BP&R Nov/Dec 23 by BP&R Magazine

issue 08/23

British Plastics and Rubber in association with interplasinsights.com

bp&r

NEW YEAR, NEW NICKERSON PMS

Meet Sam Carr, the new MD at Nickerson PMS, and his plans for 2024 and beyond — Page 16.

PLASTICS DAY IN PARLIAMENT

Philip Law on the House of Commons Reception

TALENT IN PLASTICS

Navigating tough HR by Conrad Taylor

CYCLE'S PRICE IMPACT Mike Boswell on negotiating prices

Nov/Dec

The smart, green, energy-saving machine. Seeing is believing! Visit our working showroom and meet our engineers.

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COMMENT

INDUSTRIAL STRENGTH RESILIENCE

British Plastics and Rubber www.interplasinsights.com Head of sales: Mandy O’Brien T: +44 (0) 01244 952 519 E: mandy.obrien@rapidnews.com Portfolio sales manager: Gareth Jones T: +44 (0) 1244 952 370 E: gareth.jones@rapidnews.com Portfolio sales manager: Kelley Jo Beattie T: +44 (0) 1244 952 375 E: kelleyjo.beattie@rapidnews.com Head of studio: Sam Hamlyn T: +44 (0) 1244 680 222 E: sam.hamlyn@rapidnews.com Subscriptions: T: +44 (0) 1244 680 222 E: subscriptions@rapidnews.com Publisher: Duncan Wood T: +44 (0) 1244 680 222 E: duncan.wood@rapidnews.com Print subscription: Qualifying Criteria UK – Free Europe – £249 ROW – £249 FREE digital issues available to view and download online

British Plastics & Rubber is published monthly (8 times/ year) by Rapid Plastics Media Ltd, Carlton House, Sandpiper Way, Chester Business Park, CH4 9QE T: +44 (0) 1244 680222 F: +44 (0) 1244 671074

© 2023 Rapid Plastics Media Ltd While every attempt has been made to ensure that the information contained within this publication is accurate the publisher accepts no liability for information published in error, or for views expressed. All rights for British Plastics & Rubber are reserved. Reproduction in whole or in part without prior written permission from the publisher is strictly prohibited. ISSN 0307-6164 Incorporating Polymer Age and Rubber and Plastics Age. PEFC Certified This product is from sustainably managed forests and controlled sources PEFC/16-33-254

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n this our last issue of 2023, it seems timely to look back on what has been a very eventful, if cautiously optimistic, year in the plastics industry. Having faced unprecedented challenges like rising energy costs, inflation and interest rates, supply chain disruption and everchanging regulations the industry has remained robust and resilient. Of course, Interplas is a standout highlight. The industry really came together to support the biggest UK plastics trade show in 21 years, with over 540 exhibitors across two halls and three days at the NEC, Birmingham. The mood was positive, and the atmosphere was buoyant, we have heard so many good news stories in the form of successful sales, unexpected meetings and joyous reunions with peers and clients. The introduction of the 75 industry leaders into the hall of fame was a long overdue way of recognising the commitment and longevity of service in our wonderful industry. Interplas also hosted two very well attended major networking events, which were a huge success and will be a featured highlight at the end of a long day at the 2026 show too. Speaking of Interplas, plans are well underway for the 2026 show and the floorplan is a third full already. For the 2026 edition we have moved to Halls 8, 9 and 10 at the NEC and dates to 2-4h June 2026, to run alongside our a host of manufacturing events including our sister shows TCT 3Sixty and Med-Tech Innovation Expo, as well as Subcon and Smart Factory Group and more. It might seem a way off but as the calendar flicks to 2024, Interplas preparation will be in full for what will be one of the

“In a year of challenges, our industry has shown robust resilience and optimistic growth.” most significant event weeks in the manufacturing calendar. I would also like to personally thank all of our cover stars throughout the year – Sam Carr, MD of Nickerson PMS who is featured in this issue, also Hardeep Khera, General Manager of Bole UK, Mike Boswell MD of Plastribution, Nigel Baker MD of Engel UK, Mike Bate former MD of KraussMaffei UK, James Stanton, Commercial and Operations Director of Distrupol, Richard Perry Director of STV Machinery and Chris Newman Regional Technical Manager of Albis UK. Thank you for allowing us to promote our industry leading news by using your image! You all looked great! The new year looms large and plans are underway for the first issue of 2024. We will continue to bring you the latest news from the entire plastics supply chain, from product launches to technical information and informative insight, through our print and digital channels. Thank you for your ongoing support and interest in BP&R magazine. Like the industry at large, the magazine will continue to adapt and evolve, I hope you will continue your journey with it. Happy Holidays and see you in 2024!

MANDY O'BRIEN

HEAD OF SALES, PLASTICS

CONTENTS 14

COMMENT

Industrial Strength Resilience

26 6

Through the doors at Jenco and Tool-Temp

New faces and new strategy for Nickerson PMS

MATERIALS HANDLING

INJECTION MOULDING

Aim higher at Haitian’s new showroom

PHOTOVOLTAICS

New possibilities in plastic

POLYMERMAN

Mike Boswell on resin prices

ON THE COVER

CHRISTMAS SHUTDOWNS Getting ready for the cold snap

RECRUITMENT AND SKILLS

Listgrove on a successful strategy

MOTORS

Why motor choices make all the diﬀerence

REGULARS

26 Column: Philip Law, BPF

www.interplasinsights.com

TEMPERATURE CONTROL/MATERIALS HANDLING While ancillaries supplier Jenco celebrated sixty years of supplying the plastics and other industries this year, Tool-Temp UK, the sole UK distributor for the Swiss-made Tool-Temp range of temperature control devices, continued on its fifty-year-long mission to lead the charge in moulding tech. Both firms operate from under the same roof. In two separate interviews – one during Interplas, and the other at the two firms’ midlands HQ, BP&R caught up with James Bailey, managing director at Jenco, and Jeremy Radcliﬀe, director at Tool-Temp to learn more about the synergistic new oﬀerings being brought to the fore.

enco has stood the test of time as a reliable British partner to many leading firms – not just in the plastic industry, but in the coffee and other sectors besides. This years’ Interplas – the 75th anniversary of the show – also marked the Diamond anniversary for the Jenco brand. It seemed fitting, then, for the group to name its newly launched range of vacuum loaders, the ‘Diamond’ range. Manufactured in the United Kingdom (the vast majority of materials handling equipment in the UK is imported), Jenco says it may also be the first unit of its kind to offer a brushless motor. Available in air, single phase and three phase system options, the loaders are fitted with a full Siemens PLC touch control,

“Now, with UK manufacturing and reshoring both showing encouraging signs, we wanted to move the dial back for equipment manufacturing, too.”

A tale of two COMPANIES electropolished 304 stainless steel, filter options, and are Industry 4.0 ready. “We’re moving away from importing loading equipment, towards an actual UK-manufactured product. Right now, it’s UK-assembled, but we’re heading towards manufacture in the UK as our long-term vision,” said Bailey. “They’re based entirely on our own program, they use all our own IP and our own drawings.” The other big draw for our visitors at Interplas is our blender. Jenco used to make their own material blenders for years ago. But as we know, economies shifted and the market moved towards importing ancillaries. Now, with UK manufacturing and reshoring both showing encouraging signs, we wanted to move the dial back for equipment manufacturing, too.

