Vol.3 No.5 | September-October 2015 | New Delhi | India
Fully automatic zero defect manufacturing of precision moulded parts for the automotive industry ARBURG at the Plastics & Rubber Indonesia 2015
International Trade Fair for Plastics Processing
SHOW REPORT T-PLAS 2015 Amut Group Boosts Technical Service In Vietnam And Indonesia
Well below two seconds for injection moulding plus removal...
Special show at K 2016 – Plastics shape the future Finalist of the Deutscher Zukunftspreis (German Future Prize) 2015
Printing lightweight, flexible, and functional materials 3D printing is revolutionizing the production of lightweight structures, soft robots and flexible electronics, but the technology struggles with complex, multimaterial integration. To print a flexible device, including the electronics, a 3D printer must be able to seamlessly transition from a flexible material that moves with your joints for wearable applications, to a rigid material that accommodates the electronic components. It would also need to be able to embed electrical circuitry using multiple inks of varying conductivity and resistivity, precisely switching between them. And, it would be ideal to do all of this without the stopping the printing process. The ability to integrate disparate materials and properties within printed objects is the next frontier in 3D printing. Towards this objective, Harvard researchers have designed new multimaterial printheads that mix and print concentrated viscoelastic inks that allow for the simultaneous control of composition and geometry during printing. Using active mixing and fast-switching nozzles, these novel printheads change material composition on the fly and could pave the way for entirely 3D-printed wearable devices, soft robots, and electronics. The research was led by Jennifer A. Lewis, the Hansjörg Wyss Professor of Biologically Inspired Engineering at the Harvard John A. Paulson School of Engineering and Applied Sciences (SEAS) and a Core Faculty Member at the Wyss Institute for Biologically Inspired Engineering at Harvard. The work was published in the Proceedings of the National Academy of Sciences (PNAS). Mixing complex fluids is fundamental for printing a broad range of materials. But most mixing approaches are passive, wherein two streams of fluids converge into a single channel where they undergo diffusive mixing. This method works well with low-viscosity fluids, but is ineffective with high-viscosity fluids, like gels, especially in small volumes over short timescales. To address this challenge, a new multimaterial printhead based on active mixing was designed by Lewis, along with Thomas Ober, postdoctoral research scholar at the Wyss Institute; and Daniele Foresti, the Society in Science Branco Weiss postdoctoral fellow. The active mixer efficiently mixes a wide range of complex fluids by using a rotating impeller inside a microscale nozzle. “Passive mixtures don’t guarantee perfectly mixed materials, especially highly viscous inks,” said Ober, the paper’s first author. “We developed a rational framework -- and verified it experimentally -- for designing active microfluidic mixers that can mix a wide variety of materials.” The team used this knowledge to create active mixing printheads for patterning heterogeneous materials in three dimensions. The research team demonstrated several uses of their active mixing technology. They showed that silicone elastomers can be seamlessly printed into gradient architectures composed of soft and rigid regions. These structures may find potential application in flexible electronics, wearable devices, and soft robotics. They also printed reactive materials, such as two-part epoxies, which typically harden quickly when the two parts are combined. Finally, they showed that conductive and resistive inks could be mixed on demand to embed electrical circuitry inside 3D printed objects. “The recent work by the Lewis Group is a significant advancement to the field of additive manufacturing,” said Christopher Spadaccini, Director of the Center for Engineered Materials, Manufacturing and Optimization at Lawrence Livermore National Lab. “By allowing for the mixing of two highly viscous materials on the fly, the promise of mixed material systems with disparate mechanical and functional properties becomes much more realistic. Before, this was really only a concept.
Vol.3 No.5 | September-October 2015 | New Delhi, India
ANNUAL SUBSCRIPTION: INDIA: RS.2000 | OVERSEAS: US$150
I n T h e P a g e s 4 T-PLAS 2015 - successful 4-Day exhibition! 8 Q-Button - The new concept for process monitoring 10 Amut Group Boosts Technical Service In Vietnam... 14 Arburg at the Plastics & Rubber Indonesia 2015 16 Finalist of the German Future Prize 2015 21 Well below two seconds for injection moulding... 25 Complex production unit for insert moulding... 27 Jinming Multi-layer Cast Film Equipment... 28 Special show at K 2016 – Plastics shape the future 32 Fully automatic zero defect manufacturing ... 35 BOY among the best at MSV 36 New intelligent recycling technology 40 2015 Thermoforming Parts Competition Winners 42 Fakuma 2015 – Trade Fair for Plastics Processing 45 K 2016 – Innovation takes centre stage 47 Brand new perspectives in packaging print 52 The Future Of Printing At The 6th All In Print China
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. Contacts: To advertise: advertise@plasticsandrubberreview.com, to submit a press release: editorial@plasticsandrubberreview.com, to subscribe: subscribe@plasticsandrubberreview.com, for general 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 | September-October 2015 | 3
T-PLAS 2015 Raised the Industry Bar and Produced an exceedingly successful 4-Day exhibition! • • •
283 international exhibitors introduce cutting-edge manufacturing technologies into the region at T-PLAS 2015 7,345 Quality Visitors attendance lead to Sold Machines and Strong Sales Potentials Full-House at Concurrent Seminars The Thai International Plastics and Rubber Exhibition, concluded on 29 August on a strong note, having exceeded all expectations in attracting a turnout of 7,345 highly quality visitors from 21 countries. T-PLAS 2015 received strong support from both XX leading international and XX regional companies, as well as 4 national pavilions from Austria, Malaysia, Singapore and Taiwan and numerous industry associations. The exhibition presented a comprehensive range of machinery and equipment, processing solutions and services to the international industry trade professional crowd who visited the exhibition. XXX came from XXX. Affirming its positioning as the leading exhibition Alf Hofstetter, General Manager of Leistritz SEA Pte Ltd
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noted that “T-PLAS is the largest plastic exhibition in Southeast Asia, and if you want to be active in the Southeast Asia market, it is the choice to go to.” T-PLAS was co-located with the 5th international packaging and printing show PACK PRINT INTERNATIONAL, which is also organized by Messe Düsseldorf. Tapping into a growing market, the synergistic co-location was a major success attracting a total trade visitorship of close to XXXX. The concurrently held exhibitions created an exhibitor and visitor cross-over for the packaging and plastics market who are servicing the flexible packaging market with their machine applications. “The packaging and plastics show is very important to us and when you find this combined in one place it is even better”, said Fritz Wimmer of EREMA Engineering Recycling Maschinen.
together these four sectors under one roof – will serve as that one-stop, opportune platform for industry players to tap on the burgeoning market opportunities through the building of business networks and exchanging of expertise. And from it, heighten Thailand’s manufacturing and service sectors to international
standards.’ Sold Machines & New Technologies Wittmann Battenfeld, one of the major suppliers of injection, moulding machines robot and the complete peripheral equipment for injection moulding have recognized these growth
The exhibitions were officially Opened on 26 August by Her excellency Dr. Atchaka Sibunrueng, Minister for Industry, who stated that ‘The exhibitions come at a time where Thailand’s manufacturing sectors are heading on an upward curve – reflected in the expansion of Thailand’s Gross Domestic Product (GDP) at 2.8 percent. Manufacturing in Thailand is the most important sector and accounts for 34 percent of our GDP, and the timely, value-for-demand co-staging of PACK PRINT INTERNATIONAL 2015 and T-PLAS 2015, which brings Plastics & Rubber Review | September-October 2015 | 5
patterns “The Thailand market has become one of the most important markets in Southeast Asia for us, this is also the reason why we are participating at T-PLAS!” said Dr Werner Wittmann. The Austrian exhibitor was showcasing a servo-hydraulic machine ‘SmartPower’ for the first time in Thailand, which was sold at T-PLAS. Available in clamping force sizes from 25to 120 t, this new machine boasts of precision, efficiently, compact dimensions and user-friendliness. Arburg also delivered its first ‘Freeformer’ to the Asian consumers – demonstrating the machine live at the T-PLAS. One of the world leaders in injection moulding, Arburg also presented a high speed injection moulding machine to the packaging market. David Chan Managing Director of Arburg explained that “We see a big future here, which is why we are we here to present our latest machines at T-PLAS to the ASEAN market.” But not only the show floor was abuzz with activities, sold signs of high-precision and specialised machinery as well as large reports of secured future orders. The concurrent events were also a success. Seminars such as the Advanced Injection Technology Conference held on 27 August by the Tool & Die Industry Association and the Plastic for Medical Industry Seminar held by the Plastic Institute of Thailand on the 28 August were fullhouse events! T-PLAS 2015, delivered an exhibition and concurrent events that were designed by the industry for the industry to drive international businesses and the Thai Industry forward. For more information please contact tplas@mda.com.sg or visit www.tplas.com About Messe Düsseldorf Asia (MDA) MDA is a subsidiary of Messe Düsseldorf in Germany, one of the world’s leading trade fair organizers, responsible for organizing more than 20 global No. 1 exhibitions in industries including plastics, printing and packaging, and medical and health care - specifically 6 | September-October 2015 | Plastics & Rubber Review
K, drupa, interpack, MEDICA, COMPAMED and A+A held in Düsseldorf, Germany. Since 1995, MDA’s portfolio of trade fairs in Southeast Asia includes: for the plastics and rubber sectors in Thailand (T-PLAS), Vietnam (PLASTICS & RUBBER VIETNAM) and Indonesia (INDOPLAS), the printing and packaging sectors in Thailand (PACK PRINT INTERNATIONAL) and Indonesia (INDOPACK and INDOPRINT), the wire, cable, tube and pipe sectors in Thailand (wire Southeast ASIA and Tube Southeast ASIA), the medical and health care industries in Thailand and Singapore (MEDICAL FAIR THAILAND, MEDICAL FAIR ASIA, MEDICAL MANUFACTURING ASIA) the Workplace Safety & Health sectors in Singapore(OS+H ASIA) and the metal and steel trade industries in Indonesia (indometal).
ThE ART OF pRODUcTiON EFFiciENcy
There‘s no great art in making the right choice: premium injection-moulded parts or functional 3D products, ALLROUNDER or freeformer – with us, you have freedom of choice. From one-off parts to high-volume production, all from a single source. A unique perspective – worldwide!
2015 r 13-17, Octobe ooth 3101 B , any hall A 3 , Germ hshafen c ri d e ri F
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Q-Button The new concept for a simple and expedient process monitoring
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very molding process must be monitored directly on the molded part. This is because only a monitored process guarantees that only good parts will be shipped.
PRIAMUS systems are designed to be modular and can be expanded to the limits of today´s computer capacities depending on the number of channels and monitored functions. This is also necessary to reflect the quality criteria of the molded parts in all applications and even for a high number of cavities. The effort for an expedient setting of the monitoring limits however increases with the number of monitored functions and channels. With the Q-Button PRIAMUS introduces a concept which allows the automatic setting of monitoring limits for individual or all monitoring functions and control parameters. „Q“ stands for the English „Quick“ and at the same time for quality. As soon as the process is optimized, and good parts are molded, the touch of a button is all it takes to determine preset limits for process monitoring. The basis for this serves the six sigma values which guarantee an expedient setup for the monitoring. This procedure offers a substantial simplification in production because the limits of process monitoring can be set easily and fast, independent from the number of channels and monitoring functions. Furthermore the PRIAMUS systems provide the option to detect whether the process is stable or drifting. 8 | September-October 2015 | Plastics & Rubber Review
From Control M to Control P – A Control is Coming of Age
After the concept of FILLCONTROL Control M has found more and more approval over the past years the users became increasingly aware that something special takes places. Because it has not been the injection molding machine which was controlled although its parameters were adapted, but it was directly the quality of the parts in the mold – and therefore the injection molding process itself. PRIAMUS has met the challenges and decided after a number of reviews to rename the term “Control M” (for Machine Control) into “Control P” (for Process Control). One reason for this was in the control of compression, for example, which in the current version is determined independent from the signal trace and independent from time via a peak hold function of the cavity pressure. The main reason for the name change however is the fact that a consistent quality can only be produced in the Process and not in the Machine. Incidentally, the existing users will easily get used to the new User Interface because most parts of the control software have practically not or only slightly been changed. Nevertheless they will have the impression that they have left the age of puberty behind. PRIAMUS SYSTEM TECHNOLOGIES AG Rheinweg 4, CH-8200 Schaffhausen / Switzerland Contact: Michelle Gammersbach, +41 (0)52 632 2605 PRIAMUS SYSTEM TECHNOLOGIES, LLC 3061 Nationwide Parkway, Brunswick, OH 44212 / USA Contact: Marcel Fenner, +1 877 774 2687 www.priamus.com
PACKAGING • INGREDIENTS • MACHINERY • PRIVATE LABELS • RAW MATERIALS • CONTRACT MANUFACTURING
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in cooperation with
AMUT GROUP BOOSTS TECHNICAL SERVICE IN VIETNAM AND INDONESIA to guarantee the best heating exchange between polymer and water; - the AMP850 GP thermoforming machine with a mould area of 850 x 550 mm and cutting force up to 70 tons, equipped with 50-cavity mould off set configuration to reduce the recycled material at only 40%; - a pick up stacker capable to reach a production efficiency till 92%; - a new in-line grinder composed of a rotor diameter 400 mm and 5+5 blades to increase the cutting frequency and to decrease the power consumption. - a software supervisor for an easy and friendly handling of the machine.
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ince August 2015, AMUT GROUP confirms the establishment of new technical service points in Vietnam and Indonesia boosting and consolidating a complete onsite support to the existing and potential customers. This strategy has been followed because of the great results always achieved in the extrusion and thermoforming field in the South-Eastern Asian area. AMUT has a very good reputation in these countries and even the last model of thermoforming machine has hit the mark: the AMP 850 GP delivers particular light AQUA CUPS ideal to comply the specific exigencies of these markets, such as a volume of 220 ml and a weight of barely 2.5 gr. AMUT GROUP secured two important projects in Indonesia with the in-line version of this model, perfectly fitting the standard tests for filling and sealing water cups and with an output of 96.000 pcs/hour. Reduction of the power and compressed air consumptions is definitely proven. The highlights of the in line system are: - a single screw extruder EA130 40 L/D, equipped with a new screw design reducing the mechanical stress on the PP during the melting process and granting good
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results on the cup’s impact test and keeping the max output at 800 kg/h processing till 50% of recycled material; - a calender roll equipped with three independent hard chromed polished rolls, with diameter 600 mm with a new concept of internal cooling
This met with an excellent response from the Vietnam area too. After only two months from the presentation of the VPK-C84 3-stations thermoforming machine during the last Chinaplas show, AMUT has already finalized two contracts in Vietnam: one for a AMP630 thermoforming machine for the production of PP cups (Ă˜ 85 mm) and the other for a VPK-C84 delivering PP and PET lids with diameter 85 mm and 95 mm.
