BP&R Oct 23 by BP&R Magazine

issue 07/23

British Plastics and Rubber in association with interplasinsights.com

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GOOD ADVICE

RIGHT FROM THE START Chris Newman, ALBIS UK on a successful approach to CMF – page 14 INTERPLAS REVIEW Show exceeds expectations

LEARNING FROM THE PAST Richard Brown on training and skills

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COMMENT

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Protecting polymer skills through DE&I

ell, another Interplas has come and gone. Having personally been away from the industry for the 2021 edition, 2017 was my last - and it was great to see the event return to form in such spectacular fashion post-COVID. One of my highlights was chairing the session on diversity, equity and inclusion in the plastics industry. Let’s be clear, this session was designed to shed some light on an important topic – to understand the make-up of the plastics workforce, as well as gathering knowledge about attitudes and perspectives. It was not virtue signalling, nor was it an attempt to disparage what is, I believe, a mostly wellintentioned community. All of that said, it’s impossible to deny that the industry doesn’t boast an especially diverse profile. While some protected characteristics are increasing in representation in recent years, it’s clear that ours is not the most diverse sector – a fact that is reflected across many of the engineering specialisms. One of the objectives of the session was to answer the question, why is diversity, equity and inclusion important? That may sound absurd, but it's easy to view these initiatives as a part of the zeitgeist. They’re not. And I would argue a push for diversity is more important in process engineering that many other fields, given the well-documented skills shortage. There's huge value in an indepth knowledge of the art of processing, forming, moulding or extrusion. The polymer industry is a real mix of talents – from design, material choice, chemistry, engineering, machine maintenance and people-management, to name just a few. To meet the needs of such a diverse skillset, surely you need a diverse workforce – with the benefit of multiple perspectives and experiences. Research shows diverse organisations benefit from excellent problem-solving abilities, as a result of a spectrum of experiences and perspectives. Similarly, collaboration is shown to be more effective, for similar reasons. Equity and inclusion also help to boost

“Prioritising DE&I doesnʼt need to be costly, but the rewards could be massive for the longevity of the processing sector.” staff retention. Equity differs from equality, in that the latter implies that all should be treated equally, whereas the former suggests that individual experiences and capabilities should be taken into account, to ensure that all individuals are able to achieve similar outcomes. To me, that seems wise for any company – engineering or otherwise – that wants to retain staff. Who wants to stay in a business where the odds are stacked against them? Advisory board member Richard Brown has penned a thought-provoking article on the subject of skills and training further on in this issue. It’s important to note that one of the protected characteristics is age. With a considerable amount of skilled polymer professionals due to retire out of the industry soon, it’s never been more important to offer a workplace that appeals to young people and their values. That’s going to require little financial investment, but considerable investment in education. Prioritising DE&I doesn’t need to be costly, but the rewards could be massive for the longevity of the processing sector. I’ve teamed up with the BPF to present a webinar on the subject – it’s open to all, and you can register for free here: tinyurl.com/3zbafjxx.

DAVE GRAY

HEAD OF CONTENT

CONTENTS 18

COMMENT

Dave Gray on plastics’ diversity problem

INTERPLAS

2023 event back with a bang

34 14

ON THE COVER

Albis on the secret to CMF success

OPINION

What happens to the Plastics Tax takings?

TRAINING AND SKILLS

Learning from past mistakes to close the skills gap

TESTING AND INSPECTION

New analyser makes composite applications a breeze

REGULARS

26 Industry news 32 Column: David Raine, PMMDA 34 Column: Philip Law, BPF

www.interplasinsights.com

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INTERPLAS 2023

Interplas 2023 surpasses expectations, 2026 edition to move to June The UK’s No.1 plastics event, Interplas returned to the NEC in Birmingham at the end of September, celebrating its 75th anniversary. The show was packed with product launches and the latest plastics technology and innovation from over 540 exhibitors from 30 countries. Alongside this inspiring show features and engaging presentations across two stages ensured visiting professionals gained high-level manufacturing insights and actionable ideas that they could take away. Networking was high on the agenda too, with the Interplas After Show party and Interplas Social taking place on the first two evenings of the show, enabling the industry to reconnect and recharge at the end of three extremely busy days. Feedback from exhibitors on the show floor was extremely positive. Richard Mumford, Sales Director for KraussMaffei Group UK, said: “We have been very excited about the volume of people visiting our stand and the number of new enquiries we have discussed for upcoming projects.” Daniel Williams, Joint Managing Director at Wittmann Battenfeld UK, also commented: “For us at Wittmann Battenfeld UK, the show has been really good, with many customers attending, and also some great new contacts made on the booth. With everyone’s focus on energy efficiency, it’s been great for us to showcase just how Wittmann can assist them and help to save them time and money.” Colin Tirel, Managing Director at Arburg Ltd added, “For Arburg Ltd the 2023 Interplas show was absolutely fantastic. I thought the last show in 2021 was good, but this delivered even more contacts and discussions which we can now work on. Well done the Rapid News team, we will certainly be back in 2026!” The Interplas 75 @ 75, a collection of 75 influential people in the UK plastics industry from the 75 years of Interplas were also unveiled during the week of the show.

As part of the 75th anniversary celebrations, the occasion was marked by honouring 75 individuals deemed worthy by the industry itself, based on their significant contribution to advancing the UK plastics sector during the 75 years of the show. Nominations were collected via a survey released earlier this year, and out of hundreds of nominations, the 75 individuals below are considered to have made a significant impact to the industry during this period. Duncan Wood, CEO, Rapid News Group commented, “Interplas has been a focal point for the UK plastics industry for seventy-five years and as we reflect on that history it is a timely point to recognise those individuals who have played their part in driving the UK industry forward during that period. I congratulate all of those who made the final list, their contributions are appreciated and valued by everyone across the industry”. Richard Brown, Managing Director at R J Consulting, who was recognised for his commitment to bringing young people of all backgrounds into the sector, and promoting plastics as an exciting, limitless material, commented: “It is clearly an honour for me to receive this recognition in the Interplas 75@75 from my fellow peers. It is a terrific feeling being approved for the work you have done and are doing. Working in the plastics industry has been an immense journey and this recognition is the culmination of my 53 years in the industry starting as an apprentice, to the boardroom, in roles that have enabled me to give back to the industry via training, awards judging and mentoring the future plastic professionals.” A special celebration took place on the evening of the first day at the show.

The Interplas 75@75

Nominees are as follows (in alphabetical order) Note that some nominees have retired from their listed roles, or are receiving the accolade posthumously:  ADISA AZAPAGIC, Professor of Sustainable Chemical Engineering, University of Manchester  ANDY JEWELL, Sales Director, Moulders Consulting Ltd  ANDY NICHOLLS, Consultant Trainer, RJG  BARRY TURNER, Head of the British Plastics Federation’s Packaging Group  BOB WILSON, Managing Director, Boy UK  CARL FUTCHER, Managing Director, PlastikCity & PlastikMedia  CARL REEVE, Managing Director, Haitian UK/PMM  COLIN ROBINSON, Former Sales Manager, Interplas  COLIN TIREL, Managing Director Arburg Ltd  CRAIG WARD, Managing Director, Negri Bossi  DANIEL WILLIAMS, Joint MD, Wittmann Battenfeld UK & Ireland  DARREN PARSONS, Managing Director, Agentdraw  DARREN VATER-HUTCHISON, Process & Training Engineer, Sumitomo Demag  DAVID BARGERY, Managing Director, Regis Machinery  DAVID RAINE, Managing Director, Sumitomo Demag  DAVID WILLIAMS, Former Master, The Worshipful Company of Horners  DEAN MEYNELL, Injection Process Group Manager  DON ANSELL, Founding Director, Rutland Plastics  DUNCAN WOOD, CEO, Rapid News Group  ED KOSIOR, Founder and Managing Director, Nextek Ltd  ERIC FAWCETT, ICI  FERGUS HARDIE, Chairman, Hardie Polymers  GARRICK GROVE, Director, NDC Polipak Limited  GARY PROBERT, Director, Hi-Tech Automation  GERALD BLOOM, Owner, Big Bear Plastics Products Ltd  GLEN EVES, General Manager, Sepro UK  GRAEME HERLIHY, Regional President West Europe, Engel  HARDEEP KHERA, General Manager, Bole Machinery  ISLYN THOMAS O.B.E., Thomas Manufacturing Company  ISY FERGUSON, Managing Director, Hardie Polymers  JAMES R. W. HENDRY, Engineer and Inventor  JOHN C. SWALLOW, ICI, Inventor  JOHN GOFF, CEO, G&A Moulding Technology Limited  JURAJ ULIK, Technical Manager, Plastek UK  JUSTYNA ELLIOTT, Senior Business Development Executive, British Plastics Federation  KAREN DRINKWATER, Director, JSC Rotational Moulding  KARL MILLER, Motan Colortronic  KARL PERRY, Founder, Spaceminster and STV Machinery  KEN GRACE, Editor, British Plastics & Rubber Magazine  LEE THOMAS, Managing Director, TH Plastics  MARK GUYETT, Director, Mouldshop  MATT BARBER, Sales and Events Director, Crain Communications  MICHAEL WOOD, Recycling Director, IPL  MIKE BATE, Managing Director, KraussMaffei UK  MIKE BOSWELL, Managing Director, Plastribution  MIKE JORDAN, Managing Director, Summit Systems  NICK FOX, Managing Director, Piovan UK  NIGEL BAKER, Managing Director, Engel UK  NIGEL FLOWERS, Managing Director, Sumitomo SHI Demag UK  NIKKI WILLIAMS, Association Secretary, PMMDA  PAUL EDWARDS, Managing Director, Pentagon Plastics  PAUL GOODHEW, Head of UK Sales, Sepro  PETE KIRKHAM, Managing Director, Billion UK  PETER COX, Owner, Peter Cox Associates  PETER DAVIS, Director – General, British Plastics Federation  PHILIP LAW, Director – General, British Plastics Federation  PRAVIN S MISTRY, Owner, PREA Ltd  REGINALD GIBSON, Researcher, ICI  RICHARD BROWN, Managing Director, R J Consulting  RICHARD HIRD, President, PMMDA  RICHARD ORME, Managing Director, Distrupol Ltd  RICHARD PERRY, Director, STV Machinery  RICHARD STAMPS, Director (now deceased), PlastikCity  RICKY THOMPSON, Director, Hi-Tech Automation  ROBIN KENT, Director, Tangram Technology  RON MARSH, Former CEO, RPC Group PLC  SALLY BAILEY, Owner, Common Sense PR and Marketing  SALLY BEKEN, Knowledge Transfer Manager – Polymers, Innovate UK KTN  SIMON SCHOLES, Managing Director, Conington Environmental  SIMON WRIGHTON, Sales Director, Arburg  STEPHEN HUNT, Membership Services Director, British Plastics Federation  STEPHEN MANCEY, Consultant, Mancey Consulting Ltd  TERRY COOPER, CEO, Argo International  TERRY PEARSON, CEO, Gas Injection Limited / CINPRESS LIMITED