“That’s been quite a journey, with a little bit of trial and error thrown in. But the net result is that we’ve successfully relaunched our standard ‘beside-the-press’ blender. “We’ve had some great interest already during Interplas, which is good. It’s almost like a reboot of an old classic, there are still people working in the industry who remember the originals. “We’ve changed some technology on them as well. We’ve upgraded the operation of the slide gates, to modernise the way you control the inflight of the material, so it’s the classic concept, but with contemporary technology – the best of both words.” The company has also bolstered its in-house expertise recently, with the addition of two new salespeople, both with process engineering backgrounds. This, Bailey says, is essential for helping customers troubleshoot their processes. With material handling, for example, contamination is always a major concern, especially during dosing. “The problem with dosing is, if you do a lot of colour changes, you’ve got to tackle cross-contamination. Our dosing units come with an air-driven cleanout function, so we can completely pull out those colours from the unit, and then it’s blown through

BP&R's editorial advisory board Richard Brown, Chair of Judges Design Innovation in Plastics Awards

Dr Sally Beken Knowledge Transfer Manager – Polymers Innovate UK KTN www.interplasinsights.com

Robin Kent Managing Director Tangram Technology

Dr Carmen Torres-Sanchez Reader in Multifunctional Materials Manufacturing Loughborough University

TEMPERATURE CONTROL/MATERIALS HANDLING with air. These are well-known, very common issues, but with the experience of processing our sales guys have, they can confidently support our customers and solve these problems.” Another eye-catching exhibit is the Oktomat bag emptying frame by Helios, which Jenco distributes. Bailey explained: “Health and safety is the top priority for manufacturers. The Oktomat unit enables people to eliminate or reduce fork trucks from the shop floor, because they can use a pallet truck to load their big bags to the Oktomat, and then let it do its magic. You also win a lot of space back that way.” On the wider industry, Bailey is optimistic, despite universal challenges, such as energy costs. “Companies are taking that very, very seriously. They know they’ve got to do something, and that has certainly stimulated some CAPEX investment. I’ve heard about some major machine investments being discussed at Interplas. As we go into the winter months, I think we’ll start to see energy get even higher on the agenda, and that should help future-proof the industry.” Radcliffe, meanwhile, is equally excited to share ToolTemp’s fifty-plus years of R&D in moulding temperature control. “At Interplas we wanted to try and represent the quality of the product range. Customers are interested to learn about our broad selection of units, which includes open tank universal units, which go up to 90°C, pressurised water units,

Dr Michael Junior Hopkins Managing Director Ross Polymer Services

which go up to 160°C, and also thermal oil units, which go up to 250°C. “We’ve also got a chiller range, which is quite unique to the plastics industry because they’re designed with a leak stopper facility, which we include on a lot of our temperature controllers. This means if a customer has a leak in their process, such as from a pipe or the tool itself, they can continue to run in negative pressure, enabling them to keep to their deadlines and meet customer expectations.” But perhaps the biggest highlight for the group this time round at Interplas was the MATIC temperature controller with the new IRIS control system. Suitable for all types of process temp control, the IRIS controller offers visibility over multiple fields, including temperature, pressure, flow rates, operating states, status messages, diagram data and data curves. This allows the unit to continuously optimise the process. Remote access is available via a phone, tablet or PC, and users can access the web server integrated in the temperature controller via a web browser. “Heavily drawing on AI technology, this is fully Industry 4.0 ready,” said Radcliffe. “This technology is particularly suited to high-value, high-precision sectors, such as medical, with a need to record and monitor every possible detail for quality control.” I asked Radcliffe about the trends in his customers’ requests: “We’ve had a lot of clients wanting to run their process at 250300°C. The way the technology is designed within the pump,

Heavily drawing on AI technology, this is fully Industry 4.0 ready. This technology is particularly suited to high-value, highprecision sectors, such as medical, with a need to record and monitor every possible detail for quality control.”

Pravin S Mistry Global CEO PREA Ltd.

www.interplasinsights.com

Professor Edward Kosior CEO and Founder Nextek

coupled with the design of our oil heaters, allows us to respond to those demands, and in fact we’re able to run up to 360°C. “Manufacturing our own pumps gives us a real competitive edge, to be honest”. In terms of support, like Jenco, Tool-Temp boasts a strong service team, with extensive processing knowhow. The well-stocked, extensive spare parts facility at the Wellingborough HQ ensures customers are not left in the lurch when a unit needs servicing or repair – with no lengthy wait for importing. An online chat facility on the ToolTemp UK website speeds the process up even further. The size of Tool-Temp’s UK client base varies, from customers with a couple of machines, to customers with fleets of over 150. It’s important then for the firm to stay flexible, and adapt to the challenges of the day. “One of the key features of the IRIS control system is that there’s an energy saving mode on it. So for moulders and brand owners looking to reduce their carbon footprint, the system will maintain the process temperature while slowing the pump down, reducing the heating power, etcetera. It’s a big energy saver”. 2024 promises to be another big year for both Tool-Temp and Jenco. With a renewed focus and dedication to British manufacturing, there’s little doubt that these two stalwarts of the plastics industry will continue to serve as trusted experts to moulders and other plastic processors.

Dr Thomas Bennett Research Fellow University of Manchester

Your Trusted Healthcare Polymer Partner

INJECTION MOULDING Earlier this year, Haitian UK opened a new, purpose-built showroom to demonstrate the Chinese IMM supplier’s latest technology to customers and prospective customers. BP&R took a tour of the new facility, and met with Carl Reeve, MD, and Veronica Edmunds, Business Development Manager, to find out more about the group’s continued success in the UK.

aitian UK has been quite the success story. Having entered the market back in 2005, the expanding team set themselves a five year target in 2017 to be the number one supplier of IMMs in the UK by 2022 – a feat which they believe they achieved in 2020, two years ahead of schedule. “Our strategy was to create a new market dynamic ,” said Ronnie. “We wanted to get away from the perceptions around European and Asian manufacturers, where stereotypes are involved. We just wanted to establish Haitian as a world-class brand, both in terms of how we present the machines, and how our team presents itself to the market.” In China and around the world, Haitian is massive – in fact it is the worlds largest supplier of IMMs, full stop. As a buyer of components, it has considerable purchasing power, due to the sheer volume of production. This enables the firm to build the best possible parts into the machines as standard – rather than as costly added extras. The firm also has huge plans for doubling its sales in Europe. It hopes to achieve this with a new manufacturing site in Serbia, slated to be operational in 2025, which will manufacture up to 3,000 machines a year. Carl explained: “Because of those scales of economy, it’s more cost-effective for Haitian to standardise at a better level. When Steve Jobs went back to Apple, they had thousands of different options, and a sixmonth lead time for a computer – and he just standardised it all. He upgraded to the best chips, and then instead of buying five million of the best one, and 20 million of the standard one, he just incorporated the best possible part as standard.

Aim higher with

HAITIAN

That’s just one of the things that Haitian does that differentiates the group from other Asian manufacturers.” The new showroom will of course be a demo space for the firm’s latest tech. The Haitian Team aren’t just focussed on selling machines – they strive to add value for their customer base. For example, customers with machines over three years old customers may wish to do their own servicing. So Haitian UK is keeping earlier generations of the machines in the showroom, in order that service engineers can receive training on maintaining the machines once the warranty is up. The showroom also means there are plenty of stock machines available at short notice in the UK. Additionally, Veronica stressed that thousands of bespoke options and extras are available for customers who request them. “Because we have this massive infrastructure behind us, we can give customers the best possible support. The best machine, the best service, the best price, the best options, and the best availability. The showroom is multi-purpose. We may often have customers here and not really discuss the new machines with them. It’s about helping them with what they’re already got, in a lot of cases. We do that because we believe in driving UK growth.