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Plastics & Rubber Review | September-October 2015 | 11
Adhesion modified TPEs for biinjection on hard substrates API enhances its focus on TPEs for selective combination with specific EP
API SpA actively participated in the recent DKT conference where, within the framework of its continuous activity in the field of innovative hard-soft combination, it presented the VDI 2019 standard to measure the adhesion of TPEs on injection-moulded substrates . The TPE compounding group has its headquarters in Mussolente - Northern Italy – where also a specific centre for the study and development of TPE for multi-component applications is located. VDI 2019 standard The demand to combine soft TPEs with harder materials has been constantly increasing, and today, particularly in automotive and engineering, there are more and more applications requiring a soft, rubbery-touch surface to cover rigid substrates. The combination of soft and hard materials can offer not only specific process advantages in complex applications, but also more freedom in designing geometries that would otherwise not be feasible. The trend for the next future envisages the designing of applications that combine different types of materials (often also more than two), not necessarily only plastic materials but also metal and glass for example. In this perspective, the new adhesionmodified TPE types that API is developing will become a key component in application development. 12 | September-October 2015 | Plastics & Rubber Review
The VDI 2019 standard allows to define and measure the bond strength of a soft TPE onto a rigid thermoplastic by offering a systematic peelingtest procedure and by indicating the required documentation, and could soon integrate an extension to cover the adhesion of TPEs on non-plastic rigid substrates. API took part in the committee that was formed to define this new standard for the harmonization of the different methods previously in use for the determination of the bonding strength between soft component and hard substrate. In order to support its customers in the development of innovative, multicomponent applications, API has invested in a research centre, whose equipment is in full compliance with the VDI 2019 standard. Main purpose of this centre is to bring research, industry and practical application development together and to find new synergies between product design, materials and machinery. Here, reference samples -based on specific requests of the customercan be produced, key properties of multi-component applications can be tested, and raw materials, additives and machine setups can be investigated.
Ultra-high resolution, flexibility, total decoration quality COLORA CAP, “no limits to imagination” The world-leading producer of machines and complete plants for plastic closures, Sacmi presents the innovative on-cap digital printing solution
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pioneer with over 20 years’ market experience of providing true product and process innovation, Sacmi presents COLORA CAP, a pioneering digital cap printing solution developed by subsidiary company Intesa. A specialised digital decoration machine designer and already the leading designer of ceramic tile digital decoration solutions, this Sacmi Group company has brought the industry (the previous technological benchmark for which was pad printing) all the advantages of digital printing, thus intercepting a major market opportunity and implementing a technological revolution. COLORA CAP is a new on-cap digital printing system - which allows high definition cap decoration directly on the line without having to stock caps and lets users change the decoration in real time – with numerous advantages. It gives huge competitive gains in terms of flexibility as it’s possible to set a potentially limitless number of different decorations without affecting output rates and with changeover times virtually cut to zero.
Ultra-high decoration definition and an unlimited colour range result in the freedom to choose which image to print - without the operator having to carry out any work on the machine - independently of cap size. Moreover, dedicated software allows customers to set the selected image directly without requesting assistance from a specialised Sacmi technician. To complete the picture, total finished product quality is 100% guaranteed thanks to integration with the CVS vision system, which directly checks on the line and at ultra-high speed – that the decoration corresponds to the settings. Supplied by Sacmi with comprehensive international certification, the new COLORA CAP provides producers with a considerable competitive advantage from the dual viewpoints of extreme output flexibility – and the possibility, therefore, of making cap decorations for promotional campaigns, events, prizes etc. – and stock management, as HD images can be printed on caps in just a few minutes, even on small lots. All with that Sacmi brand guarantee of reliability and a worldwide after-sales assistance network covering all key markets. Plastics & Rubber Review | September-October 2015 | 13
The hybrid Allrounder 570 H in the “Packaging” version, which is specially designed for the high demands of the packaging industry.
Arburg at the Plastics & Rubber Indonesia 2015: Freeformer and highspeed injection moulding machine Complete product range: Plastic parts produced as one-off items and in high volumes Additive manufacturing: Freeformer on view live in Thailand for first time Injection moulding highlight: Hybrid Allrounder produces 24 closures in only three seconds
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rom 18 to 21 November, at the Plastics & Rubber Indonesia 2015 in Jakarta (Hall D2, stand D-9216), Arburg will present a high-end injection moulding machine as well as the Freeformer for additive manufacturing to cover the entire production spectrum from one-off parts to mass-produced items. While a high-speed Allrounder will demonstrate the cost-effective production of drinks bottle closures, a Freeformer will show the potential of the industrial additive manufacturing of functional parts as one-off items or in multi-variant small batches.
on our exhibition stand this year will be the Freeformer. Using the Arburg Plastic Freeforming process, the innovative system additively manufactures design and functional samples from standard plastics based on 3D CAD data, without the need for a mould. We will demonstrate this based on the example of spray heads and gear cards.”
“With a hybrid Allrounder 570 H in the “Packaging” version, we will be presenting an injection moulding application designed for high volume production in the packaging industry at the Plastics & Rubber Indonesia 2015. This efficient high-speed machine produces 24 water bottle closures in only three seconds,” explains David Chan, Managing Director of Arburg Singapore and responsible for the entire ASEAN region. “The highlight
Freeformer additively processes two components The Freeformer initially melts conventional granulates in a plasticising cylinder, similarly to injection moulding. A second discharge unit can be used for an additional component, for
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example to produce a part in different colours, with special tactile qualities, or as a hard/soft combination. At the Plastics & Rubber Indonesia 2015, the Freeformer will, for example combine a standard ABS granulate with a special support material. The supporting structures used during the additive manufacturing of the gear cards and spray heads for cosmetics containers can be subsequently removed in a water bath. Packaging technology: Allrounder “Packaging” version Specially for the production of screw caps, Arburg will present a hybrid Allrounder in the “Packaging”
version in Jakarta. This efficient highspeed machine from the Hidrive series offers high productivity and reduced energy requirements for applications in the beverage industry. The exhibit, which features a clamping force of 1,800 kN and a size 800 injection unit, operates with a 24 cavity mould from Z-moulds. The high-quality closures weighing 1.25 grams are produced in a cycle time of around three seconds. 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 sectorspecific turnkey solutions and further peripherals. An innovative additive manufacturing system was added to the plastic processing range in 2013. The company places the topic of production efficiency at the centre of all its activities, taking into account the entire value-added chain. The objective is to enable the Arburg customers to manufacture their plastic products, whether one-off parts or high-volume production, in 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 2,400 employees, around 2,000 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).
Industrial additive manufacturing: with the Freeformer and Arburg Plastic Freeforming (APF), functional parts can be produced from standard granulate, without a mould.
Further information about Arburg can be found at www.arburg.com.
Plastics & Rubber Review | September-October 2015 | 15
Laser Melting with Metals (LaserCUSING)
Finalist of the Deutscher Zukunftspreis (German Future Prize) 2015 With his nomination for the Federal President’s Award for Innovation and Technology, Frank Herzog from Concept Laser is now “among the best”. Together with his two project partners, Frank Herzog, founder and CEO of the specialist for 3D metal printing, has been nominated as a candidate for the German Future Prize 2015. His inclusion in the “circle of the best” is another milestone in the anniversary year of Concept Laser GmbH. The German Future Prize is the Federal President’s Award for Innovation and Technology. It is awarded to developers from industry and science who have rendered outstanding services with projects and initiatives to Germany as an innovation location. With his nomination, Frank Herzog is now “among the best”. Frank Herzog: “After the awards in 2014 (e.g. Bavaria’s Best 50) and the Final of the German Industry’s Innovation Award, this nomination is a great honor to me. Not least, it is also appreciation of the enormous potential of the LaserCUSING process developed by me.”
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he project with the title “3D Printing in Civil Aircraft Manufacturing - a Production Revolution is Taking Off” convinced the jury of the German Future Prize 2015 with regard to its degree of innovation and economic implementation. And the project team, consisting of Peter Sander, Head of Emerging Technologies & Concepts at Airbus, Hamburg, Prof. Dr.-Ing. Claus Emmelmann, CEO of Laser Zentrum Nord GmbH, Hamburg and Frank Herzog, founder and CEO of Concept Laser GmbH, Lichtenfels was therefore nominated for the German Future Prize 2015. The project is mainly about the first additively manufactured titanium component, referred to as a “bracket”, on board the Airbus A350 XWB. It is a “bionic” holding and connecting element, which is regarded as an important contribution to the lightweight construction of aircraft. This cross-industry development is revolutionizing the way structural aircraft components are made and “lightweight construction” is implemented in civil aircraft. This component was previously a milled part made of aluminum (Al) and is now a printed part made of titanium (Ti) with a weight reduction of approx. 30%.
Success by means of pioneering spirit German Future Prize - Federal President’s Award for Innovation and Technology” (image source: © Deutscher Zukunftspreis)
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Frank Herzog is regarded as a pioneer in the field of powder bed-based laser melting. The existing plastic sintering technology led to development of the LaserCUSING method in 1998. During his studies Frank Herzog
over a wide variety of industrial fields and applications over the years. Over 400 systems installed worldwide speak for themselves.
Frank Herzog, CEO of Concept Laser: “After the awards in 2014, such as Bavaria’s Best 50, and the Final of the Innovation Award of the German Industry 2014, this nomination is a great honor to the team and me. Not least, it is also appreciation of the enormous potential of the LaserCUSING process.”
thought that what worked with plastics should also work with metals. Part stress and the failure of metal powder to fuse completely were initially the greatest challenges in the process development. However, these problems were overcome by the hard work put into the development of stochastic exposure and the application of a solid-state laser. This pioneering work resulted in the founding of the company Concept Laser in the year 2000, which presented its M3 linear prototype machine to the public at the Euromold in Frankfurt in 2001 and, in this way, celebrated its world premiere in the field of industrial 3D metal printing. Concept Laser, which is situated in Lichtenfels in Upper Franconia, were able to supply the first systems worldwide only a year later. Once an exotic outsider, this additive manufacturing strategy has taken
And 15 years of Concept Laser also means 15 years of successful process development with numerous innovations and patents. For example, the company now has its own research and development department with over 50 employees. Furthermore, Concept Laser GmbH is involved in numerous research and development partnerships with universities, technological and scientific institutes and industrial companies. And the company is also the owner of more than 50 granted patents. Concept Laser GmbH has currently approximately 100 pending patent applications and a majority of them will be granted in the near future. The number of inventions applied for patents by the company has been steadily growing. Concept Laser’s 15th anniversary in 2015 is a brilliant performance – and it has the figures to prove it. The growth of + 75 % in 2014 is being consolidated by Concept Laser at a high standard. For example, a total of 110 laser melting systems were delivered in the year 2014. This figure is to rise to 150 systems in 2015. This means growth in sales of + 35% is expected compared to the previous already very successful year.
The LaserCUSING process
The LaserCUSING process (illustration of the process)
The term LaserCUSING, composed of the C from CONCEPT Laser and the English word FUSING (to fully melt), describes the technology. The fusing process uses 3D CAD data to generate components layer by layer. This process allows the production of complex
component geometries without tools in order to implement geometries as components that are difficult or even impossible to achieve with conventional manufacturing methods. 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. With LaserCUSING, finely pulverized metal is fused using a high-energy fiber laser. The material is solidified after cooling. The component contour is created by directing the laser beam by means of a mirror deflection unit (scanner). The component is constructed layer by layer (with each layer measuring 15-150 μm) by lowering the bottom surface of the build space and 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.
General aspects of an additive manufacturing strategy Numerous options for lightweight construction and an increase in the performance of components are opened up by an additive manufacturing strategy. Key words include: functional integration, lightweight construction potential, bionics and topology, conservation of resources, waste reduction, geometrical freedom, single
Plastics & Rubber Review | September-October 2015 | 17
ionic cabin “bracket” for the Airbus A350 XWB made of Ti, manufactured by means of the LaserCUSING process (image source: Airbus)
shot production, reduction of assembly work, timely production, also “on-demand” and improvement of the cost structure, e.g. by unmanned manufacturing 24 hours a day. The laser melting process has been made first choice in numerous sectors in relation to conventional machining strategies by the current challenges posed by manufacturing. According to manufacturing experts, automation, quality, a wide range of materials, integration in the production environment and potential build speeds are essential characteristics of additive manufacturing in the digital era. Additive manufacturing in a digital process chain is consistently based, not least, on the “Industry 4.0” strategy.
Significance of laser melting to aircraft construction Laser melting with metals is gaining in significance in aircraft construction as part of an additive manufacturing strategy. Here too, the typical reasons for the selected process are quicker throughput times, more costeffective components and previously unknown freedom of design. Two new key words, “lightweight” and “bionics” point to an emerging trend: The design approaches of developers in aircraft construction are changed by an additive process. In terms of aircraft design, future components will be able to absorb specific lines of force and yet still be able to fulfill the demands of a lightweight construction approach. In general, laser melting technology is capable of manufacturing safety-related components that are even better, lighter and more durable than conventional components 18 | September-October 2015 | Plastics & Rubber Review
manufactured today. Moreover, the material properties are slightly different. Prof. Dr.-Ing. Claus Emmelmann, CEO, Laser Zentrum Nord GmbH, Hamburg: “Materials produced using laser additive manufacturing have greater rigidity while, at the same time, less ductility; however this can be enhanced with the right heat treatment.” Furthermore, the process is distinguished by sustainability and resource conservation with simultaneous improvements to the cost structure.
Geometrical freedom and lightweight construction potentials as driving factors The arguments for the laser melting of metals in aircraft construction are geometric freedom and weight reduction. The “lightweight construction” approach is intended to help airlines operate their aircraft more economically. The achievable weight reduction results in a tendency towards lower fuel consumption or the potential to increase load capacities of aircraft. A new aircraft design requires thousands of flight test installation (FTI) brackets, produced in very small quantities. Additive “layer manufacturing” allows designers to come up with new structures. The additively manufactured components are in fact more than 30 % lighter than conventional cast or milled parts. In addition, the CAD data are the direct basis for an additive build job. The omission of tools reduces the costs and shortens the time until the component is available for use by up to 75 %. Since tools are not required in the process, it is now possible at an early stage to produce functional samples of components that are similar to series produced components. This is done without upfront
costs for tools. This means that sources of error can be identified in the early stages of the design process in order to optimize the processes within the project. Peter Sander, Head of Emerging Technologies & Concepts, Airbus, Hamburg: “Previously we budgeted around six months to develop a component – now, it’s down to one month.”
Bionics in the component or product design Laser melting with metals allows extremely fine, even bone-like, i.e. porous structures to be produced. “Future aircraft components will therefore have a “bionic” look“ is what Peter Sander expects. It is not without reason that over millions of years nature has produced optimized functional and lightweight construction principles which minimize the amount of resources required in a clever way. Airbus is currently analyzing solutions found in nature in a structured manner with regard to their applicability. By relying on “intelligent exposure strategies” of the laser, it can apply layers to a component in a strategic manner in order to produce custom properties in terms of structure, rigidity and surface quality. Peter Sander: “Initial prototypes indicate great potential of a bionically motivated approach. The process is expected to launch something of a paradigm shift in design and production.”
