BP&R Sept 23

A triumphant return awaits

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ISSN 0307-6164

Incorporating Polymer Age and Rubber and Plastics Age.

You might notice this issue is a little bigger than usual. There’s just too much to write about at the moment! The industry is facing unprecedented challenges on several fronts. And yet, Interplas is set to be bigger (in terms of exhibitors in attendance) than any edition since 2002. What’s that phrase? Necessity is the mother of invention! And here we are, dealing with absurd energy costs, inflation and interest rates, supply chain disruption, conflict abroad, climate change and ever-tightening regulations and policy impacting on design/ manufacturing choices. That’s a perfect storm of necessity, crying out for some major invention – and fast.

So it’s no surprise, in some ways, that the industry is ready to come together on such a large scale in the UK. I may be biased, since this magazine is owned by the same company that organises Interplas, but I genuinely don’t know of a better platform for anyone facing any of the above challenges.

We've put together a stellar conference on the brand new Interplas Insights stage, a conference in which we’ve tried to address all of the aforementioned challenges with our roundtable-style panel discussions. Some of the leading names in injection moulding machinery will discuss big and small steps processors can take to save energy. It’s not a pitch for new machines, although we will discuss the advances in tech over the last 20 years. It’s a chance for the machinery pros to talk through the various parameters and setups that have proven most effective for their customers. And in another session, we’ll be hearing from those very customers. Some of Britain’s leading contract moulders will be taking to the stage for the first time ever, to discuss the challenges of the last few years, the resurgence in reshoring, and the current state of the market.

I’m particularly excited for the first day, when we will be announcing the 75 most influential individuals in UK plastics, as voted for by the industry. Interplas is 75 this year, and so what better way to

celebrate than to honour the people who keep the UK industry competitive on the global stage? I’ve seen the final list, and I can confidently say, the industry has put forward an impressive cross-section, covering product designers, process engineers, polymer scientists, and much more. All of them, champions for the responsible use of the material of the future.

Finally, if you’re planning to join us at the NEC, and I hope you are, make sure you spend some time in our all-new Recycling Zone. We’ve designed this to try and ensure the market gets its collective genius together in one place to solve the problem of the shortage of useable recyclate, so that people can stop paying the PPT. We’re an ambitious bunch at Rapid News Group, and we understand the true value of face-to-face events. Interplas 2023 is so much more than a trade show: it’s your chance to solve your problems, kickstart your ideas, and meet the people who’ll help you achieve your competitive potential.

Head of Content

DAVE GRAY

“Some of Britain’s leading contract moulders will be taking to the stage for the first time ever, to discuss the challenges of recent years, the resurgence in reshoring, and the state of the market”

British Plastics and Rubber

So here it is: after a two year wait, Interplas is back. The largest gathering of the plastics industry on UK shores returns for a three-day event that promises to inject more than just copious amounts of innovative materials: an injection of investment, the birth of new ideas, acquisitions, new job opportunities, optimism, learning and so much more await the plastics community at the NEC Birmingham.

Let the show begin

WORDS: Dave Gray

Let’s begin with a look at materials. The pioneers at TotalEnergies Corbion (formed in 2016 as a 50/50 joint venture of Total and PLA supplier Corbion) are showing considerable interest in the UK market and its appetite for more sustainable plastics. They’ll be bringing, to hall 4, stand E24, their line of ‘Luminy’ PLA bioplastics from annually-renewable and responsibly grown sugarcane. The product has drawn significant attention since its launch, with brand owners including IKEA, Danone and Carrefour selecting it for their products.

The portfolio includes products in four categories that can be used in various processes. These are: high heat PLA for demanding applications, standard PLA for general purpose applications, low heat PLA typically used as a seal layer, and PDLA used either as a nucleating agent or to create full stereocomplex compounds. Frank Duijzer,

business development

manager at the company (pictured right) told me: “Last year, the UK introduced a tax on non-recycled plastics. Luckily, TotalEnergies Corbion has championed the use of recycled PLA bioplastics for years. My colleagues have also helped many companies develop closed-loop systems. Beyond compliance, Luminy virgin and recycled bioplastics boast a 75% lower carbon footprint compared to traditional plastics without compromising on quality, functionality, and versatility.”

“I know I speak for my whole team when I say that we are dedicated to working with the UK government and businesses to foster sustainable solutions that resonate with their objectives.”