“Because of those scales of economy, it’s more cost-effective for Haitian to standardise at a better level. That’s just one of the things that Haitian does that differentiates the group from other Asian manufacturers” www.interplasinsights.com

We also do it, and I mean this genuinely, because we want our customer’s businesses to be as profitable as they can be. We want the part that’s coming out of the end of the machine to be the best possible quality at the best possible price,” she said. The site will also serve as a facility for factory acceptance tests and tool trials. The most recent addition is the quality testing room, which is now available for visitors to use. The machines may also be made available to help customers out with extra capacity. The team offer flexibility and in-house expertise - if they can help a customer out with a production run, they will. Skills and training, too, is another ambition for the new space. Carl explained: “It’s not just familiarisation or maintenance training, we also want to contribute to industry training. On the upper floor of the facility we’ve got a canteen, a training room, and as mentioned, the quality room. If somebody wants to come in for two or three days, they can come here to train their staff, or test a part, whatever we can help with. We’ve just had an external training provider come and use this facility to complete some modules, in fact.” Being a global machinery giant, the story doesn’t end at injection moulding for Haitian. CNC machines are a major line of business for the parent company, and the range includes vertical machining centers, gantry machining centers, horizontal machining centers, CNC lathes, and turning centers. “The group’s capabilities in CNC machinery have recently become interesting for the Italian and Polish markets, so there may be scope for expanding that area of

Your Trusted Healthcare Polymer Partner

INJECTION MOULDING business into the UK in the future” Carl said. It wouldn’t be the first time for the UK business to expand into other technologies. The UK branch is also the distributor for Haitian’s Hilectro range of robots. This followed a period of extensive quality testing on the robots, which proved them more than capable of competing with European tech. “We are already talking about taking CNC machines in. The German team is already demonstrating them too, they’ve got engineers from China supporting them, and they’ll work with some familiar partners to test them in the market before they roll them out fully. We’re hoping to collaborate with Germany on that as we gear up for [offering the technology] ourselves,” Carl added. The secret to Haitian UK’s success though, beyond the machines themselves, is the ability to listen and respond to what customers need. The size and scale of the business means they can stay flexible, and aim higher. Veronica explained: “I’d say we’re constantly trying to move the goalposts, but with a view to improving everything that we do and therefore improving the value that our customers get. The most important thing we do is to ask the customers: ‘What’s important to you?’. We genuinely want British manufacturing to thrive. We have a growth mentality about UK manufacturing, and we share that with our customers.” Carl takes great pride in the machines. His favourite, he tells me, is the Zeres 90 tonne, and the one he shows me is the standard specification of a stock machine – which is actually very high spec, for an entry level machine. “For me, this is the future of Injection Moulding machines. This is an all electric machine with built in hydraulics for core pulling, carriage movement, and nozzle contact. It is a modular platform that enables any standard machine to be

retro fitted for twin injection if required in the future. While multi-shot hasn’t been a core part of the business for Haitian UK to date, Interplas 2023 has seen more people enquiring about it. “Since Interplas, we’ve had a lot of people ask about that. Rather than buying a twin shot machine, they now know they can just add another unit onto the existing machine. These are very energy efficient, and silent when they’re running.” There are multiple machines running during my visit, and true enough, the majority of the noise I can hear comes from the material handling “Compared to a fixed or variable pump machine, this one will probably save about eighty percent in energy costs. Even better, the machine offers parallel movements, so you can do multiple functions in the same operation – for example you can be charging while you’re ejecting, and generally speaking you’re looking at a 10-20% reduction in cycle time. “The electric machines have fewer moving parts on them, so in terms of TCO, there’s less to go wrong.” Also on show is the Mars IIs machine – with over 400,000 sold globally, it’s another mainstay of the Haitian range. “It’s the best selling Haitian machine in the UK, so when this version came out, they were flying off the shelves. Those customers are coming to the end of their three year warranty now, so they’re starting to come in and learn how we would service it, which is great.” The model in the showroom is teamed with Sepro robotics. “It’s a very open platform, we can teach people to use the Sepro robot on this machine as well. And we can show them how they integrate.” The application running on the Mars is a total closed loop. Carl explained: “The sprue is a large percentage of the total www.interplasinsights.com

shot weight. At first with this application, (due to the fact that the customer was taking it offline) contamination was an issue. But with the right automation, we’ve been able to show them how easy it is to close the loop. The sprue weight is 20% of the shot, so it makes a huge difference – why wouldn’t you re-use that plastic? Here, we’re putting the waste plastic back through the process, and there’s no operator required.” The Haitian Team are aware that the facility has to appeal to multiple stakeholders. “We have process engineers, who just want to look at the keypad and understand what it is. We have maintenance teams, who want to look inside the cabinets, We have production directors, and finance people, who just want to understand the ROI. So we know we have to be able to use this to pitch to different people” said Carl. It’s an impressive facility that seriously raises the game in terms of injection moulding technology in the UK. What’s more, it’s enabled the firm to gear up for some major announcements and technology launches in the coming months and years. Haitian UK is located in Aylesbury, Buckinghamshire. 9

www.kraussmaffei.com

pioneering plastics

PHOTOVOLTAICS

ADVANCING THE FUTURE:

flexible, large-area solar cells using halide perovskites

mongst the emerging PV technologies, perovskite solar cells have gained attention in the last decade as a potential alternative to achieve highly efficient solar cells. In addition, the coupling of these materials together with new architectures based on flexible substrates could mean a breakthrough in the next generation of PV devices. This is one of the main goals of the PEROVSOL project, where AIMPLAS is the main coordinator. Climate change is no longer a distant concern; it is an immediate and tangible reality that impacts the lives of millions of people each year. Its effects are becoming increasingly evident worldwide.1,2 A primary driver of this crisis is the unregulated release of greenhouse gases into the atmosphere, a result of activities such as burning fossil fuels and biomass, such as wood and crop waste, to meet our energy needs.3 To secure a cleaner and more sustainable future for our planet and all its inhabitants, it is imperative to explore alternative, less harmful, and less polluting sources of energy. Among the array of alternatives, solar energy emerges as a standout candidate. Solar energy falls under the category of renewable energies and has seen significant advancements in recent decades. Broadly speaking, solar energy harnesses the power of sunlight and converts it into readily usable electricity. These cells typically employ semiconducting materials designed to absorb incoming photons with energies equal to or greater than their specific bandgap energy.

Technologies based on crystalline silicon dominate the current PV market, however, their development is little by little approaching its expected efficiency limit. To overcome this efficiency barrier and continue the ascent, new generations of devices and materials are needed. Paz Sebastia-Luna, Mechanochemistry & Reactive Extrusion Group at AIMPLAS writes. The absorbed energy excites an electron, causing it to transition to the conduction band while leaving behind a hole in the valence band. For the sake of simplicity, these electron and hole can be assumed as free charges moving across the different layers of materials. To prevent their recombination, selective layers for electrons (n-type) and holes (p-type) are strategically positioned on either side of the absorber material. This arrangement ensures that the charge carriers can flow through only one of these layers. Finally, electrical contacts are used to extract the charge carriers, allowing them to perform work and generate an electric current when connected to an external circuit. This remarkable process lies at the heart of solar energy generation. 4,5 Currently, the photovoltaic (PV) market is predominantly ruled by technologies centered on crystalline silicon (c-Si), which constitute approximately 95% of global PV production. Despite their prevalence, the progress and enhancement of siliconbased solar cells have been advancing at a relatively slow pace in recent decades. 6,7 To break through this efficiency barrier and continue the upward trajectory, alternative solar cell technologies have made their way into the PV market. These include cadmium telluride,

gallium arsenide, copper indium gallium selenide (CIGS), and copper zinc tin sulfide (CZTS) based solar cells, some of which have achieved efficiencies surpassing 30%, as depicted in in the renowned Efficiency Chart from NREL.7 However, it is important to note that the development and commercialization of these alternative solar cells face significant challenges, such as their toxicity, scarceness, and high production costs. 6,8 These limitations underscore the need for sustainable and environmentally friendly solutions in the pursuit of

higher efficiency solar cells. Perovskite solar cells have garnered significant attention over the past decade as a potential and promising alternative for achieving highly efficient solar cells, reaching remarkable values of approximately 26.1%.7 These efficiencies are near those achieved by siliconbased solar cells, marking a significant advancement in the field. One of the simplest and extensively studied perovskite materials is methylammonium lead iodide, denoted as MAPbI3, with its structural representation depicted in Figure 1 This compound has gained prominence primarily due to its capacity for long charge carrier diffusion lengths and high absorption coefficients.