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INTERPLAS 2023 “For Arburg Ltd the 2023 Interplas show was absolutely fantastic. I thought the last show in 2021 was good, but this delivered even more contacts and discussions which we can now work on. Well done the Rapid News team, we will certainly be back in 2026!” The Interplas Insights Conference hosted world-class presentations from Jaguar Land Rover, British Plastics Federation, RECOUP, GoRolloe and Innovate UK. Alongside the education programme, exciting features such as the Knowledge Pavilion gave attendees the chance to meet industry trade bodies, consultants and service providers to get expert advice on research and development, skills and education, regulation and materials selection. The PlastikCity Pavilion, which also returned for 2023 due to high demand, presented 20 first time exhibitors to the audience, further enhancing the range of solutions on the show floor. Wood added: “The £27 billion UK plastics industry came to Interplas to do business and our exhibitors have had an absolutely fantastic week. The industry really came out to celebrate our birthday and we are delighted with the outcome. We are privileged to own and operate this 75-year-old institution called Interplas and it was a real pleasure to announce the Interplas 75@75 during the week reflecting on who has helped shaped the industry and the event in the last 75 years.” “Now we look forward to 2026 on our new dateline of June, enabling us to co-locate with our other events TCT 3Sixty and Med-Tech Innovation Expo, and alongside a plethora of additional industrial events from partner organisers Nineteen Group and Mark Allen Group which will deliver even greater return on investment for our exhibitors and create a real focal point for UK manufacturing.”

TM Robotics Shibaura Machine, formerly known as Toshiba Machine, launched its new injection moulding offering at the show. Interplas was the first UK trade fair for Shibaura Machine since UK distributor, TM Robotics, agreed an exclusive distribution partnership with the manufacturer last year. TM Robotics now handles all industrial robot and injection moulding distribution for Shibaura Machine in the UK and Ireland. TM Robotics has long been a prominent distributor in industrial robotics and automation and has been supplying Shibaura Machine robots to the market for over two decades. At Interplas 2023, TM Robotics launched its new product offering from the Japanese manufacturer — the full all-electric injection moulding machine range, plus service and maintenance. “The new offering includes the allelectric SXIII injection moulding machine series from Shibaura Machine,” explained Nigel Smith, managing director of TM Robotics. “The range of machines feature enhanced versatility and performance

and streamlined design, providing significantly faster injection speeds than traditional moulding equipment. The series is available in 17 different injection capacities and dimensions and can be used for virtually any moulding application. “Shibaura Machine, formerly known as Toshiba Machine, were delighted to be exhibiting at the Interplas Exhibition in 2023. The exhibition was vital for us to connect with existing customers, as well as find new ones. The Shibaura Machine All-Electric Injection Moulding Machine offering is second to none in terms of its energy efficiency and we were delighted to highlight these strengths at the show.” In addition to the supply of the all-electric series, TM Robotics can also obtain parts and perform maintenance for hydraulic Shibaura Machine equipment — and legacy Toshiba Machine-branded moulding equipment that is still in operation in the field. “Our strength is in our ability to integrate injection moulding machines and robots from Shibaura Machine — we are the absolute experts in this technology for the UK and Ireland,” continued Smith. “We encourage those interested in automated solutions for injection moulding to arrange a meeting with our experts at Interplas. The team has impressive knowledge of Shibaura Machine technologies, and we have recently expanded the team with two new injection moulding experts to further support this sales area.” Peter Coltman and Jakub Urbanek joined the TM Robotics team as injection moulding machine service manager and technical support, last year. Having

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

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INTERPLAS 2023 worked exclusively with Shibaura Machine’s injection moulding equipment since 2018, the engineers can provide expert consultation and advice on any injection moulding query. Interplas followed a significant new robot launch for TM Robotics. The organisation launched its THE SCARA series for the European market at the Automatica trade fair held in Germany in June 2023. The launch saw TM Robotics introduce two new larger robots to the existing series. “The THE800 and THE1000 robots are newly available in Europe,” continued Smith. “The THE series is widely recognised as the price-to-performance leader in SCARA robots and is ideal for pick-and-place applications. Alongside these models are a number of sixaxis robot options, many of which are compatible with the Shibaura Machine injection moulding machines for loading and unloading.”

Borche The UK subsidiary of the Asian IMM manufacturer Borche exhibited two machines at the show, including a Borche BU500 ton machine from the company’s Two Platen range of machines. The BU500 was displayed running with a Six Axis Robot to remove and stack parts to the rear of the machine. Also on show was a new Borche BD130 ton machine from the company’s electric drive range of machines. The machine utilises direct drive servo motors for both the clamp and injection movement for additional positional accuracy. The company says that energy costs were the dominant theme at Interplas 2023. Managing director Raymond Fok said: “Some customers are not as busy as they would prefer at this time, but nevertheless despite this, most customers recognise the need to replace and update their older machines with the latest energy efficient models which employ servo motor technology to reduce the energy consumptionm and thus drive down the customers annual electricity costs which as we know has risen dramatically over recent years.” Fok continued: “We were delighted with the visitor attendance on the Borche stand at Interplas, both in terms of quality and volume, we welcomed customers who represented most, if not all market sectors. Some customers had immediate investment plans to discuss, and indeed two new Borche machines were sold at the

“It is clearly an honour for me to receive this recognition in the Interplas 75@75 from my fellow peers. It is a terrific feeling being approved for the work you have done and are doing. Working in the plastics industry has been an immense journey and this recognition is the culmination of my 53 years in the industry starting as an apprentice, to the boardroom, in roles that have enabled me to give back to the industry via training, awards judging and mentoring the future plastic professionals.”

Dr Michael Junior Hopkins Managing Director Ross Polymer Services

Pravin S Mistry Global CEO PREA Ltd.

www.interplasinsights.com

show, and many others had medium to longer term projects to discuss leading into 2024.” Borche says it plans to continue to expand in the UK both in terms of machine density and customer numbers etc., together with the service staffing levels, which have also increased in line with the growth in the market. Magog Hertforshire-based Magog Industries, a long-established UK designer, manufacturer and supplier showed its selection of screws, barrels, screw tip assemblies, barrel nozzles, end caps, and a selection of engineered components at the show. In addition, the stand had a focus on the latest materials and coatings available from the group. Director/General Manager John Allsop said: “Interplas 2023 was a successful platform: it provided the opportunity for us to showcase a range of approaches and solutions designed to further enhance longer life of our screws and barrels for increasingly demanding processing”. “We had a busy three days with quality enquiries and orders received. Customers are looking for greater efficiency of production, to reduce energy and faster output where possible. Further developments in biodegradable polymers and plastics recycling provide new challenges that we welcome, are

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INTERPLAS 2023 increasingly becoming significant and important. We design everything in-house but also work closely with specialist partners to meet our customers’ specific processing and production requirements”. The group’s enhanced coatings include: Thin Dense Chrome (TDC) to enhance wear with low friction and is FDA Approved for food process environments. Ceramic Seal coatings reduce porosity and increase plating/coating life 4 to 10 times longer in corrosive environments. From D2 hardened tool-steel to nickelchromium-based superalloys which also provide specific high corrosion resistance properties. In addition, HVOF (High Velocity Oxygen Fuel) was demonstrated at Interplas, and visitors were invited to see if they can scratch a treated surface. This thermally sprayed coating provides a crack-free 98 per cent density with hardness of 62 to 72 HRC. HVOF as a scratch-resistant tungsten carbide coating has gained much interest among plastics moulders. Magog also specialise in refurbishment of pre-used parts which extends the life of screws and barrels, providing a cost-effective option. Allsop added: “We never stop learning when it comes to the plastics and rubber industry. At Magog, we constantly focus on looking at measures, particularly surface treatment for abrasion and potential corrosion to increase resilience and longevity specifically in ceramic and chrome seal coatings for demanding applications such as blown film extrusion.”