BELOW: Frank Duijzer, business development manager, TotalEnergies Corbion

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INTERPLAS 2023

But regulatory changes can be conflicting, as Duijzer points out: “This year, the new ban on many forms of single-use plastics, including biobased and compostable plastics, highlights the complexities of regulatory frameworks. While I applaud the intention to reduce single-use plastics, I am concerned that it includes bioplastics as I believe they are valid alternatives for the applications banned. In Italy, biobased and compostable single-use items are allowed and have proved to limit the amount of unsorted waste produced because these items can be recycled together with food waste instead of being sent for incineration or, worse, to landfill.

“I recognise the importance of collaboration between the private sector, governments, and industries. I know I speak for my whole team when I say that we are dedicated to working with the UK government and businesses to foster sustainable solutions that resonate with their objectives. Our expertise in developing cutting-edge bioplastics positions us as a reliable partner in meeting the evolving demands of both industry and the environment.”

CLEANER AND GREENER

Another materials firm focussing on sustainable processing, is Switzerlandbased Ultra System, founded 20 years ago by two entrepreneurs “with a common vision of a world without plastic waste”.

BELOW & INSET: Purging compounds support sustainable material and colour changes.

MEET THE SPEAKER

Rosie Lawton Applications Scientist M&I Materials Ltd

What will you be speaking about at Interplas?

The benefits of using synthetic esters as a hydraulic fluid in plastic injection moulding applications and how the properties compare with mineral oil lubricants.

Who should attend your session? Individuals from the plastic industry interested in the environment, sustainability, contamination control and improved machine/ production performance.

What will visitors learn?

Hopefully they’ll learn the differences in chemistry between mineral oil and synthetic esters. They’ll also hear about the benefits of using synthetic ester as a hydraulic fluid, which include savings, performance and environmental aspects.

Headquartered in Martigny, the firm produces a line of purging compounds, known as Ultra Plast. The compounds have been designed to work well on the latest generation of polymers and masterbatch, to provide fast colour or material change, fast re-starting after a shut down and regular maintenance.

The firm has gone from strength-tostrength, with mixing plants strategically located all over the world (USA, Mexico, Brazil, Switzerland, Russia, Thailand), and you’ll find them in hall 4, stand G94 at the show.

Roberto Benzi, executive at the firm told me: “We remain surprised every time we meet companies that do not know the existence of these materials.

“We understand their point of view and we are here to show and demonstrate that you can run your colour or material change in a faster and more economical way, without plastic waste.”

The firm says it has been shown that using raw material as a ‘cleaner’ generates higher costs, a less quality result, higher down-times, and higher energy costs.

But with customer expectations and specifications getting higher and higher, non-conformities like impurities, blackspots, shadows, or stripes are generally unacceptable, particularly when solutions like purging compounds are on the market.

The firm is hoping to use Interplas to de-bunk myths around plastic, against a backdrop of negative media attention. Ultra System also hopes to clarify some misconceptions around purging compounds themselves.

Benzi added: “The use of raw materials as “a cleaner” implies a bigger quantity

Richard Brown, Chair of Judges Design Innovation in Plastics

Dr Sally Beken Knowledge Transfer Manager –Polymers

Robin Kent Managing Director Tangram Technology

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

BP&R's editorial advisory board

of material and longer machine downtime (even hours sometimes), for achieving a non-optimal result; it’s like washing your hands without soap; a lot of water, a lot of effort, a lot of time, bad result.

“Another myth to debunk is that the purging compound is an additional cost. Ultra Plast has shown (and proved) that this is not true. On the contrary, purging professionally reduces production costs. And we will be more than happy to do this calculation together with you in our stand during Interplas 2023”.

To better illustrate the benefits, the firm will run daily practical demonstrations, purging an extrusion blow moulding machine with Ultra Plast.

Ultra Plast products are supported by many certifications, including foodcontact, REACH, ISO, FDA, White Room, no heavy metal, among others, and can also be fully recycled.

MATERIAL HANDLING, TEMPERATURE CONTROL AND RECYCLING

Stand BB10, hall 3A, will mark the return of Interplas stalwarts Summit Systems. A brand-new stand design highlights the growth and development of the company over the last two years. The new stand design amalgamates the three company divisions – plastics automation, process

MEET THE SPEAKER

Dr. Terence A. Cooper Chief Executive Officer ARGO Group International

What will you be speaking about at Interplas?

I’ll be giving a presentation on the advances in physical and chemical (advanced or molecular) recycling of plastics.

Who should attend your session? Scientists, engineers, plastic processors, converters and compounders, packaging experts, designers, recyclers and reclaimers, and market developers who are interested in learning more about advances in non-mechanical recycling and its necessity.