Quality as a significant parameter For aircraft manufacturers, monitoring during the component’s build process is one of the most important aspects of the industrial application. Peter Sander: “In practice, “inline process monitoring” with the QMmeltpool QM module from Concept Laser
Airbus A350 XWB
means 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.” In 2016 this module will be extended by QMmeltpool 3D. The former, time-related 2D monitoring of the build process becomes a position-related 3D landscape. Instead of exclusively time-related data, the system now additionally delivers position-related signals for definitive allocation, comparable to a computer tomography (CT). These signals make it possible to generate 3D datasets of the part and its structure. A highly accurate 3D landscape of the component is thus created. This allows QMmeltpool 3D to provide local indication of defects in the component. As a result, subsequent inspections and tests can be reduced to a minimum. Furthermore, the data are available directly after the build process, which also saves time. Other QM modules for active quality assurance are QMcoating, QMatmosphere, QMpowder and QMlaser. They measure or monitor, for example, the laser output and also the optimum layer structure of the metal powder and document the entire manufacturing process seamlessly. An additional feature in terms of quality assurance is the capability to work in a closed system to ensure the process remains free of dust and contamination. All disruptive influences that could have a negative influence on the process are intended to be eliminated this way. Frank Herzog: “These days it’s accurate to call this a regulated manufacturing process that provides repetition accuracy and process reliability.” Prof. Dr.-Ing. Emmelmann emphasizes by saying: “The QA software 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. Disruptions due to contamination can be eliminated.” Concept Laser can call itself a pioneer in this field too, since the company has been working on different
quality improvement/monitoring modules since 2004.
“Green technology” conserves resources Milling of aircraft parts results in up to 95% recyclable waste. With laser melting, the user receives components with “near-final contours,” and the process produces only about 5 % waste. “In aircraft manufacturing, we work with the “buy to fly ratio”, and 90 % is a fantastic figure. This is, of course, also reflected by the energy balance”, according to Prof. Dr.-Ing. Claus Emmelmann. This makes the process especially attractive when using valuable and expensive aircraft materials, such as titanium. A tool-less manufacturing strategy saves time and improves the cost structure. Targeted energy consumption and conservation of resources are features of the laser melting process. Frank Herzog: “LaserCUSING is a green technology and improves the often discussed environmental footprint of production.”
Spare parts supply 2.0: Timely, decentralized and “on demand” Spare parts constitute a new playing field for “additive aeronauts”. In future it will be possible to manufacture them
“on demand” at decentralized locations without the need for tools. In the event of a component failure, the spare part can be produced directly on site. Decentralized production networks can be created and global and regional strategies are possible. This minimizes transport distances and, above all, delivery times. As a consequence, maintenance-related downtimes and inspection times for aircraft are reduced. In future it will be possible to significantly reduce the large spare parts depots with parts rarely used that are currently essential given the long life cycles of today’s aircraft. A reduced capital commitment increases flexibility and especially the time needed to obtain safety-related components. This is especially attractive given the cost pressure in the aviation industry.
Outlook Laser melting as a 3D printing technology results in “more intelligent components” which exceed the performance characteristics of conventionally manufactured components in almost every dimension. In particular, in the aerospace industry, manufacturing experts are already speaking of a change in
Plastics & Rubber Review | September-October 2015 | 19
On December 2nd, 2015 the prize will be awarded. In a festive ceremony, the German President Joachim Gauck will honor the team from the circle of the best who - according to the jury - was able to beat the other projects. Concept Laser GmbH is an independent company based in Lichtenfels, Germany. Since its founding in 2000, it has been a leading innovator in the field of laser melting technology with the patented LaserCUSING® across many industries. The term LaserCUSING®, a combination of the C from CONCEPT Laser and the word FUSING (to fully melt) describes the technology: The fusing process uses 3D CAD data to generate components layer by layer. The X line 2000R® combines the largest build envelope worldwide (800x400x500 mm3) for laser melting with metals with increased build rates. The X line 2000R’s® multi-laser technology, with 2 x 1,000 watt lasers, has a direct impact on the exposure time.
paradigms. Although, due to the batch size structures, the aerospace industry is currently pioneering additive manufacturing, an initial effect on almost all industrial sectors is expected, due to the increase in build rates and build envelope sizes. The key areas in this respect are the automotive industry, dental and medical technology and the tool and machine tool industry. Not least, new business models are created by decentralized production networks as represented, for example, by the Laser Zentrum Nord GmbH. This will also make it possible to return the value created by production from low-wage countries to traditional development and industrial locations in Europe or the USA in order to increase the innovative power and speed there. Background information on the “Deutscher Zukunftspreis 2015” With this award, the President of the Federal Republic of Germany honors researchers and developers, who implement their innovations successfully in marketable products and, in this way, generate new jobs. The award is endowed with € 250,000. The German Future Prize will be awarded in Berlin on December 2nd, 2015. In a strict, multi-stage procedure, the nominations submitted by the institutions invited to make recommendations are assessed by ten experts from science and industry and three or four projects are finally nominated for the final round and, in this way, become the focus of public attention. These teams belong to the “circle of the best” for the Federal President’s Award for Innovation and Technology. 20 | September-October 2015 | Plastics & Rubber Review
This process allows the production of complex component geometries without tools in order to implement geometries as components that are difficult or even impossible to achieve with conventional manufacturing methods. With the LaserCUSING® process, conformal cooling can be used to create tool inserts as well as direct components for the jewelry, medical, dental, automotive and aerospace industries. This applies to prototypes and series parts. The company offers both standard systems and custom concepts for metal laser melting. At Concept Laser, full-service as an option means that customers can either purchase their own metal laser melting systems or rely directly on services, including development services. Laser machining systems from Concept Laser process powder materials made from stainless steel, hot work tool steels, cobalt-chromium alloy, nickel-base alloy as well as reactive powder materials such as aluminum and titanium alloys. Precious metals such as gold or silver alloys for jewelry making are also an option. LaserCUSING® offers new perspectives in terms of cost and speed for efficient product development in industries such as: • • • • • •
Jewelry Medical and dental technology Aeronautics and space industry Tool and mold construction Automotive and motor sports Mechanical engineering
The systems reduce development time and costs substantially while offering much greater flexibility in product development. The high quality standards, level of experience and successful track record of Concept Laser guarantee reliable and cost-effective solutions with proven performance in everyday production, with a particular focus on unit cost reductions. The art of LaserCUSING® by Concept Laser Ideas for laser melting with metals in the following areas of application: automotive and motorsport, aerospace, medical and dental technology, die and mold making as well as the wider engineering business.
Well below two seconds for injection moulding plus removal of four gourmet food containers
El-Exis SP repeats record as fastest exhibit at Fakuma
At this year’s Fakuma trade show, Sumitomo (SHI) Demag will present the El-Exis SP 200, an exhibit with extremely short cycle times for injection moulding plus automation: the high-speed machine produces four 125 ml polypropylene gourmet containers and also completes their removal by a special handling robot in less than two seconds. Together with its partners Brink B.V., Harskamp/ Netherlands, for the automation and the mould, and Borealis, Vienna/Austria, for the polypropylene (PP), the manufacturer of injection moulding machinery again demonstrates its potential as an excellent system partner for producers of plastics packaging products and its expertise in the optimisation of high-speed production lines.
Brink supplied the 4-cavity hot-runner mould as well as the complete automation equipment for fast container removal. Four containers, each with a weight of only 3.4 g , a diameter of 83 mm, a wall-thickness of 0.32 mm and a flow path/wall-thickness ratio of 213 are removed from the side by a robot that moves into the mould parting line. They are placed behind the machine, stacked and conveyed along the machine’s lateral axis. The automation plus all required modules are integrated into the compact protective housing with a footprint of no more than one square meter without a conveyor-belt. The exhibited El-Exis SP 200-675 with a 25D 40 mm screw plus shear and mixing section is equipped with an important production efficiency module for cycle time optimisation. Thanks to an easy slide control system, “activeAdjust” allows machine operators to select the most suitable control characteristic. Individual machine movements as well as acceleration and deceleration ramps can be optimised to suit the requirements of the product currently processed. This includes metering, Plastics & Rubber Review | September-October 2015 | 21
the dynamics of the switchover from injection to holding pressure, mould opening and ejector movements. This optimisation is key to boosting the production capacity and cutting the cycle times of high-speed applications such as the exhibited production of gourmet containers by between 3% and 5% compared with those achieved with standard settings.
Sumitomo (SHI) Demag 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.
The El-Exis SP is also equipped with “activeQ/Q+” mould protection for sensitive monitoring of the clamping unit’s travel forces both during mould opening and closing. If required, the module will actively stop the movements in order to protect the mould from potential damage. The machine is also equipped with the “activeCool&Clean” cooling and filtering system as standard, which ensures the best oil quality and a high oil service life of up to 40,000 h for the El-Exis SP and all other hydraulic injection moulding machines from Sumitomo (SHI) Demag: in the laminar and pulsationfree oil flow of a separate low-pressure circuit, this extra-large ultrafine filter separates any contaminants and optimises the heat transfer in the cooling system. This approach extends the filter’s service life and the machine’s oil change intervals. Clean oil with a low particle contamination reduces the risk of wear in all hydraulic components and minimizes maintenance downtimes. The optimised heat transfer process increases the cooling system’s supply temperatures, which allows a free, year-round heat exchange without additional cost for cooling equipment with a cooling circuit.
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.
This exhibit is another example of Sumitomo (SHI) Demag’s leading position as a reliable and energyefficient high-speed machine manufacturer for injection moulded packaging containers and thin-wall packaging products.
As early as 1998, Sumitomo (SHI) Demag set up its first production site in Ningbo/China. In 2015, the Chinese subsidiary Demag Plastics Machinery (Ningbo) Co., Ltd. installed a new facility with a 13,000 m² floor space. It is earmarked for the production of the Systec C range with clamping forces of between 500 and 10,000 kN for the Asian market.
Alongside the El-Exis SP 200, Sumitomo (SHI) Demag will present a world premiere: a production unit for complex decorated lightweight parts with a Systec Servo 210 at its centre. The third exhibit is an all-electric IntElect 100 equipped with “activeFlowBalance” for balancing the filling of its four cavities, stabilising the process and boosting the quality of the moulded parts. Partner companies Sepro (Hall A1, Stand 1203) and ONI (Hall A5, Stand 5103) will show two additional IntElect 50 machines in live operation. Sepro will demonstrate the highly complex production of a plug connector made from PBT-GF30 in a delicate mould with sophisticated separations, which was manufactured by Stamm AG, Hallau/Switzerland. 22 | September-October 2015 | Plastics & Rubber Review
At Sumitomo’s headquarters in Chiba, Japan, the company manufactures machines with clamping forces in the small to medium range. Nearly 95 % of all delivered machines are equipped with an all-electric drive concept. 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. Demag’s German facilities in Schwaig and Wiehe produce the Systec Servo range with hybrid drive as well as the El-Exis SP and Systec SP range of high-speed, highperformance machines. The all-electric IntElect range for international customers is also being produced in Germany.
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. www.sumitomo-shi-demag.eu
All-electric injection moulding machine offers enhanced functional range IntElect with new features for more precision and quality pressure profile can now be monitored with high precision. An adjustable tolerance band allows better process control and protects the mould from overfilling. Measured value acquisition (MVA) for process analysis and optimisation now provides a selection of userdefined as well as pre-defined screens, which facilitates data processing. Additional options with new graphs enhance the MVA’s application range. The new, standard display of the machine’s energy consumption provides documented proof of the efficient operation of IntElect machines.
In mid-2015, the IntElect all-electric high-precision injection moulding machine from Sumitomo (SHI) Demag was equipped with a range of new standard features, which will be presented at the Fakuma trade
show for the first time. As a result, production processes with IntElect machines are now more reliable and repeatable, while the parts are
produced with higher precision and higher quality. In addition to this, the new features improve the machine’s usability both in operation
and during mould changes. The Fakuma exhibit presents the automatic balancing of a four-cavity mould for industrial precision parts with a
reliable reproduction of surface details even under challenging filling conditions. This machine with its production efficiency modules was
specially designed to accommodate the high precision requirements of manufacturers of industrial parts from the E+E, optics and automotive industry.
The IntElect’s interactive user navigation facilitates and accelerates mould set-up procedures significantly, while a new reference run option for clamping units and other enhanced purging functions make machine operation even easier. Several injection units for IntElect machines are now available with screws in five instead of three different diameters, which allows more versatility for processors and compliance with required residence times even for variable product ranges. During injection, the injection
Specially developed by Sumitomo (SHI) Demag, the “activeDynamics” production efficiency module, an all-electric drive concept, ensures the smooth interaction of all drive train components: motors, frequency-converters and control system are perfectly attuned to each other, which reduces axis control scan rates to a minimum and ensures high dynamics, precision and repeatability. The wide range of optional equipment for IntElect machines has also been updated. The ejector force profile across the entire forward and backward stroke can now be monitored with a high level sensitivity. This enhancement not only offers a new level of mould protection, but also allows high-speed ejector movements. Another optional add-on is the new, integrated hydraulic unit with servo drive for higher nozzle travel speeds, which can also be used
Plastics & Rubber Review | September-October 2015 | 23
for the core pullers. The “activeFlowBalance” balances irregular, fluctuating filling levels in multi-cavity moulds and prevents negative effects such as flashes, underfilling or the Diesel effect. This module uses the expansion of the compressed plasticised material at the point of changeover from injection to holding pressure to top up the filling levels in the partially filled cavities, which happens as a result of their lower counter-pressure. This way, pressure and cavity levels are balanced out naturally. This tried-andtested function was enhanced and is now even easier and safer to use. The “activeLock” adjustable non-return valve actively closes prior to the injection process, which ensures a constant closing behaviour during each cycle. Benefits of this module are better repeatability, fewer process fluctuations and a lower risk of producing waste scrap. Other production efficiency modules in operation in the exhibited machine are the “activeAdjust” axis optimisation module, the “active” active mould protection module and the new “activeMouldWater” module for electronic cavity temperature and flow rate monitoring. The NC5 plus control system analyses this important process data, which improves the accuracy of process monitoring and allows an early detection of potential interferences with the temperature control system or the mould. Fakuma exhibit: automatic balancing of a four-cavity mould for high-precision parts At Fakuma, an IntElect 100-340 with a clamping force of 1,000 kN and an SDR 11S linear robot will be operating in an integrated, space-saving protective housing. The robot takes the parts from the cavity, removes the sprue and passes them on to the downstream inspection stations, where optical measuring and temperature distribution monitoring by means of an IR camera ensure 100% quality control. The part, a cover for couplings to an AdBlue feed pipe made from PA66-GF15, has several complex structures at the end of the flow path, which poses a filling challenge and tends to produce flashes. The results delivered by the four-cavity mould manufactured by Giebeler GmbH, Eschenburg/Germany, illustrate how the IntElect machine’s “activeFlowBalance” module improves the filling quality while optimising the stability of the production process and the quality of the moulded part. This is paired with significantly lower energy consumption than hydraulic injection moulding machines and more harmonious and faster cycles with parallel machine and robot movements. The robot is able to move into the mould parting line in a synchronised way while the mould is still opening. This way, it can remove the moulded parts at the full mould opening stroke, and vice versa: the machine can start closing the mould while the robot is still moving away from of the mould parting line. 24 | September-October 2015 | Plastics & Rubber Review
Alongside the IntElect 100, Sumitomo (SHI) Demag will show two additional IntElect 50 machines in live operation at their partner companies’ stands: Sepro (Hall A1, Stand 1203) and ONI (Hall A5, Stand 5103). Sepro will demonstrate the highly complex production of a plug connector made from PBT-GF30 in a delicate mould with sophisticated separations, which was manufactured by Stamm AG, Hallau/Switzerland. At their own stand, Sumitomo (SHI) Demag will show two additional exhibits: an El-Exis SP 200 highperformance machine will produce gourmet food containers with extremely short cycle times and, in a production unit, a Systec Servo 210 will be producing complex, decorated lightweight parts. 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. 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. At Sumitomo’s headquarters in Chiba, Japan, the company manufactures machines with clamping forces in the small to medium range. Nearly 95 % of all delivered machines are equipped
with an all-electric drive concept. 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. Demag’s German facilities in Schwaig and Wiehe produce the Systec Servo range with hybrid drive as well as the El-Exis SP and Systec SP range of high-speed, high-performance machines. The all-electric IntElect range for international customers is also being produced in Germany. As early as 1998, Sumitomo (SHI) Demag set up its first production site in Ningbo/China. In 2015, the Chinese subsidiary Demag Plastics Machinery (Ningbo) Co., Ltd. installed a new facility with a 13,000 m² floor space. It is earmarked for the production of the Systec C range 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. www.sumitomo-shi-demag.eu https://www.linkedin.com/ company/sumitomo-shi-demag https://www.youtube.com/c/ Sumitomo-SHI-DemagEu https://www.facebook.com/ sumitomoshidemag https://plus.google. com/+Sumitomo-SHI-DemagEu/ about.