“Interplas has been an excellent stage and we were delighted to be part of such a high-profile international exhibition. It allowed us to reach new customers in multiple sectors and also proved a great networking opportunity for our sales team to engage with existing customers and listen to their needs whilst also providing the latest news on our own activities.” 10

“The exhibition was vital for us to connect with existing customers, as well as find new ones. The Shibaura Machine All-Electric Injection Moulding Machine offering is second to none in terms of its energy efficiency and we were delighted to highlight these strengths at the show.”

Glazpart Plastic moulding group Glazpart found Interplas to be “the perfect platform” to showcase their awardwinning products to hundreds of companies in the plastic components market. Following the three-day show, Dean Bradley, Glazpart Sales Director (pictured) commented, “Interplas proved a great success as we had so much to show visitors to our stand and also had a lot to share with potential customers in terms of our facilities, capabilities and flexibility across multiple markets.” Glazpart’s impact in the plastics industry has been significant for over 35 years but with so much activity in 2023, the company’s initiatives and products are being widely recognised. Recently, the company’s Link Vent 4000 was nominated as a finalist in the “Product of the Year” category at The Plastic Industry Awards. In addition, British Plastics Federation included the Link Vent 4000 in its review of most innovative plastic products in 2023. Aligned to the general recognition, Glazpart is also in the running for three National Fenestration Awards (NFAs) including “Product of the Year” for the Link Vent and also in the “Window Component Supplier of the Year“ category. Glazpart’s success in the last 18 months can be attributed to several www.interplasinsights.com

factors including substantial investment in high tech machinery, staying ahead of government policies and changing regulations, development of product ranges and improving its customer relations with the launch of the Glazpartners’ programme in May this year which has already seen over 40 companies sign up to be part of the initiative. As the success continues, Dean Bradley summarised, “It’s been a great year so far for Glazpart and exhibitions have more than played their part. Interplas has been an excellent stage and we were delighted to be part of such a high-profile international exhibition. It allowed us to reach new customers in multiple sectors and also proved a great networking opportunity for our sales team to engage with existing customers and listen to their needs whilst also providing the latest news on our own activities.” Wittmann The Wittmann Group’s reported a fantastic show, with ‘throngs’ of visitors enquiring at the stand. Joint UK MD, Dan Williams said: “I am delighted to say that Interplas 2023 was a really successful show across all three days - and from start to finish. Our stand was in the ideal place for the early visitors and for a good mixture of existing, old and potentially new customers who were very impressed by all the exhibits and by the wide range of Industry 4.0 ancillaries connected to

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INTERPLAS 2023 “Interplas 2023 was a really successful show across all three days - and from start to finish. Our stand was in the ideal place for the early visitors and for a good mixture of existing, old and potentially new customers who were very impressed by all the exhibits and by the wide range of Industry 4.0 ancillaries connected to our injection moulding machines.” our injection moulding machines. “The Wittmann stand also brought on a good deal of visitor interest in the chess robot, with people pitting their skills against the SONIC143 high speed technology. The stand also attracted many visitors who were keen to try and power their way to move the Wittmann Ergobike, PRIMUS14 robot. Coupled with our SmartPower120 LSR machine and EcoPower110 Biobloc, we were able to demonstrate our leading energy efficient credentials to the whole sector.” The group’s energy credentials could be seen in real time on the IMAGOxt touchscreen on Wittmann’s SmartPower injection moulding machine. The IMAGOxt technology is a breakthrough Wittmann energy management programme which WIBA UK is now offering to the UK industry for free: “It doesn’t matter what kind of injection moulding machine you are running – Wittmann or otherwise” said Williams. “IMAGOxt gives us the power to analyse just where all your energy costs lie – and then choose to take steps on how to improve them.” IMAGOxt is supplied by WIBA UK at three levels of complexity. The first – now at no cost from WIBA UK – determines and documents the energy consumption of injection moulding machines in accordance with Euromap 60.2. The second level package includes energy issues relating to the entire production cell (including ancillary equipment). The premium package then builds on the work established in the first two stages to include the implementation of energy efficient measures.

“We were delighted with the visitor attendance on the Borche stand at Interplas, both in terms of quality and volume, we welcomed customers who represented most, if not all market sectors. Some customers had immediate investment plans to discuss, and indeed two new Borche machines were sold at the show, and many others had medium to longer term projects to discuss leading into 2024.” www.interplasinsights.com

Joint WIBA UK MD, Tracy Cadman said: “Our energy efficiency expertise helps our customers with a ‘double win’. It drives down production cost, and it also signals to customers and the world that here is a business that is committed to the sustainable agenda and to the circular economy. “There were many good connections and leads generated at the show. We also achieved some good sales orders on the stand in all areas – moulding machines, automation and other ancillaries. Some of these were unexpected and this factor gave a great boost to all of our team who worked tirelessly - from the build-up on Saturday at 6am, then right the way through to the Friday evening, with the final truck of three being waved off back to Austria.”

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Q&A

ON THE COVER

GOOD ADVICE RIGHT FROM THE START: ALBIS’ SUCCESSFUL APPROACH TO CMF What it takes to successfully combine functionality and aesthetics, and why most failed product launches can be avoided with an up-front approach. Chris Newman, Regional Technical Manager, ALBIS UK writes. 14

What is CMF? Whether a product is for consumers or industrial users, how it looks, feels, and behaves influences its functional and perceived value. In product development, those characteristics are collectively known as Colour, Material, Finish, usually abbreviated as CMF.

Selecting the best CMF solution The involvement of the polymer supplier at the outset of a development project is critical as this is when key design aspects, including functional and aesthetic considerations might be first highlighted as well as determining which manufacturing process is best suited for production. As a polymer distributor, ALBIS add value by advising customers on a myriad of topics during the development of new applications. This often avoids the correction of costly mistakes which would only appear at a later stage of the project – particularly with respect to CMF. One example was the development of an internet enabled device, which consisted of a cylindrical plastic enclosure featuring an illuminated LED “halo” ring on the

ALBIS’ Approach to CMF ALBIS work as trusted advisers and solution providers. We act as independent material consultants with a strong and diverse portfolio. The distribution partners offer a variety of strengths in various CMF areas. Some polymers come to the fore when high gloss is required whereas some are more suited to matt effects. Achieving precise colours via compounding is possible from a diverse range of base materials from standard, through engineering plastics to high performance polymers. When haptics are important, thermoplastic elastomers can come into play. The role of the ALBIS Application Development team is to identify the best solutions for designers based on specific application CMF needs.

distribution partners and work closely with design agencies, converters, and OEMs to identify the optimum solution according to the given application requirements. Colour ALBIS partners with several industry leaders who specialise in colour compounds, and collaborates with its sister company, MOCOM, to offer a comprehensive range of compounding services, including license production. MOCOM’s state-of-the-art facilities and rigorous quality standards, such as IATF 16949:2016 and ISO 9001:2015, ensure that the colour compounds produced meet the highest levels of quality and consistency. MOCOM offers lot-to-lot reproducibility, meaning that regardless of the brand or colour being

“We would suggest that that the combination of a design consultancy with CMF expertise and an impartial polymer supplier like ALBIS would be a formidable team.” top of the device. A white PC+ABS was chosen and moulded well with good surface finish. However, when in operation unacceptable light bleed into the housing occurred, thereby ruining part aesthetics. As a result, product launch had to be delayed. An Alcom light blocking solution was trialled and solved the light bleed issue. However, the new grade resulted in an unacceptable matt surface finish. Rapid Alcom grade development from MOCOM came to the rescue and a high gloss, colourmatched solution was found. Had the project management team adequately considered CMF at the outset then their original product launch date might have been met. In areas such as consumer electronics, houseware, healthcare and visible automotive parts, CMF is often critical. Brand owners are looking at surface quality, feel, durability, innovation, and the emotional appeal of a solution. Today, sustainability is also a critical consideration for new designs. ALBIS’ distribution partners have expanded their portfolios to offer a wide range of sustainable solutions covering a variety of technologies, including mechanically recycled, chemically recycled, bio-based and bio-attributed products which are often drop-in solutions for fossil-based counterparts.

