tasks fast and easy. Equipped with a reel holder with a 400 mm diameter and an automatic rewind system, the self-adhesive labelling station is also highly automated thanks to a dual electronic traction paper drive solution. The glue-type labelling

station – driven by a brushless motor - is, instead, equipped with a system to control torque on the rubber roller. Both gluing stations are adjusted by way of special ball bearing guides. Completing the machine – made by a young company that is offering the market a highly innovative labeller of undoubted interest to key industry players – is the touchscreen interface, which features user-friendly software and a remote control system. The latter, in fact, makes it possible to monitor all process parameters and identify any potential problems using a wide range of mobile devices, tablets and smartphones included.

and activeAdjust, the optional technologies activeMotionControl, activeScrewDrive, activePowerLink and activeEcon are used. This allows to better align the machine with the application and to use further efficiency potential. El-Exis SP - Sophisticated concept for maximum demands

Barlo Plastik A.Ş. at Plast Eurasia 2014: Professional injection moulding of packaging applications Barlo Plastik A.Ş. presents

Versatile & Functional Solution for

Complex Packaging Applications At Plast Eurasia in Istanbul/Turkey, Barlo Plastik A.Ş. presented its efficient and economic solutions for injection moulding packaging applications. The Turkish representation of the German-Japanese machine manufacturer Sumitomo (SHI) Demag demonstrated its ElExis SP hybrid high-speed machine with IML. The exact interplay between injection molding machine, mould and automation is the key to a high output rate in the production of high-speed food packaging. With the El-Exis SP machines, Sumitomo (SHI) Demag Plastics Machinery GmbH, Schwaig/Germany, provides the ideal basis for the economical production of sophisticated packaging applications. High-speed application with IML decoration

At the Plast Eurasia the company showed its packaging expertise by producing food containers with IML on an El-Exis SP 200-920 with a clamping force of 2,000 kN. Along with the handling of Polymac Robotics b.v., the injection molding machine is designed as a compact IML manufacturing cell, allowing to produce the container in less than 3.5 seconds. The cups are made in a four-cavity (PP) mould of polypropylene made by Otto Hofstetter AG and have a shot weight of approximately 6.2 grams.

The decentralized electric drive of the clamping unit allows fast and sensitive opening and closing of the mould on the El-Exis SPmachine thus ensuring a highly accurate mould-stop position. This ensures the precise positioning of the labels and a correct removal of the finished cups. The NC5 plus control guarantees a simple, clear and intuitive operation of the machine, the hybrid drive system with energy recycling saves up to 40% of energy. The El-Exis SP machine exhibited at the Fakuma is also equipped with various active technologies of Sumitomo (SHI) Demag. In addition to the standard technology modules activeQ/ Q+ integrated, activeCool&Clean

The El-Exis SP offers technological excellence for the production of thin-walled packaging. With a combination of electric and hydraulic drives, the El-Exis SP machines are designed for maximum speed and dynamics. These machines are the result of many years of market knowledge in packaging at Sumitomo (SHI) Demag. 20 years of market expertise and 15 years of experience with the El-Exis series are manifested in a very high process stability and make the ElExis SP one of the best packaging machines worldwide. In developing the El-Exis range, economy has always been a key criterion. Due to the parallel, hybrid drives and a nearly loss-free power transmission, the machine has a low energy consumption despite high performance. After all, the energy costs are the linchpin for low-cost production in addition to the material price. Due to its proven and reliable machine technology, the El-Exis SP also reaches a high level of availability and durability.

About Barlo Plastik A.Ş. Barlo Plastik A.Ş. was established in 1992 as a member of Barlo Group of companies. Barlo Plastik represents all leading plastic machine and periphery suppliers who are technology-builders in their branches. Our aim is to present all these products and the experience of our suppliers to the Turkish plastic manufacturers with most suitable conditions. Our customers are not only oversized companies, but we seriously reply to find technical and financial solutions to the demands of customers with only 1 or 2 machines. We try that the high technology we present to our market through our suppliers may be utilized by all of the relative small and big customers. In this way our customers can increase the quality standards, the speed and capacity of the production, as well as save energy and personnel, i.e. they may be more competitive in the global market. www.barloplastik.com Plastics & Rubber Review | November-December 2014 | 53

Automatic Self-Cleaning Screen Changer Dramatically Increases Output For European Recycler Of Post-Consumer Plastics

‘V-Type’ Screen Changer from Nordson Kreyenborg Enables Recycling Company to Change Screens Once a Day instead of Every Eight Minutes

he contaminants inevitably found in post-consumer plastics place a heavy burden on the melt filtration equipment in recycling lines and can force operators to spend much time and effort simply changing filter screens. For a European company specializing in polyethylene recycling, the solution was to switch from conventional slideplate screen changers to an automatically self-cleaning system.

and discharging it in reverse direction, back through the screen, to carry away contaminant for removal from the system. The V-Type screen changer purges even heavy contaminant from the melt filter element while maintaining extrusion throughput, minimizing operator intervention, and avoiding downtime.

The recycling company has installed such systems in two recycling lines that transform postconsumer polyethylene into pellets used for blown-film production of trash bags. The company replaced two 300-mm slide plate screen changers with 200 mm “V-Type” screen changers from Nordson Kreyenborg. Because the V-Type systems are automatically self-cleaning, screen changes are necessary only once a day— instead of every eight minutes with the old equipment.

In Nordson Kreyenborg’s V-Type screen changer, melt flow from the extruder splits into four streams for filtration in two pairs of screen cavities, then the streams rejoin with no significant change in melt flow. Each pair of cavities is mounted in a piston which positions both cavities so that they can filter their respective melt streams, or removes one of them from the process to remove contaminant buildup by means of backflushing. In normal operation, polymer is flowing through all four cavities. While one of the cavities is changed, the other three remain in the process.

The key to eliminating need for frequent screen changes is Nordson Kreyenborg’s “power backflush” technology. When contaminant buildup causes the differential pressure across the screen changer to reach a pre-set level, the backflush sequence begins automatically, with hydraulic pistons compressing some of the already filtered molten polymer

The process for changing screens is initiated when a pre-defined number of backflushes is reached. This triggers the outward movement of the screen-bearing piston so that the screen pack can be removed and a new filter element is put in its place. Three of the cavities remain in the process while a new screen pack is installed in the fourth.`

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Nordson Appoints Utpal Pathak As Sales Manager In India For Extrusion Dies Industries Product Line Utpal Pathak has joined Nordson Corporation as sales manager in India for the Nordson Extrusion Dies Industries range of products. Mr. Pathak will provide sales and support services for Nordson flat die systems for extrusion of film, sheet, and coatings, as well as systems for fluid coating. In addition, this product range will continue to be represented in India by Bharat Muchhala of Shruti International, as it has since 1996. “Utpal Pathak brings 25 years of industry experience, virtually all of it focused on sales of extrusion machinery or production of extruded products such as flexible packaging,” said Mrunal Sangvi, senior sales manager for Nordson’s Polymer Processing Systems family of products. “He will be a valuable resource for helping our customers choose the optimal die system and supporting them both before and after the sale.” Mr. Pathak entered the plastics industry in 1989 as sales executive for extrusion systems at Kolsite in Ahmedabad. Subsequently he held sales positions with Mamata Brampton, Parikh Packaging, and Jayshri Propack. Most recently he was general manager at Unimark International, in charge of sales of Bandera extrusion equipment and various systems for web converting.