What will visitors learn?

The inadequacy of current mechanical recycling technologies and infrastructure to produce the amounts of recyclate, particularly for filled, coloured and contaminated plastics, mixed plastics and film structures, and the necessity for non-mechanical recycling processes, especially for food contact grade.

Physical recycling processes such as selective extraction to recover pure polymers while leaving the molecular structure intact.

Depolymerisation/repolymerisation recycling processes for condensation polymers (particularly PET) and polystyrene. Thermocatalytic recycling processes to produce feedstocks for making new virgin-grade plastics, particularly for polyolefins. And finally, oxidative and microbiological upcycling processes of plastics to functional materials to make high-value polymers.

LEFT & TOP RIGHT: The firm’s offering of materials handling, temp control and recycling equipment will all be on display.

cooling, and recycling.

On the plastics automation section of the stand, visitors can preview the full range of products from global suppliers such as Maguire, MB Conveyors, Movacolor, Plastic Systems, and Vismec.

A must see is the ULTRA Vacuum Dryer from Maguire. This advanced drying technology isn’t just removing moisture; it’s conserving energy, with ULTRA Dryers saving on average 60 to 70% energy when compared to desiccant dryer alternatives. Other reported benefits include an increase in production time, reduced maintenance, and saving materials from possible degradation and damage. The Summit team is encouraging visitors to try a new Maguire Energy Saving Calculator, to calculate the savings made possible by the vacuum drying technology.

Another drying alternative making its debut at Interplas is the DryCube from Vismec. The technology combines the efficiency of the rotor wheel dryer with an integrated pneumatic conveying system, making the process more streamlined,

Dr

Michael Junior

Hopkins Managing Director Ross Polymer Services

Pravin S Mistry Global CEO PREA Ltd.

Professor Edward Kosior CEO and Founder Nextek

Dr Thomas Bennett Research Fellow University of Manchester

INTERPLAS 2023

adaptable, and user-friendly. New for Interplas, is the Movacolor offline dosing unit; an expansion to the gravimetric dosing unit, this off-line dosing option is mainly aimed at the medical cleanroom market. Mounted away from the process, it allows for precision and eliminates the high-risk tasks of working on top of injection moulding machines or extruders, resulting in reduced vibration influence on the dosing process.

Moving over into the process cooling section of the stand, visitors can

MEET THE SPEAKER

view the range of process cooling and temperature control equipment from Frigel. The highlight here is the Microgel Syncro, the latest model, which reportedly offers an increase in production efficiency of up to 60%. Summit says it has proven ROI stats which it can share with visitors to the stand.

Anne

Hitch Business & Project Development Lead RECOUP

What will you be speaking about at Interplas?

I will be looking at the questions of plastics recycling and highlighting some key citizen insights and how this relates to kerbside recycling behaviours. Exploring the recyclability/commercial viability conundrum and seeking to rationalise the conflicting advice between recyclability and target/non-target listings for kerbside recycling. The challenges and opportunities of films and flexibles and material substitution will be explored. Where are we with compostables and bio-degradables on the ground and compatibility with existing strategies.

Who should attend your session? Local Authorities, brand owners and retailers. Anyone looking to learn more about the challenges of kerbside recycling. Those seeking to understand/ hear about how the boundaries are being pushed to drive recyclability.

Anyone interested in learning more about the linkages between the different parts of the value chain and how to future proof their plastics strategies.

What will visitors learn?

Insights from trials and projects being delivered throughout 2023 on kerbside recycling, research, and reports on sector specific topics such as agri-plastics, toys, textiles. Early insights will be shared on the RECOUP 2023 citizen insights work. Learnings from a number of Local Authority communications projects will be shared. This will all be related back to proposed legislation.

The newest expanding division of Summit Systems Group, Summit Recycling, specialises in not only the supplying of recycling equipment such as granulators and shredders from suppliers Zerma, TRIA and MO-DI-TEC, but also the trading of recycled and selling of plastics materials. The division’s recent expansion supports the recycling and waste management sectors in the UK and Irish market. Most recently, the group signed a cooperation deal with Amut, the Italian manufacturer of high-quality extrusion lines and recycling plants – keep an eye on BP&R for more news on that in coming months.

For processors looking to improve their inhouse recycling capabilities, Summit Systems is also the exclusive supplier of Zerma machinery in the UK, stocking a wide range of both very large and small granulators, single shaft shredders, which are designed for efficient recycling of various materials in all shapes and sizes.