ALBIS has close relationships with many design consultancies who offer CMF as a special area of competence. They promote their sample libraries to their clients to enable innovation. OEMs are mindful that a high proportion of (costly) product launches fail for various reasons, including overlooked CMF considerations. According to Harvard Business Review, 75% of consumerpackaged goods fail. By conducting effective market research and investing in well thought-through design brand owners aim to mitigate this risk. The ALBIS technical team is extremely well-versed in the CMF portfolios of our www.interplasinsights.com

manufactured,licenced compounds from Covestro, Envalior, INEOS Styrolution and LyondellBasell can be reliably produced to the highest quality. Additionally, MOCOM markets its own brands. A recent innovation being the Alcom® Digital Sample Plaques Library. This is a database of Alcom® Lighting and CFX (colour effects) grades. Individual plaque images are available for inspection and comparison. The Alcom® CFX range of products is aimed squarely at special aesthetic compounded effects e.g., metallic effect flake in different base polymers.

Continued on page 16

COVER STORY These are often superior to the use of masterbatch solutions which can fall short in terms of final appearance and shot-toshot consistency. A new internal digital library of colour effects enables variables such as polymer type and base colour to be easily filtered. A resulting short list can be visually compared by downloading plaque images. Whilst not replacing the physical plaque submission step, it accelerates the short-listing process. Material In the field of CMF, the Materials aspect relates to its appearance, how it feels and how it behaves. This aspect isn’t restricted to plastics as it also covers metals, fabrics and organic products. However, in terms of ease and costeffective mass production – usually with the lowest carbon footprint – then plastics are indeed hard to overlook. Within the plastics field, ALBIS acts as an independent materials advisor. If a client discussion on material choice takes an unexpected path due to new demanding requirements, then ALBIS have the portfolio breadth to handle most scenarios. For example, IXEF from Solvay is a high performance polyamide capable of being highly glass filled which has a unique combination of exceptional surface gloss, dimensional stability and structural characteristics. Ideal for those metal replacement applications where high strength and aesthetics are important. We would suggest that that the combination of a design consultancy with CMF expertise and an impartial polymer supplier like ALBIS would be a formidable team. Together we could consider aspects such as availability and technical considerations around manufacturing viability and would help deliver a workable innovative solution. Finish Designers often go to a lot of trouble to get just the right surface finish on a

final part. They stress its importance in creating a lasting emotional connection with the customer. Obviously, this is more important in, say, automotive interiors or consumer electronics than for building and construction components. ALBIS have a comprehensive range of thermoplastic elastomers, from TPV, TPS and TPU, through to high temperature resistant TPC. In many cases they are deployed to provide tactile touchpoints for comfort or ease of use on hand-held devices. Depending on the application, requirements can include scratch or mar resistance, substrate adhesion or delivering a specific texture. When it comes to how a part feels, then a further solution are the ‘cool touch’ products. Primarily developed to be thermally conductive in metal replacement applications, MOCOM’s Alcom® TC, Envalior’s Durethan® TC and Covestro’s Makrolon® TC are ideal in delivering a more metallic feel. ALBIS is well placed to advise on secondary processing steps such as painting, vacuum metallizing, and electroplating. Not all plastics can be easily metalized as many factors come into play, however, custom-made products such as Covestro’s Bayblend® PC+ABS, Envalior’s Durethan® PA, Solvay’s IXEF® PARA, INEOS Styrolution Novodur® ABS, MOCOM’s Tedur® PPS and BASF Ultramid® PA offer many ideal solutions (depending on the metallization technology employed). Application Example Partnerships with Eschmann Textures UK and ALBIS UK offer infinite design possibilities and functional surfaces. Combining 5-axis laser engraving and MOCOM’S Alcom® material, Linecross showcases an automotive console concept with discreetly concealed and illuminated buttons and displays. No painting is needed thanks to the moulded quality and glossy finish. The surface appears sleek during normal illumination

but reveals sophisticated hidden features when backlit. Project advice can be offered on the feasibility of tool textures both in terms of manufacturing and consequences for durability. A recent good example was a premium vehicle interior part. The moulder was experiencing severe difficulty obtaining a particular consistent tool texture without visible gate effects on the part’s “A” surface. In this case it was possible to switch to an INEOS Styrolution TERBLEND® N grade; solving the problem without tool modification. Car interior components liable to scuffing very often possess a coarse “elephant hide” tool texture. This has been found to generally resist maring to a higher degree than fine (sharper) textures. However, material choice is not always an obvious variable when designing such applications. Another solution is BASF Ultramid® Deep Gloss. This polyamide which has excellent chemical resistance features a lustrous deep gloss that can be used without coating in automotive interior applications. On the other hand, when a high-tech “carbon” finish might be desired then WIPAG WIC is a material of choice. In conclusion, in product development where aesthetic concerns are raised “Colour Materials Finish” is of vital importance. Partnering with product design specialists, converters and raw material suppliers can make the difference. This article highlights how a distributor such as ALBIS UK can bring the experience of our engineers and a diverse engineering polymer portfolio together to deliver spectacular results.

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OPINION One of the key issues highlighted by Plastic Recyclers Europe (PRE) is the scarcity of sorted plastic waste in Europe. The plastic recycling sector, worth over €7.7 billion in turnover, is grappling with a shortage of recyclable material. This scarcity poses a significant challenge for businesses attempting to meet the PPT requirements, especially when only 52% of recycled material comes from the UK, raising questions about the accountability for the remaining 48% brought into the country and the associated carbon emissions.

OPINION

Why the £270m from the Plastic Packaging Tax could solve long-term challenges Paul Empson, General Manager, Bakers Basco writes.

he UK Government’s recent announcement that it collected over £270 million from the Plastic Packaging Tax (PPT) in its first year sends a strong signal about the country’s commitment to tackling plastic waste. However, as we delve deeper into the implications of this tax, it becomes apparent that while legislation is a crucial step, there’s a need to address the challenges faced by businesses in sourcing recycled plastic. The PPT, introduced in April 2022, levies a £200 per tonne charge on plastic packaging containing less than 30% recycled content. This initiative aims to incentivise the use of recycled plastic in packaging and to drive greater recycling and collection efforts. On the surface, this seems like a step in the right direction, but a closer look reveals the complexities and potential setbacks for industries reliant on plastic packaging.

As a result, many companies, including smaller ones, have no option but to transition to using 30% recycled content in their products. However, this solution creates its own set of problems. While the intention behind the PPT is commendable, the supply chain struggles to provide the required amount of recycled plastic. Businesses like Bakers Basco find themselves caught between a rock and a hard place – compelled to incorporate more recycled content into their products, yet unable to access sufficient quantities of recycled material. In the short-term, the impact might be manageable, but looking ahead, it could have far-reaching consequences for the plastics industry. Without a steady supply of recycled materials, manufacturers face delays in production, causing ripple effects throughout various sectors that rely on plastic packaging. Consider Bakers Basco, whose Omega bread basket is a prime example of a reusable transit packaging designed for a circular economy. However, even with the right intentions, the company faces challenges in securing the necessary 30% recycled plastic to keep

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its production lines running smoothly. This not only affects their operations but also reverberates across the baking industry and beyond. So, how can the £270 million collected from the PPT be strategically employed to overcome these challenges? One potential avenue lies in investing in the development of domestic plastic recycling infrastructure. By allocating funds to establish efficient recycling processes, the UK can reduce its reliance on external sources of recycled material. This move could help businesses meet PPT requirements and ensure a consistent supply of recycled plastic for production. Moreover, supporting research and innovation in plastic recycling technologies could catalyse the emergence of new solutions for the shortage of recycled materials. Collaborative efforts between the government, private sector, and research institutions could yield breakthroughs that alleviate the pressures caused by the scarcity of recyclable plastic. In conclusion, the Plastic Packaging Tax’s first-year revenue underscores the UK’s commitment to combatting plastic waste. However, for this initiative to truly succeed, it’s imperative to address the challenges faced by businesses transitioning to recycled content, as well as to consider the accountability for the imported recycled material and its associated carbon emissions. Allocating a portion of the tax revenue to bolster domestic recycling infrastructure and innovation could pave the way for a more sustainable future. As we move forward, it’s essential to remember that while legislation lays the foundation, strategic actions are what build a resilient and circular plastics industry.