Complex production unit for insert moulding, insert technology and in-mould decorating UD tapes Systec Servo for innovative lightweight technical parts with decorative surface
Less weight, more functions, attractive appearance – these attributes describe the result of the latest advancement presented by Sumitomo (SHI) Demag and its technology partners at Fakuma 2014, where a production unit will manufacture a lightweight nutcracker, which is then systematically reinforced by UD tapes a complex production method. The finished product with better functionality weighs 35 % less than its predecessor. It demonstrates the integration of lightweight engineering and decoration requirements such as those needed for semi-structural optical parts in automotive applications, and proves Sumitomo (SHI) Demag’s expertise as a reliable partner for complex injection moulding system solutions. The partners involved in this brand new development, which was never shown before in this specific combination, were automation specialist M.A.i GmbH & Co. KG of Kronach/Germany, decorative foil specialist Leonhard Kurz Stiftung & Co. KG of Fürth/Germany and plastics processor HBWGubesch GmbH of Emskirchen/Germany.
a logo, which was embossed on the mould surface. Now, the decoration involves a 0.5 mm decorative foil. Injection moulded from PP-GF30 (Type Fibremod, Borealis), the reinforcing ribbing structure now has a maximum wall-thickness of only 3 mm, reduced from formerly 4 mm. In 2014, the nutcracker’s toothed structure was produced with the help of metal inserts. In the current version this structure is rendered as a corrugated contour, which is integrated in the insert moulding process. With only 92 g, the new product weighs 35% less than last year’s nutcracker, which weighed 142 g, but provides a better functional capacity. As in 2014, this current exhibit proves Sumitomo (SHI) Demag’s comprehensive system expertise.
First shown in 2014 at Sumitomo (SHI) Demag’s company stand, the lightweight production unit has now been advanced in an intense optimisation process that involved all technology partners: instead of organic sheet, this year’s nutcracker will be reinforced by a three-layered, so-called UD tape. In 2014, the nutcracker was merely decorated by
The reinforcing UD tapes made from Celstran CFR-TP PPGF70-013 (Celanese) contain continuous glass fibres in unidirectional (“UD”) orientation with a significantly increased tensile strength parallel
tothe fibre direction. This approach allows plastics processors to reinforce their products by systematically placing one or several UD tapes to suit their requirements in terms of wear and loads. This is only one advantage of UD tapes over organic sheet, which is mainly made from fibre mats with a 90° degree fibre angle, which can only provide an isotropic reinforcement. UD tapes have the same thickness of a fibre mat, but provide more tensile strength in the direction of tension than organic sheet. Hence, if the product is reinforced with thinner and more lightweight UD tapes, it still has the same tensile strength as products reinforced with heavier and thicker organic sheet. The currently exhibit includes a bundle of three thin UD tapes, which have the same overall thickness as the former reinforcement product (organic sheet) but offer a more systematic reinforcement. Another highlight of this exhibit is the newly developed M.A.i heated gripper system, a socalled hot-handling device. This system controls the heating of the tapes prior to their insertion into the mould. The result: gentler temperature control and the option of shorter processing times. Enhanced with decorative foils, the final product is suitable for all visible applications such as those required by the automotive industry. Essential elements of this production unit include a Systec Servo 210 injection moulding
Plastics & Rubber Review | September-October 2015 | 25
machine, a six-axis robot from Yaskawa with gripper system and hot-handling device for UD tapes, removal stations for the metal inserts and the decorative foil, a heater and removal station for the UD tapes, a cutting station for sprue removal and a riveting station for connection both product halves. The removal and insert gripper at the robot’s head picks up the foil, the inserts and the UD tape and moves into the open mould. There, it first removes the finished part, then places the foil, the UD blank and the metal insert into the now empty cavity. The mould closes and the insert moulding process begins anew. An intelligent production efficiency module, “activeRemote” integrates both the robot and any downstream equipment into the injection moulding machine’s NC5 plus control system. It records, processes and visualises production and process data even for complex automation tasks. Virtual network computing (VNC) integrates disparate partner systems, and also allows integration and control of any touchscreen devices. Malfunctions and production downtimes are displayed by the NC5 plus control and can be remedied to prevent the production of waste scrap. Systec Servo is also equipped with an energy saving “activeDrive“ module, which combines a frequency-controlled high-performance motor with a hydraulic pump. It restricts the capacity to the amount required by the corresponding cycle sequence, allows parallel movements with only one hydraulic pump, reduces the machine’s noise emission and is distinguished by a keen price/performance ratio. This module cuts the machine’s energy consumption by up to 50 % compared to standard hydraulic systems, particularly during processes operated with partial loads or empty runs. The “activeDrive” module is provided as standard for all Systec Servo machines. For older Systec machines, this module is available as a retrofit option. In addition to the “activeDrive” module, the Systec Servo 210 that is presented at Fakuma 2015 is equipped with the “activeCool&Clean” cooling and filter system for best oil quality and a long oil service life, and with the new axle control module “activeMotionControl” for better production quality and repeatability and a unique option for running parallel movements within one hydraulic cycle. Alongside this production unit, Sumitomo (SHI) Demag will present an El-Exis SP 200 highperformance machine in live operation, producing gourmet food containers with the cycle time of far less than two seconds –the fastest automated exhibit, and an all-electric IntElect 100, equipped 26 | September-October 2015 | Plastics & Rubber Review
with “activeFlowBalance” for balancing the filling of its four cavities, stabilising the process and boosting the quality of moulded parts. Our partner companies Sepro (Hall A1, Stand 1203) and ONI (Hall A5, Stand 5103) will show two additional machines in live operation. Sepro will demonstrate the highly complex production of a plug connector made from PBTGF30 in a delicate mould with sophisticated separations, which was manufactured by Stamm AG, Hallau/Switzerland. Sumitomo (SHI) Demag Plastics Machinery GmbH Fakuma 2015: Hall B1, Stand 1105 Sumitomo (SHI) Demag Plastics Machinery GmbH 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. 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. At Sumitomo’s headquarters in Chiba, Japan, the company manufactures machines with clamping forces in the small to medium range. Nearly 95 % of all delivered machines are equipped with an all-electric drive concept.
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. Demag’s German facilities in Schwaig and Wiehe produce the Systec Servo range with hybrid drive as well as the El-Exis SP and Systec SP range of high-speed, high-performance machines. The all-electric IntElect range for international customers is also being produced in Germany. As early as 1998, Sumitomo (SHI) Demag set up its first production site in Ningbo/China. In 2015, the Chinese subsidiary Demag Plastics Machinery (Ningbo) Co., Ltd. installed a new facility with a 13,000 m² floor space. It is earmarked for the production of the Systec C range 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. www.sumitomo-shi-demag.eu https://www.linkedin.com/ company/sumitomo-shi-demag https://www.youtube.com/c/ Sumitomo-SHI-DemagEu https://www.facebook.com/ sumitomoshidemag https://plus.google. com/+Sumitomo-SHI-DemagEu/ about
Jinming Multi-layer Cast Film Equipment Stands in the Front of the Industry Jinming is determined to build a leading brand of global film extrusion equipment. It has increased technical and funding assets to cast film machine in recent years. Its cast film equipment products and technologies have rapidly advanced to the front of the industry. film.
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2012, and since then Jinming entered into the high-
barrier cast film machine
end market of cast film equipment in China. Starting
* Multi-layer co-extrusion mulch
independent heating and cooling
with the objective of manufacturing functional cast
cast film machine
• Maximum control temperature of setting roller is up to 70 oC
film machine with wider film width and higher output, Jinming developed the China’s widest (5,500 mm) cast
Main components & features:
film equipment in 2013. In 2014, Jinming successfully
* 11-layer extrusion screw
launched an 11-layer high barrier cast film machine and
• Continuous weightless
became a Chinese enterprise that is able to produce this
measurement feeding and central
kind of equipment in the Asia Pacific.
feeding. Convenient interlamination ratio control, stable melt pressure,
• All water cooling systems are recirculating systems without water resource consumption Jinming Machinery(Guangdong) Co., Ltd | sales@jmjj.com Jinming, established
During this period, the company also launched a series
uniform mixing of functional
in 1987, is recognized as the global
of production lines, such as barrier mulch film casting
additives, and consistent product
leader in supplying plastic film extrusion
film machine and online cast stretch machine. Jinming’s
quality.
machines. Jinming provides customized
leading position in the cast equipment field is gradually
• Low-temperature extrusion
solutions of Blown Film Machines,
established, through three years’ unremitting efforts and
system developed by Jinming,
constant innovation and development of technology.
which reduces material extrusion
Cast Film Machines and Stretch Film
Their products gain trust and support from customers
temperature and shearing,
not only in China, but the machines are also exported
facilitates the reduction of unit
to the Middle East, South Asia, Southeast Asia and other
energy consumption, and achieves
countries and regions.
excellent physical performance of
Machines. By the end of 2014, we have supported customers from over 40 countries with thousands of proven machine lines and services.
Plastics & Rubber Review | September-October 2015 | 27
Special show at K 2016 – Plastics shape the future Ever since plastics were first processed into telephones, light switches and radio housings a century ago, their diversity and presence in everyday life have increased enormously. Synonymous with innovation, safety, comfort and virtually unlimited scope in applications and design, polymeric materials have meanwhile conquered all spheres of life. Without plastics and rubber, it will not be possible to master the huge challenges of the future. They are a byword for resource-conserving technologies, progressive mobility, the protection of food and drinking water, innovative medical technology, energy efficiency and sustainability.
D
uring K 2016 in Düsseldorf from 19 to 26 October, the special show “Plastics shape the future” will highlight the developments that are already taking shape and the visions that may become reality tomorrow. With reference to examples, the show demonstrates to what extent plastics are making their mark on modern living spaces – functionally, aesthetically and sustainably. Attention is also devoted to economic and environmental matters, and even problematical issues like marine litter, for example, will be addressed. Multimedia presentations and innovative stand design will enliven the
28 | September-October 2015 | Plastics & Rubber Review
programme of the special show in Hall 6, consisting of information and entertainment blocks, activities, keynote talks and rounds of discussions. Ideas from school pupils and students on how to shape the future will not only be the focus of the traditional Youth Day on the Sunday of K 2016 (23 October), but will provide fresh stimulus every day of the fair. “Plastics shape the future” promises telling insights and perspectives on the future for exhibitors and trade visitors to K 2016 as well as for the media and the general public. In 2016, the special show, a project of the German plastics industry under the leadership
of PlasticsEurope Deutschland e.V. and Messe Düsseldorf, is supplementing K’s exhibition array for the 9th time. The world’s foremost gathering of the plastics and rubber sector will again be covering everything the industry has to offer. Some 3,000 exhibitors from all continents will be taking part, and all 19 halls of Düsseldorf’s fairgrounds are already fully booked. Some 200,000 trade visitors from all over the world are expected at K 2016. K 2016 is open daily from 10 am to 6.30 pm from Wednesday, 19 October, until Wednesday, 26 October 2016.
All details can be found at www.k-online.com and on the social networks Xing: https://www.xing.com/net/pri4bd1eex/k2013 Facebook: https://www.facebook.com/K.Tradefair?fref=ts Twitter: https://twitter.com/K_tradefair
Plastics & Rubber Review | September-October 2015 | 29
WITTMANN BATTENFELD Hungary
New WITTMANN BATTENFELD subsidiary in Hungary a worldwide leader in the manufacturing of injection molding machines, robots and peripheral equipment for the plastics industry. Headquartered in Vienna/Austria, the WITTMANN Group consists of two main divisions, WITTMANN BATTENFELD and WITTMANN, which operate 10 production facilities in 7 countries, including 30 direct subsidiary offices located in all major plastics markets around the world.
F
WITTMANN BATTENFELD focuses on independent market growth in the manufacturing of state-of-the art injection molding machines and process technology, providing a modern and comprehensive range of machinery in a modular design that meets the actual and future requirements of the plastic injection molding market.
New WITTMANN BATTENFELD sales and service subsidiary in Budaörs, H
rom the beginning of September this year, the WITTMANN group will be present in Hungary with a new sales and service subsidiary. The company will be domiciled in Budaörs, near Budapest.
With the separation of sales and service activities from the WITTMANN production plant in Mosonmagyaróvár and their relocation to Budaörs near Budapest, the WITTMANN group is now located geographically within easy reach for customers from all parts of the country. The new, enlarged sales and service organization with a workforce of 14 staff members will now take care of all tasks with customer contact, including project planning, customer support, repairs and spare parts service. The organization has been completely restructured to enable it to provide customers with optimal support from a central location in Hungary. The management of the new sales subsidiary lies in the hands of Mr. Zsolt Rapolti, who has distributed the products of the Zsolt Rapolti, Managing Director of WITTMANN group in Hungary successfully the new sales and service subsidiary as a regional salesman since 2012.
30 | September-October 2015 | Plastics & Rubber Review
This move also enables the WITTMANN production company under the management of Mr. Thomas Wittmann to proceed with the necessary extensions of production capacity and buildings to accommodate the production start-up of the EcoPower machine series and the ongoing production of the robot series with up to 12 kg load capacity and the TEMPRO Basic temperature controllers. The members of the Management Board and Sales Management of the WITTMANN group are confident that the new sales organization in Hungary will ensure even better support to the local customers and wish Mr. Rapolti and his team every possible success. The WITTMANN Group The WITTMANN Group is
WITTMANN’s product range includes robots and automation systems, material handling systems, dryers, gravimetric and volumetric blenders, granulators, mold temperature controllers and chillers. With this comprehensive range of peripheral equipment, WITTMANN can provide plastics processors with solutions that cover all production requirements, ranging from autonomous work cells to integrated plant-wide systems. The syndication of the WITTMANN Group has led to connectivity between all product lines, providing the advantage plastics processors have been looking for in terms of a seamless integration of injection molding machines, automation and auxiliary equipment – all occurring at a progressive rate.
WITTMANN BATTENFELD at the Fakuma 2015 WITTMANN 4.0 – the WITTMANN group’s answer to Industrie 4.0 “plug and produce” WITTMANN 4.0 allows dynamic plug-in and plugout of the appliances mentioned even while the machine is running. Thanks to the possibility of supplying everything from a single source, which the WITTMANN can provide, WITTMANN BATTENFELD offers the implementation of its 4.0 solution as a clear advantage.