With its focus on the recycling and waste management sectors, Summit has become experienced in challenges like maintaining in-house granulation quantity, leveraging recycled content in finished products, and ensuring highquality final materials. With its line of Zerma granulators and shredders, the group says it can enhance productivity, contributing to a greener and more sustainable future.

FREE TOOLMAKING QUOTATIONS ON-SITE

One of the many firms displaying the best of British engineering will be Faulkner Moulds, in hall 4, stand J22. At the stand will be senior members of Faulkner Moulds’ team, including lead toolmakers, designers and project managers, hoping to meet with brand owners and product designers to discuss new and existing projects.

Managing director Duncan Faulkner, said: “We are very excited for this year’s show,

ABOVE: Faulkner Moulds will showcase the best of British engineering and toolmaking expertise.

as we have so much to share with the visitors. At Faulkner Moulds, we never stand still. With each passing show, we further develop our service offering. Our pioneering approach to technological investment and skills development means we among the best in our field. We would love to meet potential customers to discuss how we can harness our expertise to meet their toolmaking needs”.

In 2024, the Yorkshire toolmaker will celebrate 30 years of toolmaking excellence. Three times winner of the prestigious UK Plastics Industry Award for ‘Toolmaker of the Year’, in 2022, the group was also awarded ‘Manufacturer of the Year’ by Business for Calderdale. The award recognises manufacturers that go “above and beyond”. The judges gave the award to Faulkner Moulds for its “outstanding innovation, initiative, efficiency and customer service, and fully engaged workforce”.

At the stand, the Faulkner Moulds team is offering a free budget price rapid quotation service. Visitors need simply to bring project details or a sample to stand J22, and the team will provide a free, rapid quote during the show. The budget price will be calculated using advanced quotation software, developed in-house.

Also at the stand, the team will showcase examples of recent projects, including award-winners and world-firsts. Faulkner Moulds specialises in multi-cavity high production tooling with fast cycle times

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• New possibilities for product designers

• Distribution of different plastic components or colours over a very small area

• Channels can be intertwined with each other

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and can manufacture complex tooling such as twin-shot, overmould and unscrewing mechanisms. The Yorkshirebased toolmaker also provides services for tool repairs, modifications or servicing.

Serving all sectors, including medical, packaging, electronics and automotive, Faulkner Moulds delivers micronsaccurate tooling, and says it does so at competitive prices.

Caroline Faulkner, director, told this magazine: “The team has seen a definite shift towards reshoring of tooling in recent months. By investing in technology, we have greatly decreased fitting times and created efficiencies that benefit our customers in the reduced tooling costs we can offer them”.

Last year, Faulkner Moulds again installed pioneering toolroom technology, with an innovative robotic production cell which is a ‘UK-first’, adding new capabilities to its in-house mould tool manufacture. The production cell supports multi-cavity, highproduction tooling.

MEET THE SPEAKER

Katherine Fleet  Head of Sustainability & Circularity RECOUP

What will you be speaking about at Interplas?  RECOUP launched the inaugural edition of ‘Reusability by Design’ in early 2023 to assist stakeholders with the design of reusable plastic packaging that meets the needs of the value chain from packaging manufacturers, packer/fillers, brands, retailers, consumers, service providers through to waste management companies. Based on research, surveys, workshops and interviews, the guidance highlights the need for collaboration alongside consideration of the whole value chain needs when designing reusable packaging.

Who should attend your session?

Anyone in the value chain who uses or has an interest in using reusable packaging.

What will visitors learn?

The key areas for focus of design when considering adoption of reusable packaging. Understand the requirements of all areas of the value chain to ensure that appropriate and sustainable choices are made for reusable packaging. Learn how technology enabled reusable packaging (e.g. use of RFID) can help to achieve scale.

MAKING CONNECTIONS

With a heritage of collaborating with companies in the plastics industry for more than 60 years, Stäubli Fluid Connectors is recognised as having unrivalled expertise across all areas of the sector. Stäubli provides a comprehensive range of solutions that save time at every stage in the injection moulding process, increasing productivity, efficiencies, and profitability. Businesses within sectors such as automotive, white goods, home appliances, packaging, IT, electronics, building construction and many more rely on the quality, performance, and reliability inherent in Stäubli’s product offering.

The Stäubli Fluid Connectors stand at this year’s exhibition will feature a range of different products and technologies

including energy connection, process automation, robotic tool changers, end-of-arm-tooling, quick mould change solutions and mould temperature control.