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SKILLS & TRAINING

Can we learn from history to close the skills gap?

he educational and training landscape has been blighted over many years of political initiatives that have driven detrimental change across the board. Some of the political initiatives that have impacted technical skills are: • EITB training centres replaced by a ‘patchwork quilt’ of different types of training provision. • Technical colleges and polytechnics removed. • Political drive of degrees for all. • Legislation for education to the age of 18 introduced. • Apprenticeships became the buzzword for politicians to right their wrongs of educational change. • Introduction of the Apprenticeship levy. • T-levels, a government backed career focussed qualification for 16-19 yearolds launched The polymer industry was once represented by three bodies, Cogent, The National Skills Academy (Process Industries) and Technical Apprenticeship Service TAS, which were morphed into Cogent Skills, an Employerdriven Science Industry Partnership. However, the polymer industry is a poor partner in this relationship, as it was stated at the outset it was for the prosperous UK science-based sector by its Chair at its outset: “This partnership will put employers in the driving seat, allowing us to identify ways of attracting the best young people and in turn securing the essential skill base for a prosperous UK sciencebased sector.” - GSK Director Malcolm Skingle, Chair of the Science Industry Partnership. Cogent Skills are sector based, working with companies from across the science and technology industries embracing life

The manufacturing sector has been facing skills shortages for decades. Therefore, what we are now seeing is not new but is a build-up of historical challenges. The diﬀerence now being that we are not just facing a skills shortage, but also a labour shortage. Editorial advisory board member Richard Brown writes. sciences, industrial sciences and nuclear. Where does the core of the plastic industry fit into this? Maybe it’s the poor relation in this initiative! We are working in an industry that is being demonised by government and media turning the spotlight on plastics. This might be a handy way for government to steer public attention away from some of their significant failures of the past and for the media to give credence to on-going campaigns, but it is damaging the image of the industry reducing its attractiveness to future career prospects. However, what they fail to say is that plastics have been responsible for saving millions of lives through their use in medical devices, transportation, and food preservation. The COVID19 pandemic once again highlighted the need for plastic materials to prevent

the spread of infection. So, the enemy is not plastics which has a positive impact on our everyday lives around the world providing technological advances that benefit many fields and promote innovation. A career in the plastics industry could have a real impact but how do we get the message across? We, as an industry, need to be raising our voices and getting involved at the grass roots level. The British Plastics Federation has recognised this and have provided the means to get involved via the Polymer Ambassadors and Career Ambassadors schemes providing the tools to enable companies to interact with their local schools to improve the view of that which has arisen around careers in STEM subjects (Science, Technology, Engineering and Maths). The Institute of Materials, Minerals and Mining (IOM3)

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organise annual polymer study tours, supported by The Worshipful Company of Horners and industry sponsors, for design and technology teachers to gain first-hand experience of the polymer industry in action. This is a mix of lectures, practical sessions, and site visits supporting teachers in educating the employees of the future. Some words from teachers that have attended a tour speak for themselves: “I feel it is vital that I am able to use real-world examples of the polymers that I teach. The site visit was a great way to bring both the science and design aspects of the plastics industry together, in a way that has deepened my understanding of the subject.” “The course exceeded my expectations by far and I am confident it is going to transform my teaching of the subject. The course was incredibly well designed and paced with a packed and diverse agenda, all of it interesting.” Schools outreach is important whether via Careers Ambassadors, Polymer Ambassadors or

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SKILLS & TRAINING attending career fairs to get the message across that there are STEM careers within the plastic industry, where young people can have an impact in several industries such as medical, automotive, and aerospace applications, right through to packaging, construction and agriculture. However, Tony Blair’s mantra of “education, education, education” changed the expectations of many, who began to believe that education progression carried on through to university, with a plethora of subjects becoming available. This took the focus of many away from apprenticeships and vocational training, where a widespread snobbery existed. Whilst most parents were aware of apprenticeships and say they support them, they didn’t want their ‘little darlings’ to miss the aspirational goal, which is to achieve a degree. The revival of interest in the apprenticeship, with the introduction of the Apprenticeship Levy, was designed to put funding in the hands of employers and encourage them to invest in and create apprenticeships. This generated a raft of ‘modern apprenticeships’ as educational institutes scrambled to get a slice of the funding, adding ‘apprenticeship’ to the title of many courses. However, it is important that companies and education providers work in unison to enable better representation of what the industry requires in the courses offered. Too often, these so-called apprenticeship courses do not run, as the cohort sizes required are not met to make them financially viable with the level of funding on offer. It is the responsibility of our industry to change the perception and raise our voices as to what is required to be delivered in an apprenticeship. Currently there is a Toolmaker & Die 20

“We are working in an industry that is being demonised by government and media turning the spotlight on plastics. This might be a handy way for government to steer public attention away from some of their significant failures of the past” Maintenance Technician Apprenticeship Standard without any representation for the plastic industry. The Level 2 Science Manufacturing Process Operative and Level 3 Science & Manufacturing Technician standards are being revised and need to have a polymer specific pathway to be of use to the industry to increase uptake of the apprenticeship. The work of the BPF Skills and Education committee is key in delivering the industry needs from this redevelopment. We cannot complain if we do not get a suitable qualification that is underfunded if we are silent and not involved. How the UK compares Unfortunately, the status of a skilled individual in the UK injection moulding industry is low compared to other countries. In the UK we put a considerable emphasis on the individual possessing essential knowledge to set a moulding machine and its process to produce the correct outputs and quality, often without the underpinning knowledge as to why, hence the role as a setter. Many of our global competitors adopt a more scientific approach to gain a detailed understanding of the moulding process and related equipment resulting in the interrogation of all aspects of the process to simply setting parameters. There is not an independent body for certification of plastic training, only for apprenticeships delivered in-house or by an independent training provider registered on the Register of Apprentice Training Providers (RoATP). The new Polymer Processing Technician Apprenticeship Level 3 was approved for delivery on 9th August but until a suitable end point assessment organisation (EPAO) has given commitment to the Education and Skills Funding Agency (ESFA) to be approved, delivery cannot start. To date this has not happened. Recognition must be given to the employers involved in developing this much needed revised Level 3 who were Alphagary, Berry Plastics, Broanmain, Cooper Tires, Data Plastics, Gabriel Chemie, Genuit Group, Linecross, Numatic, Recipharm, Polymermedics, Plasgran, RPC Superfos, Rutland Plastics, Sumitomo (SHI) Demag Plastics Machinery (UK) Ltd, Uniplas and Veka PLC. There are also several training providers who have developed www.interplasinsights.com

training courses to deliver to the industry these being, Paulson Training, Polymer Training & Innovation Centre at the City of Wolverhampton College, PS Partnership, RJG UK, Sierra 57 Consult, Solutions 4 Polymers and Sumitomo Demag. Whilst most of these courses are self-certified by the training organisations, Sumitomo Demag and Sierra 57 Consult have reached out to the IoM3 to get their courses Quality Assured and PD approved recognising the value of ongoing training for professional development and increasing the knowledge and skills capital of businesses. This approach also provides reassurance to learners and employers that the courses they are undertaking are provided by an organisation with a robust foundation in delivering training and that the content meets the IoM3’s high standards. This still leaves the question unanswered as to whether the industry requires a national body to ensure all training delivered is robust and meets the future needs of the industry like that of the Construction Industry Training Board (CITB). We must ensure that the industry has a competent and inclusive workforce now and in the future. Shouldn’t there be approved training organisations that deliver training courses and qualifications to a defined and industry-agreed training standard outside of the apprenticeship structure to upskill existing staff and offer occupational traineeships offering a learner a highquality work experience? Currently the procedures that employers rely on to bring in the next generation of talent, such as apprenticeships and other work-based training, are only in some measure equipping firms and their workforces with the skills that are needed for the future. The apprenticeship levy continues

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SKILLS & TRAINING to frustrate companies, and there is only limited awareness of government initiatives intended to provide support for employers to invest more in training. Employers are becoming more focused on upskilling and retraining their existing employees, the focus being to ensure that their technical skills keep pace with changing needs of the business, and to retain that talent in the business for the future. Training is a business investment however. Investment in plant and equipment is so often seen as the main route to growth and sustainability. Unsurprisingly then many businesses see that ‘state of the art’ plant and equipment is the panacea to improvement. Having the best machinery in the world will not guarantee significant performance enhancement without the associated skills. It is the businesses that are already making investments in their current and future workforce that are preparing for the future. With the right environment and right support, the workforce can and have delivered tangible results. The manufacturer’s organisation MAKE UK has recently published a paper titled ‘2030 Skills - Closing the Gap’ in which they state: • 36% vacancies in manufacturing are classed as hard to fill – lack of skills, qualifications or experience (24% average across other industries). • In 2022, there were 95,000 live vacancies in the manufacturing sector, and; lost productivity due to vacancies in 2022 equated to £21 million per day lost UK GDP output • Only 26.5% of manufacturers were confident in their ability to acquire the skills they will need in the net 10 years. The report highlighted the trends driving skills and jobs as: 22