Schematic diagram of WITTMANN 4.0
On the way to Industrie 4.0, WITTMANN 4.0 provides an important element for integration and will be demonstrated at the Fakuma from 13 to 17 October on the injection molding machines exhibited there in hall B1, booth 1204.
In addition to WITTMANN 4.0, WITTMANN has been providing an app since the end of 2014 to monitor the status of injection molding machines and robots. With the help of the WiBa QuickLook app, it is possible to check the status of injection molding machines and robots simply and comfortably with a Smartphone within the company`s WLAN. The QuickLook app links up with the most recent software versions of WITTMANN R8.3 robots and WITTMANN BATTENFELD Unilog B6P control systems. In this way, WiBa QuickLook enables quick and easy viewing of the process data and the status of the most important appliances operating in a production cell.
Networking has been an important topic for the WITTMANN group ever since its takeover of BATTENFELD Kunststofftechnik in 2008. The integration of WITTMANN robots into the injection molding machines’ UNILOG control system was already implemented in the takeover year. Following successful integration of the robots, the WITTMANN group started integrating the peripheral equipment step by step as well. At the Fakuma 2014, the integration of temperature controllers in addition to robots could already be shown. This was followed at the end of the year by adding the FLOWCON flow controllers and GRAVIMAX gravimetric blenders, whose integration was demonstrated for the first time at the NPE in Orlando. Thus, via the machine’s B6P control system, several machines as well as robots and peripherals connected to them can be linked together and operated via the uniform Windows user interface, which enables interaction between the individual appliances. In this way, the entire manufacturing process, including material feeding and blending, temperature control, automation and injection molding can be optimally coordinated and tracked. Another important point is having all parameter settings, automation processes and formulations centrally recorded in a mold catalog and distributed from there to the correct appliances when a mold change takes place. This enables significant reductions in setup times and the resulting costs. Just as important is the central recording of error signals and machine statuses of all appliances linked together under WITTMANN 4.0. WITTMANN 4.0 transforms the injection molding machine into a control terminal for robots, peripherals as well as superordinate systems such as the “authentig” MES system from T.I.G. According to the motto
Plastics & Rubber Review | September-October 2015 | 31
Machines for Elastomer, Silicon and TPE
Fully automatic zero defect manufacturing of precision moulded parts for the automotive industry • Automation and inspection sensor technology ensure high quality and consistent flow of good parts in elastomer processing • Reduced costs, increased customer satisfaction required specification presented sales engineers Gerald Kemper and Paul-David Betea from Maplan with a series of challenges.
High level of quality assurance At the core of the production cell is the Maplan MTF400/250editionS elastomer injection moulding machine. The machine’s components enable a high level of processing in terms of process design, energy efficiency and process reliability. To ensure fully automated manufacture of precision moulded parts with metal inserts, automated separation and feed of the metal parts was required. Overall, the solutions for automation were comprised of four main assemblies:
”automation” and “zero defect manufacturing” are buzz words that are increasingly gaining importance for manufacturers of elastomer products. In particular when it comes to using resources more effectively and improvements in cost savings. The basis of this strategy is the deployment of process integrated control systems using sensors. The motto here is: more performance and optimal unit costs or higher delivery assurance with less process risks. In general this means reduced costs and increased customer satisfaction. Especially in the case of high volume elastomer parts, automation offers excellent process design and at the same time, through the use of sensors for improved vulcanisation processes, a new level of quality. Vulcanisation can then truly become an industrial process with a production flow of zero defect parts. 32 | September-October 2015 | Plastics & Rubber Review
T
he latest example of this development is the delivery of a new manufacturing unit to an important development partner of the automotive industry for precision moulded parts. These parts are subjected to tough demands in terms of temperature and medium resistance and also have to exhibit convincing elastic recovery for the life of the part. In the case of this special development on the basis of a Maplan MTF400/250editionS machine with two hydraulic drives featuring Cool-Drive technology with servo actuation, the customer
• Feed unit for metal rings • Separation and postioning unit for metal rings • Pick and place unit • Sprue removal unit The machine’s inspection module comprises of a laser sensor for sprue detection and cameras that check the moulded parts in a multi-cavity mould. For tooling and ergonomic reasons, a wider clamping unit at an optimised operating height was specified. Thus providing ample space for large multi-cavity moulds. The optimised operating height guarantees the operator improved access for inspection and maintenance as well as for changing moulds.
“Finger tip feeling” for a demanding elastomer process The precision moulded part is made out of rubber, as well one or more metal rings, which are placed in the mould by means of an automatically extendable hotplate shuttle. Paul-David Betea states: “since the whole cycle is fully automatic, there are practically no sources of error.” Productivity is maximised by means of multi-cavity moulds.
Laser sensors for improved process reliability A laser sensor is mounted on the sprue removal unit at the front of the machine. This device moves into the clamping unit of the machine on every cycle to grasp the sprue and then remove it on the basis of the “pick and place” principle. As it moves out of the machine, the laser sensor scans the sprue plate to check whether for example a sprue has not been removed from the mould. The metal rings are fed from a vibration hopper. This hopper supplies rings
sequentially. In addition, it also separates the single or multiple rings and places them in the correct position onto a separation section, so that the rings are laid out in a matrix ready for the next cycle.
Automation meets zero defect manufacturing The shuttle with the finished precision moulded parts is then moved to the rear of the machine. High resolution cameras are mounted between the rear shuttle and the machine for QA inspection purposes. The cameras check the positioning of all parts on the shuttle as it moves into the machine. When the shuttle plate moves into the machine again, the cameras check whether the moulded parts have been correctly ejected. The parts require sensitive handling – due to their shape, it is absolutely essential that they are ejected obliquely from above. The parts then fall onto a conveyor belt below which transports them to the finished
parts container. Such concepts are a logical step towards zero defect manufacturing.
Automation – a trend in elastomer processing “The trend towards higher levels of automation in connection with sensor technology is steadily growing. Customer-specific requirements have considerably increased in the last three years”, comments Paul-David Betea. Due to the high degree of globalisation of elastomer processing, in particular in the automotive industry, this effect can be seen in every region of the world. As Paul-David Betea explains further: “with reference to automation and sensor components, we estimate there is an average extra cost of up to 50% compared to conventional capital expenditure for machines. Particularly in the case of moulds for high volumes or with many cavities, there is, however, a significantly higher level of quality and considerably faster amortisation.”
Why automation pays off The integration of automation and sensor technology in new elastomer processing plant has a very long-term effect on profitability. This naturally also applies to the whole lifespan of a machine. Operating faults can be avoided or process deviations identified early on. By moving towards zero defect manufacturing, disturbance variables become more manageable. Whereas in the case of conventional machines quality has to be checked after the production process, i.e. offline, a fully automated machine can implement in-line QA controls, assuring quality during the ongoing production run. The reduced risk of faulty parts in part flow means a high degree of reliability and possible cost savings. A consistent flow of parts generates a “feel good factor” for all parties involved in the supply chain: parts producers, OEMs and users.
Zero defect manufacturing Zero defect manufacturing is a production strategy aiming to achieve zero defects. This means faultless manufacturing with no waste or rework, since it’s not producing quality that causes avoidable expense but the removal of faults. Avoiding defects is applied even during the development and design phases and is carried out throughout the whole process chain. In plant engineering, zero defect manufacturing is understood as manufacturing where the process is monitored by sensors and automation technologies and if needed these can intervene in the control or process sequence, right up to modifying process parameters. In an ideal case, the part defines the process and ensures the outward transfer of faulty parts. In principle, this way quality is what happens during production as opposed to QA
Plastics & Rubber Review | September-October 2015 | 33
Maplan company was founded as an engineering and plant construction firm in 1970 in southern Vienna under the name of “Machines and Technical Plant, Planning and manufacturing GmbH”. The field of “rubber injection moulding technology” has been expanded since the acquisition of Werner & Pfleiderer Rubber Technology in 1993. MAPLAN covers the different requirements of vulcanisation and injection moulding in elastomer processing using a modular building block principle. All drive elements (CoolDrive II) or control elements (PC5000) with integrated Cure² process optimisation are used for both methods in elastomer technology in order to ensure accuracy, repeatability or availability. High precision FIFO injection units from the “factory shelf” are available for applicationspecific processing. The orientation and the development of Maplan’s machine program consists generally of energyefficient, process reliable and compact solutions which have added value to the customer. Gerald Kemper and Paul-David Betea, sales engineers at Maplan (from left to right.): “Automation and sensor technology offer high value creation potential for elastomer processing: reduced risk of faulty parts in part flow means a high degree of reliability and possible cost savings. A consistent flow of parts generates a “feel good factor” for all parties involved in the supply chain: parts producers, OEMs and users.”
checking after the parts have been produced (ex-post checks). The results of such a zero defect strategy are usually lower QA costs, less QA work (including documentation), reliable deliveries, less waste and high customer satisfaction. Key words for automation and sensor technology in elastomer processing:
No automation/sensors
With automation/sensors
Area of application For low volume production or simple moulded parts
For higher unit volumes, complex parts or with multi-cavity technology for parts with high unit costs
Process design Normal process design
Optimal, intelligent process design with high levels of process reliability
Quality level Normal quality with a QA workload downstream of the actual production process (offline QA)
Increased quality with QA during actual production by means of sensor technology (zero defect manufacturing)
Sources of errors/ Normal level
Reduction of disturbance variables caused by operating faults.
Output quantity Normal
Significantly higher Process risk Faulty parts can be in part flow Good part flow (part flow only consists of zero defect parts)
Investment amount Tends to be a low amount of investment
Higher investment in terms of automation and sensor components, but also higher level of quality and good amortisation
34 | September-October 2015 | Plastics & Rubber Review
Our machine range includes basic machine types of horizontal and vertical designs, and also the design which injects from below. The concepts for the clamping unit include both fully hydraulic and hydro mechanical units in column construction as well as C-frame machines. The available clamping forces cover the range from 150 kN to 10,000 kN. Regarding the injection units, our product range includes different designs, mostly based on the FIFO principle with dosing volume ranging from 20 ccm to 26,000 ccm. The company manufactures over 250 vertical and horizontal elastomer injection moulding machines per year. All mechanical components of the machines are manufactured in Europe with a correspondingly high level of quality and durability. Export share is 99 percent. In addition to the production site in Austria, MAPLAN is represented by sales and service offices worldwide in over 60 countries. MAPLAN currently employs 170 people at its headquarters in Ternitz of Lower Austria (approximately 200 people worldwide) and has an annual turnover of 37 million EUR (2014).
BOY among the best at MSV
The MSV Engineering fair in Brno/Czech Republic was a complete success for BOY. Both the BOY XS and BOY 60 E injection moulding machines impressed the large number of exhibition visitors. According to the organizer, the application shown on the BOY 60 E was among the best trade fair presentations. “At this year´s MSV, we have held many promising conversations”, states Petr Betaš, Managing Partner of the local BOY distributor. The booth visitors, which were mostly domestic, responded enthusiastically when told that Plastcompany will hold an in-house symposium on 11 November in Brno. A fully automated production cell with a BOY 60 E (600 kN clamping force) produced beer glasses made of highly transparent polycarbonate. The manufactured plastic glasses were removed from the mould with the BOY SL 30 removal device, labeled with a laser and afterwards placed on a conveyor belt. A special setting on a machine switch ensured optionally or “when required” that the plastic glasses were filled with delicious Pilsener Urquell. The BOY 60 E was equipped with the energy-saving servo drive that enables energy savings up to 50 % compared with previous drive systems. In combination with the EconPlast technology, which is patent pending, the saving effect further increases. Plasticizing of materials is clearly more energy-efficient, more direct and more material-friendly due to the reduction of frictional heat. The second BOY exhibit, a compact BOY XS with 100 kN clamping force,
produced an osteosynthesis plate. This medical-technical small part is used for fixation of bone fractures. The BOY XS was equipped with a sprueless nozzle which allows direct contact to the mould. Therefore, sprues are eliminated. The BOY XS was controlled via the Procan ALPHA ® 2 machine control. The multi-patented control has a “smart operating system” with multi-touch functions. Clearly arranged screen pages with less text and memorable symbols allow a fast and intuitive operation solely via the multi-touch display. Therefore, operating functions like scrolling of screen pages or page changes through wiping – like with modern communication devices – are possible. Because the machine manual is integrated in the control, browsing is significantly made easier. Company profile Dr. Boy GmbH & Co. KG is one of the leading worldwide manufacturers of injection moulding machines with clamping forces up to 1,000 kN. The very compact, durable machines work precise, energy-saving and therefore highly economical. BOY continually sets new standards in our industry with innovative concepts and solutions. Since the company was founded in 1968, over 40,000 injection moulding machines have been delivered worldwide. The privately owned company continues to put special emphasis on engineered performance and highclass “made in Germany” workmanship. For further information visit http://www.dr-boy.de/. Plastics & Rubber Review | September-October 2015 | 35
New intelligent components for proven recycling technology Starlinger recycling technology has relaunched its time-tested recoSTAR universal line with revamped technology and design. The new version features even greater process variety, simplicity and ease of operation, as well as reduced energy consumption.
ACTIVE shredder: Versatile and intelligent material preparation The new ACTIVE shredder enables the recoSTAR universal recycling line to process input material in almost any form without pregrinding. Edge trim can be 36 | September-October 2015 | Plastics & Rubber Review
fed to the line directly from the production line, other plastic waste directly from the reel feeder or the conveyor belt. The loadcontrolled dosing screw provides stable supply to the extruder even when the bulk density of the input material varies. Individual motors for the grinder and the extruder ensure accurate material dosing and controlled output. The highperformance rotor, which can be cooled or heated as required, processes hard and stiff materials as well as flexible ones and prepares them optimally for the downstream process.
High system availability and innovative process adaptation Simple knife change and easily accessible service openings make the ACTIVE shredder highly operator-friendly and ensure maximum uptime. The self-reversing rotor removes material build-up
automatically during production, while the speed-controlled dosing screw ensures the stability of the production process. The recycling line performs the start-up and shutdown operations entirely automatically, thereby allowing the operators – especially in inline applications – to devote their full attention to the actual production process. The option of cold-feeding the extruder makes preheating times unnecessary. Upcycling and compounding are possible by introducing additives via the dosing unit; the quality of the recycled material produced is monitored by a feedback loop.
Even more energy-efficient: “rECO” The “rECO” energy concept by Starlinger recycling technology stands for an innovative machine design which significantly increases the energy efficiency of the lines. Up to 10 % energy savings can be
achieved with the “rECO” package, which profits not only the plant operator through lower costs, but also the environment through an improved carbon footprint. Energy savings are achieved using the new extruder drive concept as well as by using motors classified IE3 and infrared heaters on the extruder barrel. The use of the radiant heat of the extruder for material processing helps to recover additional energy.
depending on the input material; for pelletising, a water ring, an underwater or a strand pelletiser can be used.
A universal genius
Starlinger at ITMA in Milan: November 12-19, 2015 in Hall 04, Stand D127.
recoSTAR universal recycling lines are designed for processing a wide range of plastic waste – from films and injection moulding parts to fibres, filaments and fleece made of PE, PP, PS, PA, PES, PET, PPS, PLA and many more. Various degassing and filter systems for purifying and filtering the melt are available
A recoSTAR universal recycling line will be shown processing polypropylene raffia production waste at the Starlinger In-House Exhibition in Weissenbach/Triesting, scheduled in November to flank the textile machinery exhibition ITMA being held in Milan.