Figure 1. Schematic structure of general-type ABX3 perovskite. Adapted from literature.10

“Perovskite solar cells have garnered significant attention over the past decade as a potential and promising alternative for achieving highly efficient solar cells, reaching remarkable values of approximately 26.1%.”

www.interplasinsights.com

Shadowfree Valve gating technology Extremely fast colour change with valve gate systems The innovative Shadowfree technology eliminates the flow shadows in valve gate systems, and enables an up to 70% faster colour change in the hot runner. • Elimination of the needle shadow • Screwed-on, additively manufactured modules • Even rinsing of the needle

www.hasco.com Anz_Shadowfree_190x124_EN.indd 1

Built to Innovate. 21.11.2023 07:21:56

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pioneering plastics

PHOTOVOLTAICS However, it is crucial to acknowledge that the presence of lead (Pb) within their composition is a notable concern. This toxicity issue limits the practical use of leadbased perovskite solar cells in commercial PV modules. Consequently, ongoing research endeavors are now exploring new photovoltaic materials based on elements such as tin (Sn), bismuth (Bi), antimony (Sb), and germanium (Ge) as potential replacements for lead perovskites. 11,12 With funding from IVACE, AIMPLAS is embarking on the PEROVSOL project aimed at the development of large-area perovskite solar cells. The project entails an exploration of various perovskite stoichiometries to identify those exhibiting superior absorption coefficients, processability, and anticipated performance, especially regarding the selection of transport layers. The primary focus of this cell configuration lies in scalability, transitioning from laboratoryscale devices to larger surface areas, thereby enhancing their suitability for industrial applications. Employing solution processing methods like slot-die or serigraphy will ensure precise material deposition and facilitate the scaling-up process. Based on the insights gained from the preceding SOLARFLEX project, the substrates employed in these newly developed devices will be derived from sustainable sources, primarily polymer-based. This choice of substrate imparts flexibility to the solar cell while mitigating its environmental footprint. The use of polymer-based flexible substrates presents a significant advantage, as it opens a wide range of possibilities for integrating the solar cell into diverse applications where rigid structures would be impractical. These applications span smart devices, fabrics, building materials, and more. 12

Furthermore, the PEROVSOL project will address the existing stability concerns associated with current solar cells. It aims to achieve this by formulating an epoxy resin-based adhesive that ensures the proper encapsulation of the entire layer stack, thereby extending the solar cell’s operational lifetime.

REFERENCES:

(1) NASA - Global Climate Change. The effects of climate change. https://climate. nasa.gov/effects/ (accessed 2022-08-01). (2) European Comission. Consequences of climate change. https://ec.europa.eu/ clima/climate-change/consequences-climate-change_en (accessed 2022-08-01). (3) Ritchie, H.; Roser, M.; Rosado, P. CO2 and greenhouse gas emissions. https:// ourworldindata.org/greenhouse-gas-emissions (accessed 2022-08-01). (4) American Chemical Society. How a Solar Cell Works. https://www.acs.org/ content/acs/en/education/resources/highschool/chemmatters/past-issues/ archive-2013-2014/how-a-solar-cell-works.html (accessed 2022-08-24). (5) TU Delft OpenCourseWare. Solar Energy: The Working Principle of a Solar Cell. (6) Asim, N.; Sopian, K.; Ahmadi, S.; Saeedfar, K.; Alghoul, M. A.; Saadatian, O.; Zaidi, S. H. A Review on the Role of Materials Science in Solar Cells. Renewable and Sustainable Energy Reviews 2012, 16 (8), 5834–5847. https://doi.org/10.1016/J. RSER.2012.06.004. (7) National Renewable Energy Laboratory (NREL). Best Research-Cell Efficiency Chart. (8) Lei, H.; Chen, J.; Tan, Z.; Fang, G. Review of Recent Progress in Antimony Chalcogenide-Based Solar Cells: Materials and Devices. Solar RRL 2019, 3 (6), 1–27. https://doi.org/10.1002/solr.201900026. (9) Park, N.-G.; Grätzel, M.; Miyasaka, T. Organic-Inorganic Halide Perovskite Photovoltaics; Springer, 2016. https://doi.org/10.1007/978-3-319-35114-8. (10) Sebastia-Luna, P. Low Toxicity Metal Halide Semiconductors for Optoelectronics and Thermoelectrics, University of Valencia, 2023. (11) Wang, R.; Wang, J.; Tan, S.; Duan, Y.; Wang, Z.-K.; Yang, Y. Opportunities and Challenges of Lead-Free Perovskite Optoelectronic Devices. Trends Chem 2019, 1 (4), 368–379. https://doi.org/10.1016/J.TRECHM.2019.04.004. (12) Kour, R.; Arya, S.; Verma, S.; Gupta, J.; Bandhoria, P.; Bharti, V.; Datt, R.; Gupta, V. Potential Substitutes for Replacement of Lead in Perovskite Solar Cells: A Review. Global Challenges 2019, 3 (11), 1900050. https://doi.org/10.1002/ gch2.201900050. (13) Ritchie, H.; Roser, M.; Rosado, P. Energy - Our World in Data. https:// ourworldindata.org/energy-mix (accessed 2022-08-01). (14) Eurostat. Energy statistics - an overview. https://ec.europa.eu/eurostat/statisticsexplained/index.php?title=Energy_statistics_-_an_overview (accessed 2022-0801). (15) World Health Organization. Lead poisoning. https://www.who.int/news-room/factsheets/detail/lead-poisoning-and-health (accessed 2022-06-09).

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Materials Handling… Made in Britain

The New Diamond Range — Vacuum Loading equipment manufactured in the UK

• Maintenance-free brushless motor • Available in air, single phase and 3 phase system options • Fitted with a full Siemens PLC touch control • Modular design • Electropolished 304 stainless steel • Filter options • Industry 4.0-ready • LED handles to show mode of operation

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Edition 23

A Fast Turnaround Screw & Barrels Specialists Immaculate Customer Service Bespoke products from our own workshop Distributor of AIRTECT products

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2023 Cover.indd 2

23/03/2023 15:32

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POLYMERMAN

How will bottom of cycle polymer production economics lead to tough price negotiations?

BP&R’s resin pricing guru Mike Boswell (aka Polymerman) writes.

ottom of cycle polymer production economics refer to the situation in which market prices for volume polymers fall to the extent that profitability for a significant proportion of polymer producers becomes negative, and for the rest becomes much more marginal. At this point factors such as: • Feedstock Costs • Logistic Costs • Import Duties • Energy Costs become critical. In many cases polymer producers struggle even to cover variable costs. An initial review of polyolefin pricing, covering a 15-year period from mid-2008, suggests that pricing has been more a case of upper and mid cycle economics.

However, the 2008 banking crisis (Lehman Brothers shock) reveals a seven-month period from November 2008 through June 2009 when polymer pricing was extremely depressed. Those with more extensive history in the sector will recall an extended period in the 1990’s when prices languished at historically low prices with volatility limited to +/- 10%.

place the supply/demand balance in the favour of polymer converters, there is no doubt that this will result in polymer producers trying to exploit any available opportunity to create a price premium in order to improve economics. This is likely to result in increased price deltas for grades that are produced on a more regional basis, and also for different materials from product families such as LDPE within the PE group and possibly more differentiation between LDPE materials produced by autoclave over tubular polymerisation technologies. Further consequences include: 1. Lower levels of reliability. Polymer producers are likely to cut back on nonsafety related maintenance programs with consequences for plant reliability. 2. Reduced European Polymerisation Capacity. The combination of aged plant, high feedstock costs, and expensive energy are likely to result in more European polymerisation capacity being permanently shuttered. 3. Lower rates of mechanical recycling. Low virgin polymer prices tend to deflate the price of recycled materials, often pushing recycling economics below breakeven. Given recycling is typically an SME business, new investment will be stifled, and existing operations may be suspended. Given both the economic scale and length of time taken to invest in polymerisation capacity combined with the lacklustre state of global economic growth, a version of ‘stagflation’ looks set to impact the upstream economics of polyolefins for some time to come.