“The Level 2 Science Manufacturing Process Operative and Level 3 Science & Manufacturing Technician standards are being revised and need to have a polymer specific pathway to be of use to the industry to increase uptake of the apprenticeship.” • 56% of manufacturers said that flexible working was a key trend driving changes to jobs and skills between now and 2030. • 59% of manufacturers cited automation as a trend that is changing jobs and skills needs for their business. • 50% of manufactures cited wider digitalisation where new digital technologies can boost productivity. • 37% of manufacturers cited environmental issues as a factor in changing skills needs. Key to this is the access to high-level skills such as innovation and management, as digital and green skills are needed to meet the challenge of net-zero. Automation, digitalisation, and the environment all reinforce the view of an increase in demand for higher level technical skills over the longer term and invites the question as to whether we will have enough people with the right skills to fulfil manufacturers’ long-term ambitions. The change in skills need to align to manufacturers’ wider growth ambitions. And yet, when it comes to apprenticeships and T levels: • Only 50% of manufacturers recruit apprentices - this should be 75–80% to meet industry demands1. How much of this is down to the structure of the levy restricting access to funding and lack of approved RoATP within the polymer industry? • 58% are aged 16–18 years but only 10% over 22 years - this provides a real opportunity for the manufacturing sector • Pre-levy there were 75,020 apprentices, post-levy there were 59,970; post levy and pandemic there were 39,510 – the levy needs looking at as a matter of urgency! • £3.3 billion unspent levy returned to Treasury in the last three years under the Government’s use-it-or-lose-it apprenticeship levy rules. What is government doing? Recently we heard the rhetoric from Rishi Sunak that “One in five graduates would be better-off financially if they had never gone to university.” He went on to say “But the fact that almost 30% of graduates don’t progress into highly skilled roles or further study after graduating just isn’t good enough. Too many young people are being sold a false dream of doing a poorquality course that doesn’t offer the prospect of a good job at the end of it. We’re protecting students and taxpayers against rip-off degree courses that have high drop out rates and don’t lead to good jobs.” He has promised to strengthen apprenticeships and T Levels and make sure that parents and students are aware there are other routes into the workforce other than a university degree – often with better career prospects and at a lower cost. He also said that they would make it easier for employers to take on apprentices - cutting the steps needed for businesses to take on an apprentice by a third. If this is delivered it would have a major impact over the bureaucracy currently involved in accessing the levy funding for SMEs. Widening access, boosting jobs. Growing the economy becoming the mantra for the current government. The UK plastic industry is the third largest employer in the www.interplasinsights.com

UK with 155,000 people employed. The turnover of the industry is £25bn, consisting of 5,800 companies. However, around 25% of the companies are small SMEs that are family owned, with the majority of the owners over 55, many of whom will be retiring in the next 10 years so. Apprenticeships and skills training are vitally important to ensure people can be successful at work and meet their career aspirations and businesses can fill skills gaps. However, the Treasury aren’t being transparent about where billions of pounds of apprenticeship funding, which is being misdirected, is used. Are they using the unspent levy in a way that best supports the places most in need of levelling up, or is it being used to create more entry-level apprenticeships, after numbers have plummeted in recent years? Over £3 billion in funds, that businesses haven’t used, appear to have been lost into a Treasury black hole. Lack of transparency undermines confidence that money for apprentices is being used in the most effective and

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SKILLS & TRAINING fair way. The fact that so much apprenticeship funding is lost to the Treasury is a symptom of a system that is far too rigid and confusing to navigate for businesses. Going forward the system should be made more flexible and companies supported to be able to access levy funding to boost apprenticeship opportunities. The Apprenticeship Levy has become a stealth tax on employers who should be able to use the monies towards training schemes, but in practice the options are limited. The Apprenticeship Levy was sold by the government as a ‘win-win’ for manufacturing but it’s fair to say in its current form it is a ‘lose-lose’ outcome. Manufacturers are restricted in what training they can spend it on, how they spend it and when they can spend it. So, it’s important that as an industry we invest in people and skills, that are within our current workforces as well as the next generation coming into the workplace. Despite commitments to invest in people there remain barriers to doing so. The factors we hear that stop skills investment often are: • lack of time to train as a barrier. • lack of external finance, e.g., government support. • lack of appetite from employees (often also attributed to a lack of time). • internal budget has been consumed by the Apprenticeship Levy. • access to relevant training provision. The government has set out a blueprint for reshaping the technical skills system to better meet the needs of employers and the wider economy. As part of this new approach, the Department for Education (DfE) introduced local skills improvement plans (LSIPs) and a new local skills improvement fund (LSIF), which replaces the strategic development fund (SDF). The LSIF will be available over two financial years, £80 million in 2023 to 2024 (£40 million revenue and £40 million capital), £85 million capital in 2024 to 2025. It would appear initially the SDF funding though was used to

reshape teaching and training provision and enable facilities to be updated in preparation for the 2023/24 rollout of the LSIPs. The Government also announced the creation of the Unit for Future Skills (UFS), an analytical unit which will collect labour market data to inform the development of education, skills and employment policy – this is intended to focus on future skills needs. It will be important that all these initiatives support effective collaboration between manufacturers and local training providers, and thereby facilitate more productive engagement ,which has been so often lacking. Time to speak up It is critical that the voice of the plastic industry is heard and communicated. One of the channels to do this is via the BPF’s Education and Skill Committee whereby the BPF can then pass on the views and requirements of its members onto the relevant bodies. What more can be done to open access to the labour needed immediately? Maybe thinking outside the box is needed; investing in our current workforces to take on skilled roles that they could achieve with the right encouragement to fill those job roles in the future. When upskilling and training employees, there are tax breaks available as the work-related training tax exemption allows companies to offer their employees training programmes while recouping part of the cost through tax breaks. Growing future leaders and managers is also important and the government’s Help to Grow: Management scheme is a long-awaited attempt to address some of these issues. However for many manufacturers, awareness and understanding of the scheme is low. This is a 90% government-funded leadership course, spread over 12 weeks

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to fit around your business. It is designed to help boost the business performance and resilience of your business. Another opportunity for those in the sector who have recently become economically inactive or are planning to retire is for them to make a contribution without being on the frontline of industry, that is by entering the teaching workforce to pass on their relevant direct experience of working in industry. As we look to the future, having the tools to adapt, innovate and be agile are vital. Training and development however, cost pressures, a lack of the correct expertise, and at times being stuck in old habits, holding many manufacturing businesses back from reaching their full potential. It’s fair to say that employee training is a smart business decision, because if you’re not training them, who will? Skilled employees need less supervision and less management to get the job done, leaving them time to address other business challenges. Untrained staff cost significantly more to employ and support than skilled workers in the longterm. Although despite this training, at times is perceived as unglamorous and a necessary evil that gets in the way of day-to-day business. It is necessary to recognise that well trained staff are critical to future success of a business. If you are failing to plan training, are you planning for your business to fail? It was George Santayana who said: “Those who fail to learn from history are condemned to repeat it”. The size of the prize of a highly skilled plastics sector can only be achieved if we work together, get our voices heard and accelerate training and development. In this manner we will unlock growth and deliver a stronger sector for the future, thus retaining jobs in the UK. 23

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s industries pursue high-performance composite materials with new functions, the demand for in-depth evaluations using thermal analysis grows. For example, sectors like automotive, aircraft and electronics increasingly require DMA analysis to understand properties like carbon-fibrereinforced plastics and adhesive behaviours. DMA technology is utilised to measure the viscoelastic properties of materials, with a primary focus on glass transition detection. Additionally, it can assess secondary transitions, material stiffness, curing level and damping properties. This versatile tool finds extensive applications in mechanical characterisation for applied research and R&D, including composites, plastics, rubber, and film materials. As the most recent addition to Hitachi High-Tech’s high-specification thermal analysis range, the DMA200 offers increased maximum force capability and built-in efficiency with straightforward troubleshooting, seamless data exchange and easy measuring head interchangeability. Real View enables valuable realtime furnace observations, ‘Guidance Mode’ aids DMA novices and electrical gas cooling as an alternative to liquid nitrogen for sub-zero measurements. The upgraded 20N maximum force capability of the DMA200 is a twofold increase compared to our previous model. This allows customers to exert higher levels of stress on their samples, making it ideal for characterising materials that require significant force for deformation. This expanded functionality is particularly beneficial for customers dealing with stiff samples, such as carbon fibre composites, enabling them