Starlinger In-House Exhibition: November 9-11 and November 16-20, intelligenten Komponenten 2015 in Weissenbach/Triesting, Austria. recoSTAR® ist a trademark of Starlinger & Co. GmbH.
About Starlinger recycling technology Starlinger recycling technology is a division of Austrian-based Starlinger & Co GmbH, world market leader in the field of machinery and complete lines for woven plastic packaging production. For more than 25 years Starlinger recycling technology has been providing machinery solutions for the recycling and refining of a wide scope of plastics such as PE, PP, PA, PS, BOPP and PET. Starlinger PET recycling systems produce food-safe rPET and are approved for use in food applications by many brand owners as well as various national and international authorities. The worldwide sales and service support network and technical consulting service help customers to achieve optimum results in the manufacturing process. Further information: Starlinger & Co. Ges.m.b.H., Sonnenuhrgasse 4, 1060 Wien, Österreich T: +43 1 59955-0,, F: +43 1 59955-180 E-mail: recycling@starlinger.com, www.recycling.starlinger.com Plastics & Rubber Review | September-October 2015 | 37
Another Solid Gain for Plastics Machinery Shipments in Q2 The value of plastics machinery shipped by North American suppliers registered a solid rise in the second quarter of 2015, according to statistics compiled and reported by SPI: The Plastics Industry Trade Association’s Committee on Equipment Statistics (CES).
“
The CES shipments data have steadily posted year-over-year gains in every quarter since 2010. This is a better performance than many other sectors of the U.S. and global economy. U.S. GDP will continue to grow at an annualized pace of at least 2 percent for the remainder of 2015, and the outlook is for accelerating growth in 2016. This bodes well for the plastics machinery markets because it will continue to generate rising aggregate demand,” according to Bill Wood, the economic analyst who reports on the plastics machinery markets for the CES. Shipments of primary plastics equipment (injection molding, single-screw extrusion, twin-screw extrusion, and blow molding equipment) for reporting companies totaled $303.5 million in Q2. This was an increase of 5.5 percent from the shipments total of $287.7 million in Q1 of 2015, and it was a gain of 6.7 percent when compared with the shipments total from same quarter of a year ago. For the year-to-date, the value of primary plastics equipment shipments is up 3.9 percent over last year.
PRIMARY PLASTICS EQUIPMENT SHIPMENTS
A breakout of the CES data shows that the shipments value of injection molding machinery escalated 3.9 percent in Q2 when compared with same quarter from last year. The shipments value of single-screw extruders slipped 1.5 percent from last year. The value of shipments of twin-screw extruders (includes both co-rotating and counter-rotating machines) eked out a gain of 1.0 percent in Q2. The Q2 shipments value of blow molding machines jumped 66.4 percent. The CES also compiles data on the auxiliary equipment segment (robotics, temperature control, materials handling, etc.) of the plastics machinery industry. New bookings of auxiliary equipment for reporting companies totaled $121.4 million dollars in Q2. This was a jump of 12.4 percent when compared with the total from Q2 of last year. The growth in the CES data on plastics machinery shipments was moderately slower than the yearover-year increase of 5.5 percent (seasonally-adjusted, annualized rate) in total business investment in industrial equipment (plastics machinery is a subset of this data) compiled and reported by the Bureau of Economic Analysis as
38 | September-October 2015 | Plastics & Rubber Review
The Q2 gain in the CES shipments data was moderately stronger than the other major industrial machinery market indicator, compiled and reported monthly by the Census Bureau, which showed that the total value of shipments of industrial machinery increased by 2.4 percent in Q2 when compared with the year before (plastics machinery shipments are also a subset of this data).
Q2 respondents indicated that automotive and packaging will remain strong in terms of demand for plastics products and equipment. Expectations for all other major end-markets call for firm market conditions to persist during the next 12 months.
“Despite the volatility in the stock market in recent weeks, the underlying fundamentals indicate that the recovery in the U.S. economy is still intact. The plastics industry has been a growth leader for the US manufacturing sector throughout the recovery, and this will continue through the foreseeable future. Consumer confidence is rising, residential construction activity is accelerating, and stronger economic growth is expected for the rest of the year. Overall, we are reaping the benefits of low interest rates, low energy prices, and rising household incomes resulting from stronger employment levels. This is more than enough to offset the drag caused by weakness in the oil patch, a stronger dollar, and slower export demand,� said Wood.
The industry and survey analysis that appears in this media report was contributed by Bill Wood of Mountaintop Economics & Research, Inc., a supplier of market analyses and forecasts for decision makers in the plastics Industry. Mr. Wood is a plastics market economist with more than 28 years of experience in industrial market analysis and forecasting. (billwood@ plasticseconomics.com)
part of their quarterly GDP data release.
The CES also conducts a quarterly survey of plastics machinery suppliers that asks about present market conditions and expectations for the future. The responses from the Q2 survey indicate that machinery suppliers remain optimistic about the market demand for their products in the coming months. Both in the coming quarter and during the next twelve months, 88 percent of the respondents expect conditions to either improve or hold steady. Quoting activity was higher in the second quarter for half of the survey participants. North America and Mexico are the global regions where the most promising market conditions for machinery suppliers are expected in the coming year. Expectations for Latin America are for mostly steady market conditions, while the outlook for Europe and Asia are steady-to-weaker. When asked about their expectations for the major end-markets, the
The SPI Committee on Equipment Statistics (CES) collects monthly orders and shipments data from manufacturers of plastic injection molding, extrusion, blow molding, thermoforming, hot runners and auxiliary equipment. A confidential, third-party fiduciary, VERIS Consulting, LLC (VERIS), compiles the monthly data and analyzes individual company data for consistency and accuracy. Once this crucial process is completed, VERIS aggregates and disseminates reports to participating companies. If this is something you and your company are interested in please contact Katie Masterson at kmasterson@plasticsindustry.org or 202-974-5296. Founded in 1937, SPI: The Plastics Industry Trade Association promotes growth in the $373 billion U.S. plastics industry. Representing nearly 900,000 American workers in the third largest U.S. manufacturing industry, SPI delivers legislative and regulatory advocacy, market research, industry promotion and the fostering of business relationships and zero waste strategies. SPI also owns and produces the international NPE trade show. All profits from NPE are reinvested into SPI’s industry services. Find SPI online at www. plasticsindustry.org and www. inthehopper.org.
Plastics & Rubber Review | September-October 2015 | 39
Society of Plastics Engineers (SPE)
2015 Thermoforming Parts Competition Winners PEOPLES’ CHOICE AWARD (A Tie) Allied Plastics, Twin Lakes, Wisconsin Mobile Light Tower Enclosure
Plastitel, Chazy, New York POD’S, used for the Stryker IsoLibrium bed
Overview: This two-piece enclosure houses the engine and fuel tank for a mobile light tower.
Overview: This Vacuum formed component is being used for the most recent technology offered for patient care in the Medical industry. The POD`s role is critical to the success of the 2015 Stryker IsoLibrium Bed (as the main support surface).
Features and Benefits: The material is a high flexural modulus thermoplastic polyolefin (TPO) with varying color combinations. A starting thickness of .275” is used for the front enclosure and .325” used for the rear.
Features and Benefits: The primary part of this component is manufactured using Vacuum Thermoforming; The POD`S are divide into 4 sections individually controlled to maintain the correct pressure needed for the patient. The POD`S help the mobility of the patients ensuring regular movement while they are in the bed helping some vital organs function. The POD`S also help reduce bed sores and improve circulation.
Parts are produced from water-cooled, cast aluminum production molds. The molds were cast-oversized, then 100% CNC machined to the customer supplied CAD data. Part orientation on the tool was very critical, as depth of draw versus multiple potential undercut features needed to be addressed. The parts had to be designed with structure, as the plastic enclosures replaced a metal housing. A metal frame was incorporated into the design to help reinforce the new TPO housing. The new tough, durable shell eliminates the need for painting and is corrosion proof. The TPO housing offers a weight savings when compared to the metal housing that is replaced. 40 | September-October 2015 | Plastics & Rubber Review
Two major challenges are ensuring a minimum thickness on every individual POD and accurately measuring them. Every Vacuumed part is subjected to vigorous inspection. Material is a Thermoplastic polyurethane (TPU) 0.080 custom color Blue with a matte finish. The part size 58``x 28``x 6`` with a total of 69 individual POD`s. The component is assembled and tested on site prior to shipping to OEM. Custom packaging was design inhouse specifically for the component to ensure its integrity during shipping. The reusable thermoformed cases are disassemble and shipped back to be reused eliminating packaging waste.
ROLL FED CONSUMER - GOLD
think4D, Altona, Manitoba Canada Gillette Venus Swirl™
Overview: The Venus Swirl™ packaging incorporates think4D multi dimensional technology to print and form the silver FLEXIBALL™ on the package. This think4D technology was described as a “Thermoforming Breakthrough” when featured on the cover of Packaging World in April 2014. The use of this disruptive packaging innovation is matched by the disruptive product innovation inside – the Venus Swirl™ with FLEXIBALL™ technology. Features and Benefits: This project is the first printed and formed blister packaging with think4D technology to be heat-sealed in a fully automated environment. Production challenges include the need for very tight tolerances on every packaging component and custom ink formulations to withstand the stresses of the 400 deg F heat-sealing process without splitting or cracking. Heat-sealing flat lids to an arched surface is very challenging and traditionally has higher scrap rates. This challenge was solved by think4D using their innovative pack-out system. The multi-dimensional lids are packed hot right off the thermoforming line onto thermoformed packing trays and residual heat maintains the desired arc required; resulting in packaging-line efficiencies, reducing scrap rate while increasing line speeds. Aluminum production tooling with six lids per index, dynamic, temperature controlled, roll-fed, pressure forming and die cut inline. Challenges included precise registration to the pre-printed and sculptured detail. The lid becomes the front panel of the package, it’s really the only part of the package the consumer sees on the shelf – so a highly decorated, eye catching lid is essential to provide differentiation and shelf appeal. Venus Swirl™ packaging displays exceptional attention to detail, balancing functional structural design, while providing an easy to open package with safe product removal by the consumer. This packaging is produced using advanced HD printing on a Flexographic press using 10 stations, including holographic security features and new decorating effects and is well embraced by consumers. “I love the look of the packaging! The fact that it had a round ball right on the package made it stand out to me! Made me see that it had something unique about it (more) than other razors near it in the store!” The Venus Swirl™ package is automation-friendly and runs consistently on Gillette’s global packaging lines. Made from PETG, rPET & paperboard all pre-consumer waste is recycled and the final package is completely recyclable. The end results are cost effective, environmentally responsible packaging with an innovative multidimensional formed FLEXIBALL™ and eye catching visuals showing customers this is an innovative new product from their trusted brand. Plastics & Rubber Review | September-October 2015 | 41
Fakuma 2015 – International Trade Fair for Plastics Processing
24th Fakuma – Plastics Technologies and Processes “The Best Fakuma Ever” and “Record-Breaking Numbers at Fakuma 2014”, as well as “Fakuma at 2nd Place in Worldwide Rankings – these and other similar headlines appeared on the occasion of the last Fakuma in the fall of 2014, held on Lake Constance where Germany, Austria and Switzerland meet. For private trade fair promoters P.E. Schall GmbH & Co. KG, who have been working together with the Friedrichshafen Exhibition Centre for many years in trusting collaboration, the record-breaking figures achieved in 2014 also represent a duty to further develop the Fakuma international trade fair for plastics processing while maintaining its current high levels. The chances that this will happen are quite good, because Fakuma project manager Annemarie Lipp has already announced that due to enormous demand well in 42 | September-October 2015 | Plastics & Rubber Review
advance, all availabnle floor space at the Friedrichshafen Exhibition Centre will be occupied and fully allocated. Consequently, Fakuma 2015 will literally tread in the footsteps of last year’s trade fair and promises a world-class industry event at its 24th edition. “We have to work incessantly at maintaining these standards”, says event promoter Paul E. Schall, “because the competition in the trade fair business is splitting up both internationally and at the technical level, and only a few leading trade fairs remain with genuine global acceptance, for example Fakuma. Manufacturers and distributors of machines, tooling, material flow technology
and peripheral equipment in all areas of industrial plastics processing are faced with similarly large challenges. Above all the hype which is demonstrating nearly hysterical traits regarding the complex issue of generative production should be stressed within this context, which has gotten entirely out of control during the last two years and is finally beginning to settle down now that its industrial usefulness is being closely scrutinised. In the interest of the exhibitors and expert visitors, we as promoters provide for objectivisation – especially in light of the fact that we’ve been active in the fields of additive, generative and prototyping processes for more than 25 years by creating a
platform at a very early stage for exhibitors from research and industry, in order to familiarise the expert visitors with the latest, most highly promising technologies and processes.” There were lots of exhibitors at the last Fakuma offering 3D printing systems and generative processes to the market, and there will surely be quite a few more at the 24th Fakuma. After all, the established manufacturers of plastics processing machines have recognised the opportunities presented by generative production and are taking their usual professional approach towards getting 3D, and soon 4D printing ready for broad-based industrial use with high quality original materials. In this respect it’s interesting to note that generative production technologies and processes differ greatly amongst each other in the sense that new processes are being added to the already more or less well-known ones, which are not used for the production of plastic parts but rather, for example, to construct injection moulds made of layered, powdered metal in tooling quality with cooling system structures which are extremely close to the contour. Here as well, Fakuma was, and still is, one step ahead and presented MPA technology with combined metal deposition and 5-axis milling processes within the framework of its enormous “tooling systems” exhibition segment last year. The most up-to-date technologies and applied innovative processes – these were met with great interest by nearly 1800 exhibitors from 36 countries (nearly 600 from outside of Germany) and nearly 46,000 expert visitors from 117 countries around the world in 2014 – and thus the criteria for Fakuma 2015 (13 to 17 October 2015) have already been set! Plastics & Rubber Review | September-October 2015 | 43
All there is to know about Tyre Industry, Its Manufacturing and Machinery in sunshine.
The Manufacturing Process
According to the reports, the tyre industry is the largest consumer of rubber in the world with average industrial revenue of $17.6 billion annually where 21% of sales are contributed by OEMs and 79% of sales are replacement tyres. In today’s highly competitive tyre and rubber manufacturing, businesses across the globe face unprecedented and volatile changes. Manufacturers, material suppliers, and machine builders (OEMs), are affected by shifting customer demands, globalization, industry consolidation, technology innovations, safety requirements, government regulations and the demand for lower customer prices. Tyre manufacturers must reap the most productivity from every stage of their manufacturing process. At the same time, they must ensure the tyres produced meet their customers’ specifications and overall quality standards.