In the cases of both polypropylene and polyethylene current expectations are for an extended period of low pricing, possibly lasting 12 to 24 months, with PE pricing likely to recover before PP. The basis of these predictions comes from a combination of low global demand combined with massive increases in polyolefin production capacity, which is either already on stream, or due to be commissioned in the near future. Whilst oversupply will clearly Who is ‘Polymerman’? Mike Boswell is Managing Director of UK materials distributor, Plastribution, as well as the Chairman of the British Plastic Federation’s Polymer Compounders and Distributors Group and its ‘BREXIT Committee’. ‘Polymerman’ is the title used for announcements made via his Twitter account. This column is compiled using data from PIE (Plastics Information Europe) www.plastribution.co.uk | www.pieweb.com

An infinite product range to match our colours. Leveraging our unparalleled expertise, we consistently meet the demand for precise colour matching. Additionally, we create some of the most innovative performance-enhancing additives, which are currently utilised across a wide array of products and industries. Reach out to us to discuss your needs. The opportunities we can provide are Limitless.

Performance Masterbatches Telephone: +44 (0)1495 310583 Email: customer.service@pmb.co.uk

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MACHINE

SHUT-DOWN

DO YOU KNOW ALL THE BENEFITS OF SEALING YOUR MACHINE WITH ULTRA PLAST ® THE PURGING COMPOUND?

Find the answers to the nine typical questions in this magazine.

Q&A

ON THE COVER

NEW YEAR, NEW NICKERSON PMS As the year comes to a close, 2024 is looking bright for moulding supplies firm Nickerson PMS. Alongside a new brand identity and new website, the group has a new Managing Director in Sam Carr. BP&R caught up with Sam to learn about his plans for the future. 16

BP&R: How has your startty as the new MD at Nickerson PMS been? What have you learned? SC: Busy, challenging, but incredibly enjoyable! I have joined a superb team who are highly ambitious and match my own aspirations for the future. In the first few weeks of my time here, I have made it my priority to understand how our business operates and take on board as much information as I can. One key identification was our website, which our team have worked incredibly hard on this year. I am proud to say that this has been updated, making purchasing much easier for our customers and ultimately, enhances their purchase experience online. I have confidence that with our improvements, Nickerson PMS will evolve to be the one of the best-known brands in our industry.

BP&R: What’s the strategic direction for the company going forward? SC: As a complete entity we have enormous potential to grow and really make a positive impact on our industry by supporting SME’s in the UK. We will achieve this by increasing our brand awareness, starting with our logo and revamped website. We recently ran a “Black Friday” promotion, which was hugely successful – We plan more special promotions in the future. Our approach will also be to support IMM manufacturers with our product lines & vast range of consumables that their customers will be using. To enhance our customer experience further, we will be stepping up our availability for site visits, product demonstrations, and trade show attendance.

SC: Interplas was a great experience for the team to connect with customers and suppliers, whilst interacting with industry colleagues too. The stand was wellpositioned on the show floor which gave the team several new enquiries to follow up on. We also had the chance to display our more innovative products like our Airtect system, which gives protection against leaks on IMM’s and Hot Runners. On the whole, Interplas gave us a great insight into our customer needs and how we can innovate to support them in the future too. We see Interplas 2026 as the showcase of our development. BP&R: What sets Nickerson PMS apart from the competition? SC: Nickerson PMS is a trusted brand which has supplied our industry for over 30 years. We pride ourselves on not only

“I hope to bring a fresh approach to the business and perfect our existing customer relationships. Being from a sales background, I understand the importance of keeping our customers happy, well-informed and looked after – This is my number one priority.” BP&R: What have you learned from your career in the plastics industry to date, that you hope to bring to Nickerson PMS? SC: From the outset I have been fortunate enough to work alongside several industry leaders in my career. Looking back at the recent Interplas 75 @ 75, I spotted a number of names who have offered me support and guidance in my career so far. Taking the learnings from more experienced heads over the years, I have a strong footing to develop my own leadership style. I hope to bring a fresh approach to the business and perfect our existing customer relationships. Being from a sales background, I understand the importance of keeping our customers happy, well-informed and looked after – This is my number one priority. We’re also keen to increase our customer base and the industries that we provide into as well. INSET: The company's new brand identity

ABOVE: Ethan Di-Iorio (Engineering Supervisor) and Ian Clayton (Engineering Manager)

BP&R: The team were at Interplas – how did they find the show this year, can you talk about the contacts and enquiries you had? www.interplasinsights.com

supplying a comprehensive range of high-quality products to our customers but also customised solutions from our CNC workshop. With our experienced team, we can produce unique and custom components tailored to our customers specific needs. In addition, our ability to supply new and refurbished screws and barrels is one of our USPs. 17

COVER STORY Our main focus is to assist our customers in overcoming challenges quickly.

time, reduces waste, and the amount of additional energy placed on the machine during changeover periods.

BP&R: To what extent is your business impacted by anti-plastic rhetoric? SC: As a business, we have seen no change. However, we have seen an increase in customers using a higher percentage of recycled material, which has boosted sales of certain products in our range to support them. The industry has stayed incredibly resilient against the “Anti-Plastic” campaign in recent years and I think we should be very proud of the sector we work in. Recent BPF figures show our industry directly employs over 155,000 people in the UK and our industry sits in the top 10 of the UK’s exports. Unfortunately, there is a skill-gap in our industry that will become an issue in the coming years. We should continue to push the recruitment drive of younger people to come and join us in the manufacturing sector as a whole.

BP&R: Tell us about the team – what combined expertise do you have on board?

ABOVE: Ethan Di-Iorio in the company's new branded clothing BELOW: Sam Carr and Oliver Hourd (Marketing Manager)

SC: PMS was established in 1992 before becoming Nickerson PMS in 2005. We are proud to say that Sales Manager Matthew Hay was the first employee of PMS in the company’s history and he is still as chatty as ever! He has unrivalled product knowledge and supports our customers on a daily basis. Our strong team also includes Technical Sales Manager; Pete Smalley who has worked in various maintenance and engineering supervisor positions across his career. His technical knowledge of screws and barrels is key for us to understand our customer’s requirements. We’re also blessed with a highly-skilled workshop team, headed up by Ian Clayton who also just hit 30 year’s service with the company – a true testament to our company culture over the years. We recently celebrated Matthew and Ian’s 30 year’s service. The younger generation is also well represented with Sean Littlejohn who looks after our Business Development and Ethan Di-Iorio who is Ian’s successor in our workshop. We have a large customer base that our staff support extremely well and I’m immensely proud of their efforts since my arrival. BP&R: Finally, what do you want your customers to know?

At Nickerson PMS, we are proud to support an apprentice in our workshop. He has thrived under our guidance and experienced team, whilst learning engineering at college. If we continue to create exciting career paths and portray how important plastic is, we will inspire the next generation. Nickerson PMS will continue to support our industry and the vital work that our customers do in many different sectors. BP&R: And how about energy costs, which continue to dog the industry – can you help processors with that? SC: Absolutely. I have been a big champion of the industry advancing their 18

SC: Well, as a thank you to our customers for all their support this year, a special code for 10% discount “BP&R10” will be live from 1st December until the end of the year. Looking to 2024, customers will be at the forefront of everything that we do, and this will start with the Southern Manufacturing show in February. We will be showcasing our comprehensive range, new identity, website, and new products. Looking further ahead, plans are already in place for Interplas 2026. This will be a key marker for me to evaluate our position in the market and the positive progress that we have made with our customers. Lastly, I hope everyone has a great Christmas with their families, and I look forward to seeing you all in 2024!