High-tech thermal analysers part of the solution for new composites Hitachi High-Tech Analytical Science Corporation has launched a new product in the NEXTA series, the NEXTA DMA200, a dynamic mechanical analyser (DMA) for advanced materials development and product quality control. to achieve precise and reliable material characterizations. From aerospace applications to cutting-edge automotive technologies, the DMA200’s enhanced force capability enables deeper exploration of the mechanical behaviour of a wide range of materials. “With the NEXTA DMA200’s high-force capability, we empower researchers to explore new possibilities in advanced materials analysis, achieving precise characterizations of stiff materials and driving innovations across industries,” said Dawn Brooks, Managing Director at Hitachi High-Tech Analytical Science The DMA200 features an upgraded Real View high-resolution camera at the core of the system. This enables improved observation of the sample during the measurement over a wide temperature range, capturing images in real time that can be related directly to the DMA signal. It proves to be an ideal option when using the DMA200 for research, teaching, troubleshooting, and measuring the size of the affected area. The Real View system incorporates colour analysis (RGB, CMYK, and L*a*b*) and allows for the creation of result videos. This helps to identify physical property changes and the added visual information to the DMA output simplifies interpretation, particularly when conducting failure analysis, foreign particle analysis and investigating abnormal results. The DMA200 provides three cooling options: by air, liquid nitrogen, and electrical gas cooling. The advantage of the electrical gas cooling feature is its simplicity and ease, as it solely requires power to operate, eliminating the need for external resources like liquid nitrogen. This streamlined cooling process makes the DMA200 more user-friendly, ensuring www.interplasinsights.com

effortless and efficient operation for materials analysis. ‘Guidance Mode,’ an intuitive software feature, is purposefully crafted to assist customers who lack prior DMA experience by providing systematic, step-by-step measurement and analysis instructions. From method overviews to published results, this mode supports international standard methods and allows customisation for individual needs. It is simple to learn, easy to teach and adaptable to a multi-tasking workforce, making it an ideal choice for busy laboratories. Additionally, the newly incorporated lighting system enhances measuring heads and sample interchangeability, providing efficiency and convenience during the analysis process. Olivier Savard, Product Manager for thermal analysers at Hitachi High-Tech Analytical Science, stated, “Designed in response to the demanding environments our customers operate in, the DMA200 – with its advanced efficiencyfocused features and capabilities – is set to make a meaningful impact in various industries. We are confident that this dynamic mechanical analyser will empower researchers and professionals to drive innovation and uncover valuable insights.”

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INDUSTRY NEWS

Celebrating their 22nd anniversary in 2023, the Plastics Industry Awards recognise the many ways in which plastics product design, manufacture and recycling contribute to successful and sustainable innovation in everything from medical devices and electronics to packaging and automotive components. Finalists for the Best Product Design Award sponsored by Distrupol include a bespoke colostomy bag, a vertical farming tray, a vacuum cleaner, a construction safety hole cover and a window trickle vent. The farming tray has also been shortlisted for Best Recycled Plastic Product, alongside a Bluetooth speaker, a classroom chair, a full body dryer, circular packaging and a drainage access chamber. Four individuals have been nominated in the new category of Rising Star: Rowan Fletcher of IPL Global, Daniel Kelk of Plastek UK, Luke Parsons of Summit Systems and Luke Brown MSc also from IPL Global. Six have qualified for the Apprentice or Trainee of the Year, sponsored by Meusburger, and supported with a cash prize of £500 donated by the Polymer Machinery Manufacturers and Distributors Association (PMMDA): Leah Ebbs of OGM, Cody Etchells of Complexa HPE, Youssef Hafid of Pentagon Plastics, Nathan

Marcus Brigstocke to host Plastics Industry Awards 2023

Marcus Brigstocke, star of TV, radio and stand-up comedian, actor and writer will host this year’s Plastics Industry Awards, a glamorous, black tie gala evening with live entertainment at the Intercontinental London Park Lane on Friday 17th November. Thanks to a record entry this year, there are more than 70 finalists across 14 categories.

ABOVE – Comedian Marcus Brigstocke

“Four individuals have been nominated in the new Rising Star category: Rowan Fletcher of IPL Global, Daniel Kelk of Plastek UK, Luke Parsons of Summit Systems and Luke Brown, also from IPL Global”

Plastics magazine and website, all of whom are represented on the judging panel. A limited number of tables for the gala dinner and awards ceremony are currently available via the awards website. Tickets include a champagne reception, four course dinner with wine, awards presentation, afterdinner entertainment and charity casino.

Hensley of Reliance Worldwide Corporation, Rebekah Parsons Tex Plastics, Sierra 57 Consult and Benjamin Smith of Berry Norwich. Interplas is sponsoring the champagne reception in celebration of its 75th anniversary this year. The after-show entertainment and party are sponsored

by ENGEL UK and KraussMaffei Group UK are sponsoring the winners’ champagne prizes. Arburg is sponsoring the Charity Casino at the event, with all funds raised going to Myton Hospice, which serves the area around Coventry, Rugby and Warwick. The casino winner’s

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prize is a luxury dining experience at The Shard in London. The awards also enjoy the support of multiple industry associations including The BPF (British Plastics Federation), the GTMA, PMMDA (Polymer Machinery Manufacturers & Distributors Association), the SPRA (Scottish Plastics & Rubber Association), and Sustainable

LEFT – Karen Laird, Editor, Sustainable Plastics at the last PIAs

To book a table and to see a full list of 2023 fin alists, visit: www.plasticsawa rds.com

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INDUSTRY NEWS

TDP creating lasting digital memorials on recycled plastic benches An award-winning Derbyshire sustainable business making outdoor furniture from recycled plastic is helping tell the stories of those who have passed on, with a new memorial bench digital platform. Wirksworth-based TDP Ltd, recently crowned with a coveted King’s Award for Sustainable Development, is launching ‘My Place and Story’ this month. The platform will allow those who buy one of TDP Ltd’s commemorative benches in memory of a loved one to add a QR code so that anyone sitting on it can scan the code and read the life story of the person commemorated. The QR code can also be used to record information about the place where a bench has been situated, with one of the first examples being Shipley Country Park in Derbyshire. TDP Ltd commercial director Kym Barlow, whose parents Rob and Anne set up the company, said: “We are very excited about our My Place and Story project and we hope that it may provide some comfort to those who want to remember their loved ones with a memorial bench, to know that others can now find out more about their life. “Memorial benches are a lovely way to remember those who have left us. They give an opportunity for people to sit quietly in a place that person used to visit, and think about the happy times. Here at TDP we have gone one step further and created a digital platform so that people sitting on a memorial bench can, if they choose, find out about a person’s life by simply scanning the code on their phone. “Everyone deserves to be remembered and we hope that our scheme will allow more memories to be preserved. “We also felt it was important for people to be able to discover more about places they visit, too. The QR Code placed on one of our benches can be used for visitors to places to discover more about where they are, including its history and interesting landmarks.” One of the first life stories 28

to be commemorated in the benches is former Welsh international rugby player Brian Davies. The bench commemorating Brian, who won three rugby caps for Wales in the 1960s, sits proudly outside the rugby club house at Pentrych near Cardiff – his last club before he passed away in September 2020. It is among the company’s first to feature a QR code so that anyone passing by can learn more about Brian’s life and the reason why his memorial bench is situated at Pentrych. Brian’s widow Enid said she could not be more pleased and touched that her husband’s story was being commemorated in such a way. She said: “I think it’s a lovely idea, it really is. You see these plaques put in parks and you think ‘that’s nice’ – you see a name but there’s always a story too. I think it’s a lovely thing to do, to not think of sad things but to think of all the joyous things.” Those who happen to pass by the bench commemorating Brian Davies can now find out all about the man whose rugby playing career started out at Stradley Park Llanelli near his home village of Llangennech. He went on to win his first cap for Wales in a 1962 game against Ireland. Brian remained a well-known voice on rugby as a radio and television commentator, and he lent his expertise to Pentrych Rugby Club by transforming the way players trained and played. TDP’s benches are made from 100 per cent British recycled plastic, with company owners Rob and Anne passionate in their mission to prevent plastic from getting into landfill where it often ends up clogging up waterways and oceans. With every order, TDP provides a certificate with detailed information about how much plastic has been saved from the

oceans, and how much CO2 has been prevented from going into the atmosphere too. A Dale Commemorative bench, for example, contains recycled waste from 36,985 plastic bottle tops, stopping 1.49 cubic metres of plastic from going into landfill. Environmentally speaking, the saving is the equivalent of a 975 mile car journey – around the distance from London to Florence in Italy. Rob said: “The idea behind My Place and Story is to create lasting memories and stories to pass on to future generations. It seems very fitting to us that by

using recycled plastic we are helping make not only furniture that is long-lasting and durable, but with our unique digital platform, memories that will live on for a long time too. It’s great to think that we can help preserve stories of people’s lives that will then form part of our cultural history for future generations.”

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INDUSTRY NEWS Taking home the Horners award for Plastics Innovation and Design is: Suscons’ Emergency Relief Shelter. Its shelter is made from 75% recycled PVC window and door frames and can be 100% recycled after its 10-year lifespan without significant loss in physical properties, creating a closed loop humanitarian society. They can be quickly erected, do not require skilled labour, and provide not only emergency shelter but also longer-term temporary accommodation considering their lifespan. As the Horners Committee found it to be a practical innovated solution to long term displaced families and homeless people not just in the UK but globally, they also chose to accord Sucsons

Winners of 2023

The event was also attended by local councillor Mandy Darling, her assistant Lily and Mandy’s ‘seeing eye’ dog Pepsi. The final guest was Jim Davison from MAKE UK, who wanted to show his support for our participation in NMD23. The event marked a milestone for the team at Hymid – they welcomed the largest number of visitors we have ever hosted in a single day. The students embarked on an educational journey, exploring the inner workings of a manufacturing business. They not only learned about the intricacies of plastics manufacturing but also engaged in friendly competitions and activities, sparking their creativity, teamworking skills and critical thinking. As the students travelled around the production facility in teams of five, they were awarded points for interest and engagement; undertaking measurement and pricing exercises. Students were also challenged to design a novel trophy using the company’s 3D printing capability. The results are being compiled, with the competition winner being announced ‘on our social channels soon!’ The company will be 3D printing the winning team’s trophy design and then presenting their trophy plus some ‘extra goodies’ at their school assembly.