Raw Materials Rubber is the main raw material used in manufacturing tyres, and
both natural and synthetic rubber is used. To produce the raw rubber used in tyre manufacturing, the liquid latex is mixed with acids that cause the rubber to solidify. Presses squeeze out excess water and form the rubber into sheets, and then the sheets are dried in tall smokehouses, pressed into enormous bales, and shipped to tyre factories around the world. The other primary ingredient in tyre rubber is carbon black. So much carbon black is required for manufacturing tyres that rail cars transport it and huge silos store the carbon black at the tyre factory until it is needed. Sulfur and other chemicals are also used in tyres. Specific chemicals, when mixed with rubber and then heated, produce specific tyre characteristics such as high friction (but low mileage) for a racing tyre or high mileage (but lower friction) for a passenger car tyre. Some chemicals keep the rubber flexible while it is being shaped into a tyre while other chemicals protect the rubber from the ultraviolet radiation
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A passenger car tyre is manufactured by wrapping multiple layers of specially formulated rubber around a metal drum in a tyre-forming machine. The different components of the tyre are carried to the forming machine, where a skilled assembler cuts and positions the strips to form the different parts of the tyre, called a “green tyre” at this point. When a green tyre is finished, the metal drum collapses, allowing the tyre assembler to remove the tyre. The green tyre is then taken to a mold for curing.
Tyre Building Machine Building is the process of assembling all the components onto a tyre building drum. Tyrebuilding machines (TBM) can be manually operated or fully automatic. Typical TBM operations include the first-stage operation, where inner liner, body plies, and sidewalls are wrapped around the drum, the beads are placed, and the assembly turned up over the bead. In the second stage operation the belt package and tread are applied and the green tyre is inflated and shaped. The largest tyre makers have internally developed automated tyre-
assembly machines in an effort to create competitive advantages in tyre construction precision, high production yield, and reduced labor. Nevertheless there is a large base of machine builders who produce tyre-building machines.
What the future holds Constant improvements in rubber chemistry and tyre design are creating exciting new tyres that offer greater mileage and improved performance in extreme weather conditions. Manufacturers now offer tyres estimated to last up to 80,000 miles. Treads, designed and tested by computer, now feature unique asymmetrical bands for improved traction and safety on wet or snowy roads. Tyre design engineers are also experimenting with non-pneumatic tyres that can never go flat because they don’t contain air under pressure. One such non-pneumatic tyre is simply one slab of thick plastic attached to the wheel rim. The plastic curves out from the rim to a point where a rubber tread is secured to the plastic for contact with the road. Such a tyre offers lower rolling resistance for greater fuel economy and superior handling because of a greater area of contact between tread and road.
K 2016 – Innovation takes centre stage Interview with Werner Matthias Dornscheidt, President and CEO, Messe Düsseldorf GmbH Q: Mr. Dornscheidt, the registration period for participation in K 2016 closed a few weeks ago. How would you rate the response from the global plastics and rubber industry? A: Extremely positive! The demand for exhibition space has risen once again and all of the 19 halls at the Düsseldorf exhibition centre are completely booked up. More than 3,000 exhibitors from all five continents will be taking part and presenting their innovations. The spectrum of participating companies ranges from globally operating industrial groups to start-ups and covers all segments of the world market for polymers. K 2016 will be presenting a panorama of unmatched breadth and depth.
internationalism, both on the exhibitor and on the visitor side. This guarantees that trade visitors will find world-class products and services in every area covered. And it gives the exhibitors the opportunity to meet industry experts from over 100 countries and establish contacts with potential customers that they might not have been able to reach in other ways.
So innovation will take centre stage at K 2016. Will there be additional offerings providing insights
into new developments and perspectives alongside what the exhibitors will be showcasing? Enterprises from the industry and research institutes will be taking advantage of K 2016 to spotlight developments and future prospects in the plastics and rubber industry. This will be done not only at the exhibitors’ stands but also in the extensive supporting programme which offers the trade visitors another range of interesting topics. To mention just two:
Will all of the companies who have registered actually be able to take part? We will keep our promise: all companies that registered by 31st May and whose exhibits meet the K 2016 nomenclature will be allocated a stand. In some cases, it might be necessary to compromise on the stand size, but I am confident that we will find a good solution for everyone.
What is so special about K in Düsseldorf? Other industry events have large numbers of exhibitors too. K is the premiering platform for the plastics and rubber industry. No other trade fair sparks off so many new ideas. Right now, companies throughout the industry are already working hard to make sure they present themselves in the best light when the date comes around in October 2016. And “in the best light” stands for “with interesting innovations”. Because innovative products are the most important asset in a competitive environment. Only those who can offer new technologies that bring real benefits to their customers will be able to hold their own against strong competition. Another unique feature of K is its high degree of
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The global events calendar for the plastics and rubber industry has seen quite an upheaval recently regarding shifting of dates. How does this affect K 2016?
The special show in Hall 6 gives insights into how plastics can shape the future and solve tomorrow’s challenges – in functional, aesthetic and sustainable ways. Topics like resource efficiency, lightweight construction, new materials and Industry 4.0, and even the controversial marine litter, will be addressed in panel discussions and presented in multiple media. The special show is organised by the German plastics industry under the auspices of PlasticsEurope Deutschland and Messe Düsseldorf. While the special show is directed at industry decision-makers and also reaches the general public through multipliers and the media, the Science Campus is the meeting place for the scientific community. This is where institutions, universities and other establishments present their latest research results in the complex field of plastics and rubber and dialogue with industrial users.
With such a broad array of offerings, will the trade visitors be able to find all the highlights at the trade fair? Yes, of course! K 2016 offers huge variety, but at the same time it is very clearly structured. The exhibition halls are dedicated to the specific areas of • raw materials, auxiliaries • semi-finished products, technical parts and reinforced plastics • machinery and equipment, and • services This structure ensures that each visitor can easily locate the exhibitors most likely to match his or her professional interests. An extensive range of web-based services makes planning very easy before and during visits to the trade fair. As an additional resource, the Innovation Compass is being optimised to allow even better identification of the new developments presented by exhibitors.
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Thanks to its scope and the unrivalled internationality, K has a very special standing in the world. It is seen as the heart of the industry and the starting point for major decisions regarding products, processes and solutions. One of the key reasons why K is so successful is its concept, which we designed from the very beginning in consultation with manufacturers and processers and their industry associations and have continued to develop jointly with them ever since. This interaction has proved to be a winning combination and ensured that the trade fair has remained the undisputed leader for decades. And right now we are hearing that suppliers and decision-makers have a very high preference for Düsseldorf. People in the industry are rescheduling their events calendar worldwide to ensure that nothing clashes with K.
K 2016- The World’s No. 1 Trade Fair for Plastics and Rubber 19 to 26 October 2016
The world’s premier trade fair for the plastics and rubber industry will once again be presenting the entire range of products and services that the industry has to offer, from the latest state of the art to groundbreaking innovations to visionary developments. At K 2013, a total of 3,220 exhibitors from 59 countries showcased their capabilities, and 218,000 trade visitors from over 100 countries used this event as a business platform for information and investments. 82% of visitors at K 2013 were directly involved in investment decisions. The visitors categories at K are manufacturers of plastic and rubber products as well as developers, designers and manufacturing specialists from user industries, such as the automotive, consumer goods, electrical and electronics, aerospace and construction sectors. K 2016 will be occupying all 19 halls of the Düsseldorf exhibition grounds. Suppliers of machinery and equipment are traditionally the largest group among the exhibitors, and their live presentations of sophisticated production units offer a globally unique experience. The producers of raw materials, semi-finished products and technical parts will be focusing on novel products and applications in addition to energy-efficient and environmentally sustainable solutions. K 2016 will be open from 10 a.m. to 6.30 p.m. daily from Wednesday, 19 October, to Wednesday, 26 October. All the details can be found at www.konline.com
Author: Des King Des King has worked as a freelance journalist in the printing & packaging industries for the past twenty years. During this time he has appeared regularly in leading UK magazines as well as several of the leading European & international trade publications. He writes a regular monthly opinion column in Packaging News. Des is a long-standing member of IPPO, The International Packaging Press Organisation. Over the past four years he has edited UK print & packaging industry supplements within The Times, the Guardian and the Daily Telegraph and has been responsible for editing the Englishlanguage version on-site show newspapers at interpack ’08, ’11 and ’14 in Düsseldorf. Prior to joining the ranks of the ‘fourth estate’, Des King was marketing director at Reed Exhibitions (UK) for seventeen years, during which time he was responsible for the promotion of PACKEX (packaging); INTERPLAS (plastics) and IPEX (printing) events. His main interests within the packaging sector are the increasing impact of digital technology in accelerating time to market and increasing on-shelf impact; the role of packaging within product branding strategies; and ways in which packaging can be made more user-friendly to fellow grey consumers.
Brand new perspectives in packaging print under such highly testing conditions is one half of the brand owner’s greatest challenge. The other is to meet it at an affordable cost.
Looks count and first impressions matter. How products are judged by their many differing attributes - not least fitness for purpose, consistent reliability and value for money - will determine the extent to which they build market share on an ongoing basis. Prior to that, however, it will probably be a particular spot colour, a distinctive font, or else the artful application of a metallic ink on the exterior of the pack that initiates the relationship between a brand and a consumer. “Thanks to impressive print packaging, brands can seduce customers into a change of purchasing vote at the point of purchase,” says Superbrands founder Marcel Knobil. “We would end up with less brand and more bland were it not for the attention that the packaging attracts.” Superbrands is acclaimed worldwide as being an independent authority and arbiter of branding excellence, committed to paying tribute to exceptional brands and promoting the discipline of branding. The impact of a winning combination of text and graphics extends way beyond fronting up that initial beauty parade. As well as being the ‘eye candy’ that hooks the consumer in the first instance, a perfectly reproduced external image provides consumers with an often subliminal product recognition and reassurance that can be the brand owner’s banker in a congested retail space.
Controlling quality
With the high probability of colour variations occurring not only between different substrates, but also print processes - and indeed from one printer to another, not only in different locations but even when they are running presses made by the same manufacturer - maintaining consistency can be a complex undertaking.
Today’s packaging trends are driven by longer supermarket opening hours, continually enhanced print technologies and capabilities and demand to protect brands and increase recognition. Not only surviving but attaining the status as the preferred choice 1 16 | July-August 2015 | Printing Review
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It’s not just improvement at the front-end that is raising quality and performance standards in flexo, still the sector’s most widely used print process accounting for over 40% of a current global printed packaging market worth around an estimated €250bn per annum, particularly for flexibles and corrugated board applications. Speed on the press and consistency across substrates are key. Ultimate Packaging has recently installed two additional servo-driven Bobst flexo presses. Offset has also responded positively to deliver cost-efficient shorter run-lengths.
The best way to meet it is to ensure that all the contributory links within the supply chain which are engaged in steering the progress of a printed pack from hatch to despatch are all able to interact via an open entry web-based platform.
“Our vision is to connect the supply chain from the brand owner to the retailer and to make that flow broader and richer,” Jef Stoffels, Esko Marketing
Director.
Digital mindset
“We do this by adding greater functionality which meets the go-to-market and quality needs of CPG (consumer packaged goods) businesses and retailers. We also make it possible for the brand owner to ensure that the flow of data is secure and transparent, mistakes and errors can be picked up early or avoided altogether and the net result is to get products to market faster.”
What has sparked these improvements in analogue press technology is the increasingly potent challenge posed by digital print; not least in meeting brand owner requirements for cost-efficient shorter run lengths – and thereby, lower inventory levels – and the ability to differentiate products on-shelf through customisation. Whilst affordably utilising variable data has always been part and parcel of the digital print proposition, it’s now clearly on the retail marketing radar following its successful adoption by high-profile retail marketing campaigns run by Coca Cola, Heineken, Nutella and a steadily growing band of global blue-chip brands. “To take our brand off the packaging and replace it with something other than the Coca Cola script wasn’t easy to do within a structure like ours, where we operate according to very tight brand guidelines to protecting it,” says Coca Cola Packaging Innovator Greg Bentley. “The digital print capability enabled it to happen, but the marketing campaign is the really smart thing.”
“The combination of technological muscle and marketing inspiration is what it takes to make customisation fly,” Paul Randall, HP Worldwide Brands Business Development Manager.
Similarly web-based colour management systems can extend the same degree of comfort and control to brand owners over how pre-determined colour parameters are then replicated accurately irrespective of substrate or supplier, ensuring a guaranteed consistency of colour reproduction that underpins brand authenticity and integrity. The X-Rite PantoneLIVE colour management solution is ideal for the brand owner as it has control over the pre-determined colour parameters, these are then stored in the cloud for use as and when required by his supply chain. This ensures accurate replications of the accredited brand image irrespective of substrate or supplier.
“It’s breaking away from the mindset of packaging being the static bearer of logos and ingredients tables and using it as a media opportunity for consumer engagement to the benefit of the brand. The media landscape has changed. It is becoming increasingly fragmented between above the line spend (bought media), PR and below the line (earned media), and packaging (owned media) – with the latter two increasingly linked together. Not surprisingly, brand owners are now regular visitors to HP’s Graphics Experience Centre in Barcelona.”
Pressed to perform
Converters equipped with smarter production facilities can be more directly instrumental in achieving cost and performance benefits to brand owners. Using high-definition flexo plate and software technologies, it is now possible to meet the requirements of 85% of current flexo-printed, flexible packaging without detriment to the finished result from CMYK + white rather than using special inks. “Working out of a reduced colour palette means there are less plates and less waste ink. It ticks a lot of boxes,” says Ultimate Packaging (UK) Sales Director, Chris Tonge. “Whilst global players like Unilever and P&G have been specifying these solutions for the past 10 to 15 years, smaller brands are realising there is a cost advantage in that you can control the colours a lot better if you set the right standards.”
Likewise Xeikon’s technology centre in Antwerp. “For brand owners attending our Xeikon Café programme, it’s a two-track learning curve,” says Labels & Packaging Marketing Director, Filip 2
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The new frontier
Weymans. “First, understanding how the benefits of digital production can be translated into diversifying communication towards the audience they’re reaching out to and second, how the technology can address needs within their business model - notably, being faster to market and making better use of working capital.”
“The adoption of online-oriented technologies is pointing the way towards next generation applications aimed at facilitating greater engagement between brand and consumer,” says Sun Branding Solutions Packaging Technology Director, Gillian Garside-Wight. “Who would have thought that the Apple watch would be available five years ago? Brand owners need to deliver what consumers want including smarter packs that integrate with a digitally driven smarter life-style.”
“While the adoption of digital is an accelerating trend, despite the buzz being created it’s still under-selling its potential,” says SAB Miller Global Packaging Manager, Doug Hutt. “The top ten brand owners in the world are generating over a quarter of a trillion dollars in sales. If just 10 - 20% of these were digitised with the balance going to analogue, that is still a very large potential revenue that converters haven’t yet grasped.”
Quite a number of applications on the market bring into play mobile technology. For example, on-pack augmented reality (AR) applications pioneered by Blippar that allow users to simply look at an object through the camera on their smartphone to activate an instantaneous digital search and draw down information from the web. In a recent campaign for Perrier, the invitation to consumers to shake their phone like a cocktail shaker to reveal a recipe was a typically innovative way to highlight the overall concept and add fun by using the technology to unique advantage.
“FMCG companies should be more proactive in going out and talking to the packaging industry – and the packaging industry should be addressing those issues and coming up with solutions,” Doug Hutt, SAB Miller Global Packaging Manager.
Rather than position an icon on-pack to facilitate interaction, UK-based prepress specialist Reproflex3’s proprietary ‘PackLinc’ scanning technology embeds a hidden code within the ink itself, enabling the consumer to effectively treat the entire pack as a portal. Most recently applied within a limited edition run of the children’s POM-BEAR crisp packet, the system was the recipient of EFIA (European Flexographic Industry Association) and the prestigious Starpack gold awards last year. Debbie Waldron-Hoines, EFIA Director says, “Brand owners need a deeper understanding of the processes so that they can help make considered decisions on what is best suited for their brand. Both flexo and digital can work wonderfully together to enhance the brand.”