Use code BP&R10 for 10% off on our brand-new website across December!

factories and moving to a more energy-efficient future with IMMs. We can also assist customers with energy saving initiatives by supplying them with products like our thermal barrel insulation jackets which can reduce the heating element running costs by up to 60%. We’re also the exclusive supplier of SLIDE products in the UK, which includes their advanced NuPurge technology purging compound. The compound is pre-mixed, FDA compliant and can be used in barrels up to temperatures of 315 degrees. Products like this save our customers www.interplasinsights.com

WWW.PLASTRIBUTION.CO.UK | EXPERTS IN THERMOPLASTICS

CHRISTMAS SHUTDOWNS

uch in the same way that our bodies need to detox after too much festive indulgence, IMMs benefit from a similar treatment, allowing them to start up fresh once again. A combination of oxidation and polymer degradation can lead to problems across the components of the machine. The last thing you need on your first day back to work is a pile of scrap resulting from black spots or contamination. One expert in the field of machine maintenance is Roberto Benzi, executive at Ultra System, the manufacturer of Ultra Purge. “The Christmas machine shutdown is one of the most important operations for plastic converters. They are normally using this time to put in plan maintenance, dismantling and other typical actions that they can rarely do during the season. During this period, the machines are left off, and this is where the purging compound comes into play. The same applies for any extended shutdown,” Benzi said. The importance of planning cannot be overstated. How long does it take to get going again without proper planning? Longer than you might think, and of course, time is money.

carbons, impurities, various residues are generated. And it can take hours to get rid of all of them. By leaving the purging compound inside the machine, you will avoid these problems, and your machine will immediately be ready to work It is an extremely easy process, according to Benzi. You just need to fill the machine with the right amount of the compound, and then switch-off. You can run a purge before or after filling the machine, too.

Do your machines need a festive detox? Christmas is a time for rest and relaxation… but when the parties are over and work resumes, it’s normal to feel a little rusty – especially if you over-indulge. It’s similar for injection moulding machines. After 12 months of near constant labour, the downtime during the Christmas shutdown can actually be damaging, if operators fail to prepare… “There are many problems that will occur if you do not plan a correct shutdown operation. Machines could

“The importance of planning cannot be overstated. How long does it take to get going again without proper planning? Longer than you might think, and of course, time is money.”

(and will) take a long time to properly restart. And by “properly restart”, I mean that it could take hours before you get completely acceptable parts. “Although in some cases, adding purging compound during the shutdown is not strictly necessary, when needed, the latest purging compounds (of which Ultra Plast is just one) can help moulders to get their machine ready to work almost immediately after the restarting. “To work properly, leave our purging compounds in the barrel. The main problem after the shutdown is that during the re-starting a lot of

www.interplasinsights.com

“There are some further tailor-made details that we normally discuss with the customer just before the shutdown operation. At the re-starting, when temperature and parameters are those of production, you just push out our material from the barrel and start the production” said Benzi. It’s an added cost to your maintenance plans, but it doesn’t consume as much material as you might think. Ultra Plast will offer a table to help you calculate the right amount to use, depending on the size of the screw. Besides that, you need a little extra for the head and hot runners – but that’s it. “Many moulders today leave the screw empty or filled with a polymer, during the shutdown. In both cases the risk of creating burnt parts and carbons during the increasing of the temperature is real and this will delay the re-starting of the production. “Our products are characterised by the absence of abrasive additives, no need for soaking time, no smell, no smoke, more than 30 certifications (FDA, food compliance, RoHs and many others including for medical applications). Furthermore, Ultra Plast can be recycled. 19

WWW.PLASTRIBUTION.CO.UK | EXPERTS IN THERMOPLASTICS

SKILLS & RECRUITMENT It is no secret that recruitment is and always has been, challenging. Since the Covid pandemic and the ‘Great Reshuffle’ that followed, recruiting and retaining people at any level, has become even more difficult. Conrad Taylor, global operations director – executive at Listgrove writes.

n a 2022 LinkedIn survey, 87% of recruiting professionals believe that the role of Talent Acquisition has become more strategic over the last year. Advertising a role in the traditional channels, is no longer enough and by doing so, talent professionals risk a ‘time-to-hire’ that, not only exceeds their industry average but also stretches both internal budgets and resource past their limits. To recruit the right person for their business, companies must respond to the everchanging business landscape. Navigating turbulence, change and competition for highlyskilled candidates, will all be necessary to feed their talent pipeline. The true cost of ‘time-to-hire’

Recruiting from outside an organisation into a leadership role is often the most challenging task of all. Leaders with excellent people engagement skills, high integrity, values aligned with the company and the ability to manage complexity and uncertainty, are highly sought, meaning competition is fierce. Companies presented with a resignation from a senior leader (whether expected or not) often face the daunting task of finding a suitable replacement, whilst covering all of the associated tasks and responsibilities of the role. All of this, on top of the need for the time and resource for the recruitment process, comes at a cost. Does the vacancy leave an open sales territory, or stretch those covering their own areas thinner? Will there be an impact on efficiency and process within the department? How long can you afford to pause continuous improvement projects, in lieu of an appropriate hire? On top of the tangible pressures already mentioned, it is also 20

Navigating turbulence to recruit future plastics industry talent worth considering the time it will take for the new hire to get ‘up-to-speed’ and to become optimised in their new position. Future-proofing

A combination of market factors affecting the industry broadly and the additional stressors of specific hiring requirements, all bring the whole area of talent acquisition to the fore. The pressure on ‘time-to-hire’ and the need for ‘smart’ recruitment processes mean that those best equipped to operate an effective talentpipeline and succession planning strategy, will be most successful in, not only bringing the required talent into their business but also in retaining existing talent. Staying one step ahead

To cope with high-volume of demand many large organisations have responded to the need for change by creating their own internal talent departments. By advertising via their own networks and using tools such as LinkedIn, this approach works well, particularly when combined with a strong employer brand and clear development plans. Sometimes, if a role is

challenging or considered ‘hard-to-fill’, they may reach out to a specialist recruitment partner to support their own search or to broaden their networks; it is important that any third-party is carefully selected to collaborate seamlessly with their own team. For smaller businesses with fewer resources, there are benefits to not only outsourcing individual recruitment projects but also in developing longerterm talent strategies with a specialist partner, enabling the recruitment consultants to act as an expert extension of the hiring company. The impact of ‘time-to-hire’ on the candidate experience

It is possible to reduce the ‘time-to-hire’ by working with a recruitment partner that has the market understanding, industry presence, network and competencies to fulfil the need. By working on a long-term partnership with companies, to build knowledge and value into the relationship, it is easier to agree a clear briefing, work together for an exceptional candidate experience and to communicate in a way that proactively meets their

www.interplasinsights.com

expectations. The converse effect of not managing a process or partnership in this way, can lead to delays which, in turn, easily results in the loss of candidates to other employers or even a sense of apathy from the candidate, as momentum fades. Of course, this is not a new way of thinking but it is important to recognise that the hiring process is two-way and that just as candidates must work hard and research well to impress during assessment, employers and recruiters must present themselves in the best possible way, to sell the opportunity to potential employees. Taking the time to ensure the process is not too onerous and providing constructive interview feedback to all candidates, will go a long way to create a lasting positive impression. How can you improve?

Companies that have well-thought-out talent acquisition strategies, collaborative relationships with their recruitment partners, streamlined processes and that work hard on the delivering a positive candidate experience will thrive in this demanding employment market. Those that stick to the more traditional approach, that is too employer-led, may struggle to bring in the talent that makes the difference. Listgrove has evolved to become the leading industry expert and longest serving specialist recruitment provider to the global plastics, packaging, chemicals, petrochemicals, energy and recycling sectors – but one thing remains the same: we champion performance through people.