It is claimed that guests were equally impressed by what they saw, commending the professional attitude of staff and the pristine operating environment, helping to squash some common misconceptions about manufacturing being a noisy, dirty place. According to organisers ‘We were thrilled to see their support for the event, for Hymid, and for our fellow MAKE UK members, as we collectively endeavour to dispel some myths about manufacturing, to educate the next generation and to garner interest in the promising future for UK manufacturing.’

Horners Awards announced After an incredibly competitive year, the Horners Committee announced the winners of several awards for innovation within plastics. with the David Williams Award (presented to those who make an outstanding contribution to society through plastics). This year’s winner of the Bottlemakers Award was Berry Superfos with their Closed Loop Paint Containers, in which waste paint is collected and re-engineered into new paint, while the plastic containers in which the paint was originally packed are recycled into new paint cans for the recovered paint. This reduces the environmental impact of both the paint and its packaging through the reduction of

Hymid opens its doors to students for National Manufacturing Day Hymid recently took part in MAKE UK’s National Manufacturing Day 2023 (NMD’23); ‘a day filled with enthusiasm, learning and collaboration’, as the company opened its doors to 60 GCSE students from four local secondary schools, their teachers and distinguished guests including the MP for Torbay Kevin Foster and the Civic Mayor for Torbay Mark Spacagna.

product promotes all the benefits of sustainability (lower embodied carbon, strength, and lower weight) without compromising on long term effectiveness. The Chairman of the Worshipful Company of Horners Awards Committee Professor Stefaan Simons stated: Once again, we had a strong field of entries, covering everything from kitchen flooring to antimicrobial chemistry. However, Suscons’s Transitional Shelter really stood out for its inventiveness and its significant societal impacts, not least in the closed-loop recycling of waste PVC. For

this reason, Suscons are worthy winners of both the Horners’ Award and the David Williams Award. We also congratulate Berry Superfos as winners of the Bottlemakers’ Award for their closed-loop recycled paint containers. It is encouraging to see that both our winners are developing innovative closed-loop solutions that reduce, reuse and recycle materials and help us move forward to net zero carbon emissions. Sucsons and Berry Superfos were formally presented with their awards at the recently held Horners Banquet by the Lord Mayor. Polypipe Civils & Green Urbanisation will be commended at the BPF Annual Dinner. Those interested in entering next year’s awards can find details on the BPF website.

waste product sent to landfill and the carbon emissions associated with incineration, saving approximately 2.8 tonnes of CO2 for each tonne of plastic not incinerated. The winner of the 2023 British Plastics Federation Award is Ridgidrain by Polypipe Civils & Green Urbanisation - the very first twinwall surface drainage system in the UK with Highways Authority Product Approval Scheme status, which is made from 100% recycled, high strength HDPE. The judges were impressed with its excellent performance, as the

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COLUMN

Dave Raine Dave Raine reﬂects on his first year as Chairman of the PMMDA.

Cautious optimism

s I sit and write this month’s article, I am suddenly aware that this will be the first one of my second year as Chairman of the PMMDA - the last twelve months have flown by, and I have to say what a year its been. Since late 2022, we’ve seen the election of our first nonmale committee member in the PMMDA, our first female speaker at the annual SPRA dinner, a complete re-vamp of the PMMDA website, and our first post-Covid Interplas. Whilst none of these in isolation should be seen as either ground-breaking, or even unusual in current times, I for one am very proud to have been a small part of these, and believe these are the little changes and continuous improvements we can make to build upon and keep the change momentum up. Reflecting on Interplas 2023, there seems to be a sense of optimism, albeit cautious, about opportunities, and I believe this in no small part is a result of the excellent work Rapid News Group as organisers (and Mouldshop for their usual unparalleled contribution to the post show event). The atmosphere in and around the hall on Tuesday evening was terrific, and I believe helped to create a positive vibe about the event and the industry as a whole. In addition to the above, I personally felt very privileged

to have been nominated for the 75 at 75 wall, and I know many others who felt the same way - it was an honour to be named and selected, and be in the company of some real industry giants. 2024 is clearly going to be a challenge, and the associations will, I feel, be more important than ever in helping and guiding companies through difficult times. However, one thing is very clear to me - there are many dedicated individuals in the industry who are equally, if not more passionate than me, and our aim must be to

ensure this enthusiasm, coupled with the positivity created by Interplas, is not allowed to wane - we must keep the momentum going, and investment in training and education, both from a skills and also from a plastics image point of view, is essential if were to secure the long term future of the industry. I for one am fully committed to this. Dave Raine Chairman, PMMDA

“Reflecting on Interplas 2023, there seems to be a sense of optimism, albeit cautious, about opportunities, and I believe this in no small part is a result of the excellent work Rapid News Group as organisers (and Mouldshop for their usual unparalleled contribution to the post show event). The atmosphere in and around the hall on Tuesday evening was terrific, and I believe helped to create a positive vibe about the event and the industry as a whole.”

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COLUMN

Philip Law Philip Law, director general, British Plastics Federation, reports on this year’s BPF annual dinner.

An air of success at the Annual Dinner Presided over by President Nigel Flowers BPF’s 90th Anniversary Annual Dinner passed off very successfully with over 500 attendees. As with Interplas, this is a strong sign that despite challenges in the marketplace, companies want to interact, and indeed see benefits and solutions in sharing their experiences and acting jointly through their BPF. Nigel reviewed the upcoming landscape: “The immediate task dominating the year ahead will inevitably be strongly political. Already the BPF has been laying out its stall to the political parties and has had meetings with Shadow Environment and Business Ministers emphasising our key role in helping to achieve a circular economy and a low carbon world”. He urged, as many member firms as possible to attend our Parliamentary Reception on 21st November and to bring their Member of Parliament with them. He added: “I think we all are dismayed by the government’s stop, start, stop approach to legislation; particularly those affecting consistent collection by Local Authorities and Net Zero Carbon. The Parliamentary Reception will be a great opportunity to help get chemical recycling across the line, especially after the current consultation on Mass Balance”. Nigel told the audience that the BPF’s work on productivity is now nearing completion. This was begun just in the wake of Brexit to help improve our international competitiveness in

a harsher trading environment. He said: “We have Working Groups on Material, Product Design, Tooling, Equipment and Digitalisation. Certainly my company believes that productivity gains of 50% or higher are entirely reachable using a combination of tools which the BPF will publish”. Nigel said: “Related to this is another factor which I passionately believe in. The need to attract skilled labour into the industry. Time and again, survey after survey shows that the most consistent factor holding the industry back is the lack of skilled personnel. BPF has an Education & Skills Committee chaired by Jo Davis of Broanmain. She needs your help and support. We are producing highly effective tools to help you engage with schools. We now have a Careers Ambassadors programme which helps you access schools to explain the careers available in the industry. We can give people international careers – fantastic opportunities. But it needs you, the industry to take initiative and sign up to Careers Ambassadors”. Nigel was pleased to present three awards. The BPF Energy Award for energy efficiency achievements went to James Walker & Co of Cockermouth and the BPF’s own Award for Innovation, Design and Sustainability went to Polypipe Civils and Green Urbanisation Rigidrain, the first twin wall pipe for surface drainage made from 100% recycled HDPE. The BPF’s Gold Medal for Services to the

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BPF and to the industry was presented to Dr Robin Kent, ‘an Antipodean in UK plastics’. Over many years Robin has given great support to the BPF. He is a former Chairman of the BPF’s Windows Group Technical Committee and most recently the BPF published Robin’s ‘Sustainable Management in Plastics Processing’, which Nigel described as an absolute ‘tour de force’. He’s a great expert on all aspects our operations. His career includes Thermos, Rehau, and Heywood Williams where he operated at Board level. He then set up his own Consultancy Tangram Technologies. He made Energy Efficiency his own special subject, long before it became fashionable. I described the BPF’s progress through its 90 year history. We’ve survived 20 Prime Ministers from Ramsay MacDonald through to Rishi Sunak, we survived a World War when our office windows were blown out in Pall Mall during the Blitz, we embraced the UK’s entry into the European Free Trade Area and then subsequently embraced membership of the Common Market and witnessed, like innocent bystanders at the scene of a major accident, the UK’s withdrawal from the EU. Additionally, we survived three energy crises. To help the Annual Dinner on its way I invoked the spirit of the late President of GE in the United States, Jack Welch, the man who put ‘Noryl’ on the map. His advice to his managers was always ‘you can never celebrate your successes enough’.

FROM PLASTICS. TO THE FUTURE.

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