Meanwhile, faster-running inkjet technology looks poised to dictate the next chapter in the digital packaging print story, not least via the keenly anticipated commercialisation of digital guru Benny Landa’s ‘nanographic’ presses engineered to deliver variable data printed material at offset speeds.
The finishing touch
Customisation is not the only route to catching the consumer’s eye on-shelf. Short-run, cost-effective special effects such as high gloss, glitter, metallic without recourse to hot-foil stamping and even Braille are also within the remit of next-generation digital post-press enhancement technology now establishing itself within the finishing sector. Also providing a more cost-effective means of achieving greater stand-out is the take-up of cold foiling using the analogue process - notably as an alternative to laminated / metallised substrates for labels and cartons. Meanwhile, at the higher end of the scale is the arresting 3D effect achieved through the use of Fresnel lens technology providing instant ‘stand-out’ in retail duty-free for cartons containing the global gin brand Bombay Sapphire. “It’s obviously more expensive than a normal foil by about one-third, but you do get significantly greater impact. If you want something that is undeniably eye-catching and alluring then that’s what it takes,” Dominic Burke, Webb deVlam UK Managing Director.
Underpinning product security and thereby underpinning brand integrity is another obvious avenue being explored by smart technologies. A fully printed near-field communication sensor tag (NFC) developed by Thin Film Electronics for Diageo’s Johnnie Walker whisky doubles as a security and anti-counterfeiting device as well as interacting with smartphones to dispense product advice and information. As a lot of the labelling and pre-printed information currently required to be displayed on-pack is gradually phased out, just imagine the potential for branding afforded by that freed-up real estate. Brands are currently getting maybe only 40% of the pack’s surface for its primary purpose. However, if one small interactive barcode resolves all the regulatory and legal requirements 90% of the print surface could be released for marketing the product. 3
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“Brand owners need to meet the challenges faced by counterfeiting, product security in the supply chain, consumer engagement and ‘Big Data’ management. Brand protection and better marketing of their products are major starting points towards averting potential reputational damage and simply saving money.”
“Ironically, the most practical bridge linking brand and consumer might simply entail upgrading the humble linear barcode into a 2D format,” says Domino Printing Sciences Global Account Manager, Craig Stobie. “Brand owners are yet to fully realise the potential in having a machine-readable code that not only contains a lot more data but with the same footprint or smaller than a human-readable, but can also actually be cheaper.”
Eye-catching and innovative printed packaging is a shrewd investment towards building a loyal and enduring customer-base, concludes Des King. Whilst consumers are exercising greater versatility than ever before in choosing how and where they are able to gather information through which to determine product preferences, packaging offers the brand owner a uniquely guaranteed opportunity to control how they communicate with prospective customers face to face in-store at the very point of purchase. No surprise then that the ways in which the package is printed will occupy centre-stage at drupa 2016.
“Whether it be products that communicate with your tablet or temperature or time sensitive thermochromic inks that indicate when your lager is perfectly chilled or provide the re-assurance that pre-packaged meat is safe to eat, the facility for interactivity ticks all the right boxes for forward-looking brand owners,” Eef
de Ferrante, Managing Director of the Active & Intelligent Packaging Industry Association (AIPIA).
Executive summary
Printed packaging is the key mechanism enabling brand owners to build expanding and enduring customer loyalty in order to out-sell and out-perform their competition. Changing patterns of communication have elevated the role of packaging from protective wrapper to front-line sales & marketing tool. In a media-neutral environment it’s a function that is increasingly as much marketing as technology, and that provides the brand owner with guaranteed profiling and exposure in front of the consumer. In order to optimise consumer response at the point of sale, brand owners will want to invest not only in imaginative, innovative and well-executed creative design in order to achieve distinction and differentiation, but also in the appropriate colour management technologies to ensure its accurate replication irrespective of substrate or geographical location. The latest developments in web-based workflow platforms and systems that link all components within the packaging print supply chain will be on show at drupa 2016. Whilst a consistently reproduced and instantly recognisable image is vital in underpinning authenticity, brand owners are increasingly required to be able to demonstrate rapid response agility in order to maintain competitive edge via updated printed messaging and as these tactics are often short-term and invariably short-run, as cost-effectively as possible. The same level of expediency applies to the introduction of brand extensions and new products. Enhanced analogue process print and next-generation digital equipment designed to deliver accelerated cost-effective time to market will compete for attention at drupa 2016. Special decorative effects and added functionality are increasingly providing an added value finishing touch that can extend beyond the point of purchase to enhance the consumer’s relationship with the branding proposition throughout its life expectancy. The appropriate systems and solutions to accomplish all of these imperatives are not only readily available to print service providers but contact person: Pressupdated centre for drupa 2016 are constantly and extended. Applications to facilitate the synergy between printed text and graphics, the internet and social Monika Kissing/Anne Schröer (Assistant)interactivity accessed by smart mobile technology will constitute a growing area of visitor media through the development of on-pack Tel.: +49 (0)211-4560 543 interest in Dϋsseldorf. E-Mail: KissingM@messe-duesseldorf.de E-Mail: SchroeerA@messe-duesseldorf.de
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Tel.: +49(0)211-4560 465 Fax: +49 (0)211-4560 87543
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WITTMANN BATTENFELD at the Fakuma 2015 SmartPower 350 – the largest model of the servo hydraulic machine series from WITTMANN BATTENFELD
WITTMANN
BATTENFELD’s highlight at this year’s Fakuma in Friedrichshafen is the SmartPower 350. With this machine, on show from 13 to 17 October in hall B1, stand 1204, WITTMANN BATTENFELD has completed its PowerSeries product range. The SmartPower machine series was presented for the first time at the Fakuma 2014 with clamping forces of up to 120 t. Now this series has been completed with the larger sizes from 160 to 350 t. The SmartPower is equipped as standard with an extremely energyefficient, innovative servo hydraulic drive, which stands out by its high dynamism and low noise level. Moreover, the drive technology of the SmartPower makes it possible to use the KERS (Kinetic Energy Recovery System) developed for the EcoPower. KERS transforms the kinetic energy released by deceleration into electrical energy. The electrical energy recovered in this way is partly stored, used by other drive systems for parallel movements, transferred to barrel heating or used to generate the voltage for the control system. This means that the entire deceleration energy is used within the machine. The clamping system of the SmartPower comes with a centrally operating cylinder piston. The hydraulic blocks are integrated directly on the clamping side to ensure extremely high control accuracy and dynamic movement sequences. Two symmetrically positioned traveling cylinders provide force transmission with mold protection and fast movements. In this machine series, injection control is effected via the highly dynamic servo drive. The open design of this machine simplifies its operation and
coordination with material feeding and drying equipment. With the SmartPower, the clamping force range of the hydraulic machine series has been extended from 300 t for the previous model HM to 350 t. The diagonal distance between tie-bars has also been increased. The SmartPower 350 offers generous mold fixing dimensions of 800 x 720 mm distance between tie-bars, combined with an extremely compact footprint of the machine. The open design of the SmartPower frame includes an open ejection area in three directions. The installation of conveyor belts for parts removal presents no problems. Another special feature of the SmartPower is the easily pivoting injection unit, available up to size 3400. This pivoting injection unit significantly facilitates access to the nozzle and the screw, and consequently servicing of the screw. At the Fakuma, a “natural fiber organic sheet” component will be produced with a single-cavity mold from Georg Kaufmann, CH, on a SmartPower 350/2250. The mold is equipped with a hot runner with needle shut-off, an edge folding slider for in-mold forming of the organic sheet and a punching die to punch out an aperture in it. The automation system developed by WITTMANN Robot Systeme in Nuremberg is custom-made for this application and comes with a station to feed the organic sheets cut to size, a heating station to heat the organic sheets with heating elements supplied by Krelus, CH, and a multi-functional gripper with a needle gripper to pick up the heated organic sheet, and a suction unit for finished parts removal. Plastics & Rubber Review | September-October 2015 | 51
DISCOVER THE FUTURE OF PRINTING AT THE 6th ALL IN PRINT CHINA
uncertainty. In 2013, total output of Chinese printing industry hit a high record of RMB 1039.85 billion, up 9.3% over the previous year.
Brief of All-in-Print China Recent years have witnessed difficult economic recovery in developed countries and slower growth pace in emerging markets. Nevertheless, Chinese economy maintains steady growth amid this global economic
Geographically, Asian countries such as China and India continue to improve their rankings in the global printing market (second and fifth place, respectively) due to a constant rise in the output volume and value. Asia has become a region with the most growth potential and the strongest momentum. Shanghai remains to be one of the core areas of the Chinese printing industry. With the development of Shanghai Free Trade Zone,
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its position in the global investment and trading network will become more obvious. The 6th All in Print China will be held again on October 18-22, 2016 in Shanghai New International Expo Centre. It is organized by The Printing Technology Association of China, China Academy of Printing Technology, and Messe Düsseldorf (Shanghai) Co., Ltd. under the approval by the Ministry of Commerce of the People's Republic of China, with Keyin Print Media, The Printing Technology Association of China and Messe Düsseldorf (Shanghai) Co., Ltd. as the undertak-
ers, and Shanghai Printing Trade Association as the co-organizer. It is one of the most important professional exhibitions of the printing industry in China and is bound to become another successful international event among the Chinese printing industry and in the whole Asia. To know more from the official website: www.allinprint.com. High Lights Starting from 2014, All in Print China will be switched from a 3-year cycle to a 2-year cycle, with the exhibition duration extended from 4
days to 5 days. 6 halls including the outdoor sections individually themed to present precise categories of the exhibition. More than 30 professional conferences and seminars will be held concurrently. All in Print China will extend the steam of drupa, raising its heat to the top of Asia. The Press Conference of All in Print 2016 The press conference of the All in Print China 2016 was successfully held at Sheraton Dongguan Hotel in Guangdong in this April. A line-up of almost 100 representatives also participated in the press conference including those from over 20 media groups from home and abroad; those from industrial associations as well as representatives from exhibitors such as Heidelberg, Founder, Lenovo, Hans Gronhi, Siegwerk etc,. With the theme of “Discover the Future of Printing”, All
on-site picture of the press conference
in Print China 2016 will demonstrate the all-round vitality and dynamics inspired by the variety of printing technologies, keep close with the market updates and present core segments with bold and creative highlights.
rated very satisfied
A witness of resounding success for 10 years
Owning the largest booth at the All in Print China 2014, Canon shows its commitment to deeply engage in the digital printing industry via such large-scale participation. At the
81.94% exhibitors were satisfied with this exhibition, with 23.26%
85.80% visitors were satisfied with this exhibition, with 32.34% rated very satisfied Voices of Industry:
exhibition, both the number of customers interested in Canon and the market’s acceptance of Canon products are beyond our expectations. We participate in a very good and even the best exhibition. Ver -Welber t V er heyen, Vice president of Canon Inc. (China) & Person-in-charge of Professional Printing Products Depar tment HP pays great attention to the Chinese market. All in Print China 2014 is of great significance for HP. At the exhibition, our achievements in the first two days exceeded our goals. I believe that HP will gain more at the exhibition. -Gido V an Praag, Vice presiVan dent/general manager of Graphics Solution Business for Printing and Personal Systems Group,HP Asia Pacific & Japan Contact for Exhibitors: Ms. Evian Gu Tel: +86-21-6169 8357 Fax: +86-21-6169 8301 Email: evian.gu@mds.cn Contact for Visitors: Ms: Tracy Cui Tel: +86-21-6169 8342 Fax: +86-21-6169 8301 Email: tracy.cui@mds.cn
Plastics & Rubber ReviewReview | September-October Printing | July-August 2015 2015 | |53 15
AKRON RANGE OF IPA-REDUCING / ELIMINATING FOUNTAIN SOLUTIONS
assured that by switching over to Akron Range of fountain solutions, they are able to maintain the same levels of quality as earlier without any compromises whatsoever.” Kale also adds that the Akron Range is designed to keep the pressroom workflow smooth and hassle-free. The Akron Range of fountain solutions offer printers a never before ‘Dose & Forget’ convenience due to its exceptional wetting stability & very high levels of plate protection agents, at a low cost-in-use. This allows printers to concentrate on producing highquality prints, rather than worrying about ink-water balance.
TechNova’s Next Gen fountain solutions help printers achieve a perfect balance between Quality and Safety in their pressrooms.
T
he Akron Range of IPAreducing / eliminating fountain solutions consists of Fogra approved, ultra-low foaming fountain solutions that are designed for sheet-fed offset presses with alcohol and integrated dampening systems. The range is 100% compatible with all TechNova plates and is perfectly suited for all popular machine configurations and for different waters conditions. Since its introduction, the Akron Range of fountain solutions have been successfully meeting the needs of quality-conscious printers across
India. THE AKRON RANGE OF FOUNTAIN SOLUTIONS COMPRISES OF : AkronGold CF1A : Fogra approved, IPA reducing / eliminating fountain solution, designed to work with 0% to 4% isopropanol, depending on machine configuration and type of jobs. AkronDiamond : IPA reducing / eliminating fountain solution designed to work with 4% to 6% isopropanol or isopropanol substitute. AkronGold: This ultra-low foaming fountain solution is designed to
| September-October 2015 2015 | Plastics Rubber Review 454| September-October Printing&Review
work with 6% to 10% isopropanol or isopropanol substitutes. The Akron Range combines benefits of supreme stability and highest quality output in one single package. It offers controlled wetting with zerofoam, and is compatible with both IPA and IPA substitute products like TechNova’s AlcoZAP. The strong biocidal system of Akron Range also ensures improved productivity and optimal maintenance with extended bath life. Milind Kale, Manager Business Development - Chemicals, TechNova, says, “The most important benefit is that it reduces the use of chemicals in the pressroom, making the workplace Safer and Greener. Printers can rest
The Akron Range of Fountain Solutions is manufactured in the same state-of-the-art facility as TechNova’s plates are manufactured. Mr. Kale says that as a result of this, the R&D teams of both plates and chemicals work closely and ensure that both are perfectly compatible, and are manufactured to the highquality standards that customers associate with TechNova. Moreover, he added that, since it is a TechNova product, printers are guaranteed 24x7 technical support and other Value Added Services during and post installation. To benefit from the power of Akron Range for your press, please contact the TechNova Helpdesk on 1800 22 7474 or eMail TechNova on help@technovaworld.com
LAUNCH OF PLASTASIA 2016
Your Premier Destination for Business Opportunities Highlights India's flagship event in the field of plastics, raw materials, processing, machinery and finished goods. Highly Targeted: With its carefully focused profile and highly targeted audience, Plastasia allows you to direct your sales and marketing efforts cost-effectively. Helps makers and users of plastic to understand the trends and future of plastics. It brings together key players from the industry in order to learn, network and capitalise on the business opportunities. International Pavilion from China, Taiwan, Korea, Japan & Italy.
Date : 3rd to 6th March 2016 Venue : Pragati Maidan, New Delhi, India. Hall No : 8, 9, 10, 11, 12, 12A & 14 E M C
Government of India RNI Regn. No. DELENG/2013/56469