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Online Auction Sale Range of Large Capacity Engel/Krauss Maffei Injection Moulding Machines (1700 – 160 Tons) Material Dryers, Compressors, Racking Surplus to the ongoing requirements of Petford Moulding Limited Bidding Ends: Tuesday 12th December 2023 at 3.00pm (UK Time) ·Engel Duo 11050 /1700 Injection Moulding Machine (2005) ·Krauss Maffei KM1600-8100 MX Injection Moulding Machine (2011) ·Krauss Maffei KM1100-8100 MX Injection Moulding Machine (2007) ·Krauss Maffei KM900-6100 GX Blue Power Injection Moulding Machine (2016) ·Krauss Maffei KM650-4300 GX Blue Power Injection Moulding Machine (2018) ·Krauss Maffei KM650-4300 GX Injection Moulding Machine (2012) ·Krauss Maffei KM400-3000 GX Injection Moulding Machine (2018) ·Krauss Maffei KM160-750 Blue Power Injection Moulding Machine (2015) ·Krauss Maffei KM300-1900 C1 Injection Moulding Machine (1997) ·Piovan DP619 Dryer with Piovan 400kg Hopper (2010) ·Piovan Type DSN 522ME 36kw Dryer (1995) ·Moretto 150kg Hopper Loader (2012) with Moretto 375kg Hopper Loader (2012) with Moretto 375kg Hopper with Plastic Systems TMM25 Receiver 2 (2012) ·Piovan DSH520ME Dryer (2003) ·Piovan DP619 Dryer (2016) ·Piovan DS406 Dryer with Piovan 100kg Hopper (1999) ·Simatec DES-120 Dryer with TH Plastics 150kg Hopper (2010) ·Yudo Plas Dryer with Morreto 200kg Hopper ·Piovan DPM613 Dryer (2006) with Piovan 275kg Hopper ·Piovan DPM615 Dryer (2007) with Piovan 275kg Hopper ·Plastic Systems PD3-50 Suction Filter (2011) ·Mann + Hummel Somos TF70 Dryers ·Plus Many Others...

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▪ Tel: + 44 (0) 121 328 2424 ▪ Email: info@cottandco.com ▪ Cottrill & Co is a Trade Name of Cottrill & Associates Ltd

MOTORS

OPTIMISING PLASTIC PRODUCTION with high dynamic performance motors

rom cast film extrusion to injection molding, blow molding, blown film lines, and more, electric motors are critical at almost every step of plastic processing. Due to rapid advancements in motor technology over the past decade, the newest high dynamic performance (HPD) electric motors have overcome numerous limitations of their older DC counterparts. They offer benefits in size, precision, and other critical areas, giving plastics OEM machine builders and end users a competitive edge in productivity. Mainstream challenges

Machine builders and users in plastic manufacturing are deeply immersed in digitalisation, having already progressed to the second era of this transformative process. Initially, they focused on establishing and managing manufacturing execution systems (MES). Now, in this second phase, they aim to drill deeper into the component aspect, such as motors, drives, PLCs, HMIs, and sensors. Historically, plastics processing facilities relied on low-powered DC motors for motor-driven equipment despite their drawbacks. These motors are bulky, lack energy efficiency, and pose maintenance challenges, mainly due to the wear-prone carbon brushes, leading to shortened machinery lifespan. In contrast, modern machinery employs AC motors, offering various advantages. Yet, standard AC motors come with their own set of limitations. The most significant is their high rotor inertia, which complicates their precise control. This presents a considerable 22

LEFT: Figure 1: Full range of machinery motors optimised for high power density rotation with greater speed and precision. This advantage can lead to a productivity increase of up to 15% when compared to standard AC motors.

Fausto Belotti, Global Segment Manager, Rubber and Plastics, ABB Motion writes. challenge in the latest plastic applications, where high productivity levels are required in terms of pieces per hour, and consistent product quality demands such control. The unit price of many items in plastic production is typically only a few cents, such as the plastic cap of a PET water bottle. Since the production cost is low, manufacturers must produce a high volume of pieces per hour to make it feasible. Therefore, high motor reliability is critical. Furthermore, in the plastics industry, labor costs are equivalent to electricity costs. To control the latter, machine builders and end users want motors that also offer superior energy efficiency. Another major challenge facing plastic producers is the cost of downtime. For instance, a PET line can produce approximately 2,000 1.5L bottles per hour. During downtime, production halts, causing bottlenecks, and the entire 40m-long production line comes to a standstill. This downtime could result in losses amounting to several thousand dollars per hour. Specialised AC motors – often called square frame induction motors, low inertia motors, or vector motors – offer a proven solution. Models like ABB’s HDP motors demonstrate substantially higher power density compared to conventional AC motors. The main features of HDP motors are their rectangular housing, light and robust construction, high dynamic performance, and excellent power-to-size ratio. The benefits of HDP motors

HDP motors offer numerous advantages in plastic production applications. Their low rotor inertia, high overload capacity, and exceptional dynamic response translate into significant production benefits. The motor’s low rotor inertia allows faster cycling times, enabling controlled machinery movements and www.interplasinsights.com

The high power density of HDP motors makes them notably more compact than other motor types. Consequently, they require a smaller installation area, allowing for a reduced footprint or accommodating more plastic lines within the same space. However, this compactness may restrict access space for maintenance, which is why the motor’s highreliability design is crucial. Additionally, in regions where space is at a premium and costly, HDP motors offer an ideal solution, enabling higher production within the same confined space. A noteworthy benefit for OEMs is that they have the flexibility to make late configurations to the HDP motors to suit their applications better, even if they’re already in their workshops. Drives for precision control

A further advantage is that the HDP motors are part of a complete package with variable speed drives (VSDs). A VSD allows precise motor control by adjusting the supplied electricity’s voltage and frequency. Motor-drive packages provide significant precision advantages and are well-suited for applications like mixers, extruders, conveyors, injection molders, and more. ABB VSDs are specifically

+44 (0)1793 827666 sales@transxl.co.uk www.transxl.co.uk

SHEET LINES

PIPE/PROFILE

1100mm wide Kentya twin screw PET extrusion line

220mm x 200mm Tria auger fed granulator

300 Litre hopper with D160 Rotordryer 55-185deg c

1370mm Wide Welex 3 Station Winder with adjustable torque

1000mm wide Maier 2 station auto splice winder

1800mm Wide Caimi Model CM1800/2 Guillotine

THERMOFORMING

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Supplying ABS, ASA, PC/ABS and Polycarbonate Compounds Materials tailored to your specifications with quantity, flexibility and fast turnaround Serving injection moulders & OEM’s since 1993 Ask us about our new range of environmentally friendly flame retardant polymers, Notoxicom® Scan the QR Code for more information. +44 (0) 191 378 3737

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Meadowﬁeld, Durham DH7 8RL, UK

MOTORS designed to seamlessly integrate with HDP motors for the best possible performance solution. Moreover, VSDs enhance energy efficiency in motors. Without VSD control, motors run at full speed, consuming more power. Even minor reductions in total speed, as seen in processes like extrusion, lead to significant energy savings. For example, reducing a motor’s speed by just 20 percent using a drive can cut its energy consumption by half. Specifying the same brand of motor and drive enables additional optimisation, boosting the system’s energy efficiency while reducing harmful harmonics. Consequently, this allows the utilisation of lower cable crosssections alongside a smaller transformer, reducing overall costs. Reduced need for maintenance

HDP motors offer significant maintenance benefits since they are also designed for intensive work in applications where lots of plastic dust is present. The motors are brushless, containing fewer moving parts than DC motors. Although engineered for intensive use, they are, therefore, easier to maintain and inherently more reliable. It’s also possible to specify liquid-cooled solutions. Such an option provides a perfect seal, safeguarding the motor’s internal components from plastic dust that might cause wear or failure. Liquid cooling is also significantly more efficient than air cooling, enabling a further increase in power density compared to standard air-cooled HDP motors. In addition, liquidcooled motors eliminate the need for fans aligned to the shaft, enhancing their efficiency.

ABOVE: Figure 2: Plastic manufacturers can access the benefits of HDP motors in both retrofits and new installations. The water jacket also diminishes motor noise, contributing to a more pleasant work environment. Liquid-cooled HDP motors are particularly advantageous in the plastics industry, where water is readily available in plants as part of the production process. HDP motors can provide power output of up to 2 megawatts (MW). They are available in diverse frame sizes, ranging from 80 to 400, with different designs. This versatility simplifies the integration of HDP motors into various machine types. There are options for high-speed and liquid-cooled models, and HDP motors can be used with integrated mechanical brakes. HDP motors are also compatible with programmable encoders. Suitable for new and existing installations

Machine builders can capitalise on the high power density of HDP motors in two ways. Due to their common frame sizes, they can be used to retrofit an existing machine. Even if there is no increase in the current operational speed, operators still gain advantages from the new motor’s improved inertial properties, overload capacity, and responsiveness. In new installations, a facility can specify a smaller low-inertia HDP motor to achieve equivalent work as a larger, higherinertia model. Even at the same IP rating, a new HDP model is generally at least one frame size smaller than a standard induction motor. Consequently, the machinery takes up less

“HDP motors offer significant maintenance benefits since they are also designed for intensive work in applications where lots of plastic dust is present. The motors are brushless, containing fewer moving parts than DC motors. Although engineered for intensive use, they are, therefore, easier to maintain and inherently more reliable.” www.interplasinsights.com

floor space, enabling the facility to accommodate more equipment and increase throughput. More power, better products

In the competitive plastics industry, machine builders and end users are under immense pressure to deliver highquality products at affordable prices. The most effective approach to achieving this goal is investing in equipment that maximises throughput and increases product consistency. Machine builders need to partner with a global player that offers comprehensive support worldwide, including easy access to spare parts procurement. Flexibility is another key aspect since machine builders require adaptable solutions, such as a single drive that can accommodate various shaft or axle requirements and formats. HDP motors stand out due to their higher torque and smaller size in comparison to conventional AC motors. Additionally, they offer major advantages over the DC motors still in use at some facilities. This makes HDP motors the clear choice for upgrading existing systems and specifying new equipment within plastic facilities. A matching motor and drive package offers the complete solution.

BP&R BUYER’S GUIDE MATERIALS MASTERBATCH

MOULD RELEASE

HAMPTON COLOURS LIMITED TO ADVERTISE IN THIS SPACE CONTACT MANDY O’BRIEN 01244 952519

Tel: +44 (0)1453 731555 Fax: +44 (0)1453 731234 sales@hamptoncolours.co.uk POLYMER SPECIFIC AND UNIVERSAL MASTERBATCH, SMALL LOT SPECIALITY COMPOUNDS PLUS MATCHING SERVICE

Super Bluish Titanium Dioxide

TO ADVERTISE IN THIS SPACE CONTACT MANDY O’BRIEN 01244 952519

MATERIALS

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MACHINERY & EQUIPMENT SCREWS & BARRELS

High Quality UPVC Recycled White pellet Recycled Jazz Pellet and Pulver Virgin compound, pellets or pulver T 07516 029 591 E recycling@deceuninck.com

PRINTERS

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TO ADVERTISE IN THIS SPACE CONTACT MANDY O’BRIEN 01244 952519

Injection Moulding Machine Services

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MACHINERY

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We buy & sell all manner of plasscs equipment.

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Visit our workshop in Wellingborough, Northants.

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CAD/CAM

COLUMN

Philip Law As the year wraps up, the BPF’s director-general Philip Law shares his comments from the recent plastics parliamentary reception.

Plastics’ day in parliament BPF’s programme of political contact reached a climax with its Parliamentary Reception held in the House of Commons in November. This was attended by 25 MPs and Peers in a room crammed with BPF member firm representatives. For this kind of event, this was a large number. Government was represented by Kevin Hollinrake, the Parliamentary Under-Secretary of State and Minister for Enterprise and Markets. I reproduce below an edited version of my speech: ‘’I am delighted to speak to you on the 90th anniversary of the BPF and the 161st anniversary of the commercial introduction of plastics into the UK. The first plastics material –‘Parkesine’- was invented here in the UK and was manufactured just downstream from Westminster, in Hackney Wick. Today plastics underpin most innovations. Currently the plastics industry has a £25 billion turnover and with 155,000 employees, it is the third largest manufacturing sector by employment in the UK. It is also among the top 10 exporting sectors. The bulk of the industry is located in the ‘levelling-up regions’, and we have tremendous potential to help the UK as a source of highquality employment, indeed offering international careers. For those who are not thinking about plastics day in, day out here are some key points: Crucially the UK plastics industry is key to the UK’s national security. Our products underpin defence, our electronic infrastructure, energy infrastructure, transport and healthcare. They play a major role in keeping the UK’s population fed with a fresh varied diet. The UK plastics industry is of strategic importance. We are immensely grateful for the £4.5 billion investment in

manufacturing, as announced late Friday, but we have to ask the question what exactly is the strategy from which it sprang and which companies are eligible to apply? Broad concepts were stated – ‘Advanced Manufacturing’ and ‘Green Industries’. It is absolutely crucial that plastics are placed at the heart of any categorisation of ‘Advanced Manufacturing’ and ‘Green Industries’. To release the full potential of the plastics industry for this country we need some urgent changes in mindset, policy and legislation. We ask you to seriously consider supporting six key requests from the UK plastics industry. 1. We need support for businesses to fill long-term skills vacancies and a further review of the effectiveness of the Apprenticeship Levy for manufacturers. We have a great many vacancies at shop floor and skilled levels. The knowledge in the industry resides with older age groups. This is a major brake on the development of the industry and its customers. 2. We urge you to work towards minimising formal or informal barriers to trade, particularly with the EU which remains the major trading partner. Where it makes sense (and it doesn’t always make sense), we need regulatory alignment with the EU. We also need a renaissance of the Trade Show Support Programme which enabled UK exporters to secure considerable returns for a relatively modest outlay. 3. We also urge you to Increase the funding available for the deployment of energy efficient machinery and equipment. Technology is available which can help secure the industry in the face of any future energy supply issues, assist the path to ‘net zero carbon’ as well as boosting productivity. Alongside this we need early clarity on the future of Climate Change Agreements which have done so much to push energy to the forefront of the industry’s agenda.

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4. In the Packaging arena we need greater stability in legislation. Intermittent green/red /stop/go signals just will not do. We urge you to accelerate the waste collection and packaging reforms and I apologise if I appear to be using the coded language of a secret brotherhood, but I am talking about ‘Simpler Recycling’, the Deposit Return Scheme and Extended Producer Responsibility. And we need these measures to apply in equal measure and consistently across all parts of our still – United Kingdom 5. To help us complete a fully circular economy in plastics we need you as legislators to approve the use of mass balance verification with a fuel exempt allocation method to permit the scale-up of chemical recycling in relation to the Plastics Packaging Tax. If you don’t, then we will fall behind other countries in the technology stakes. This will impact negatively not just on packaging waste management but also on dealing with waste from other markets such as construction. 6. Staying with the Plastics Packaging Tax, and this is the only tax I’m going to comment on, there is absolutely no excuse for not ploughing back the tax revenues into the plastics recycling infrastructure to expand recycling capacity and improve the sorting of waste streams. As it, stands, without this investment, stripped bare, the Plastics Packaging Tax is nothing more than a smash and grab raid on the plastics industry. The Budget announced the following day brought many good things which have been well covered in the national press, but one key point has escaped widespread attention and that is the extension of Climate Change Agreements until March 31st 2033.BPF has one of the largest Climate Change Agreements signed between Government and an industry sector. ‘’

FROM PLASTICS. TO THE FUTURE.

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