Of particular interest to visitors to the Stäubli Fluid Connectors stand will be the latest in magnetic mould clamping technology –QMC123, the result of the recent strategic partnership between Stäubli and Mag Autoblok – Tecnomagnete. The combined expertise of the two companies has taken the capabilities of magnetic clamping technology to a new level, with enhancements and improvements across a number of key areas. Also on show will be examples from the company’s comprehensive range of Automatic Robotic Tool Changers and End-Of-ArmTooling (EOAT).

Stäubli can be found in hall 4, stand number H32, where the company’s experts will be on hand throughout the show to offer advice on how Stäubli products and solutions can improve plastics manufacturing processes.

ANCILLARIES AND MORE

TH Plastics, a supplier of ancillary products and solutions, with a portfolio of customers which includes some of the most high-profile and technically demanding plastic manufacturers in Britain, will return to hall 4, stand D90. As the exclusive distributor of Moretto, Rapid Granulator, Altero and Crizaf in the UK, TH Plastics supplies, installs and services ancillary equipment across the British plastics industry.

TH Plastics’ line of equipment will include material feeding, dosing, blending, drying, cooling, conveying, granulating, and re-pelletising. Each system will be showcased on the stand so that visitors

RIGHT & OVERLEAF:

TH Plastics’ line of equipment will include material feeding, dosing, blending, drying, cooling, conveying, granulating, and re-pelletising

“The team will provide a free, rapid quote during the show. The budget price will be calculated using advanced quotation software, developed in-house.”

INTERPLAS 2023

can experience, start to finish, how each component may be used to enhance the functionality of their facilities and educate on how systems can be further developed to ensure maximum efficiency and future proofing. Demonstrations and interactive displays will also be provided on the stand to highlight the remainder of TH Plastics line of equipment.

One of the products that will be featured is the new DGM Mini Blender from Moretto. Launched at K Fair 2022,

MEET THE SPEAKER

David Russell

Owner

David Russell Associates

What will you be speaking about at Interplas?

I will be describing how savings and technical innovation will accrue from the use of ‘AI’ – i.e. 21st century computing power with simulation software developed from within the blow moulding and thermoforming sectors.

Who should attend your session?

Designers, early in the design phase, will quickly see the outcome of their designs, identify risks and respond to optimise performance and cost. Manufacturing managers and process engineers will avoid costly and time-consuming tool modifications and will improve process settings, cycle times and costs. Lessons learned can be applied to reduce costs in existing jobs.

What will visitors learn?

Visitors will learn from case studies how simulation will support and improve – but not replace – their expertise.

this blender is aimed at machines under 30kgh, encompassing high levels of accurate dosing for up to four materials and reducing waste from production inconsistency and material wastage.

Rapid Granulator will have a host of equipment on the stand which will feature a 150 series flying blade and OneCUT slow-speed press-side granulator, a 300 Series flying blade granulator and the new GT1100 Thermoforming granulator.

The 300 series has a distinctive “open-hearted” design which provides operators with a quick and simple access to the granulator cutting chamber for cleaning and maintenance. The 150 series will be a popular product with plastics manufacturers, with TH claiming it is “the world’s most popular” press-side granulator.

The water ring from Altero’s re-pelletising line will also be on display. The refined pelletisation line has established a technique for economically and effectively turning plastic waste into high-quality reusable pellets, as well as a concept for sustainable recycling.

After the newly announced partnership earlier in the year, the stand will also feature Crizaf conveyors showing their automated handling capabilities with a range of conveyors, box shifters and counting devices to help customers maximise production efficiencies. Due to partnerships with Moretto, Rapid Granulator, Altero Machinery and Crizaf, TH is able to offer a “closedloop” recycling system. Green initiatives are a major part of the overarching sustainability goals for many companies, and TH Plastics encourages visitors to

bring with them problems for discussion to test TH Plastics engineering know-how in their manufacturing facilities.

A NEW LAUNCH FROM SISE

During Interplas, temp control specialist SISE will launch its new generation of E.THERM-W90 temperature mould controllers equipped with a new 7’’ colour touch screen developed by the company. This efficient new generation provides optimised hydraulic circuits for cooling. It also provides additional protection for the interface sockets. Regulation control is adaptive depending on the type of appliance. Advanced and programmable management of alarms and failures ensures optimal operation. The customisable colour touch interface can be adapted according to the options installed. Three levels of communication are available: 0-10V, Arburg protocol and E82.1 (OPCUA). This flexible modular generation incorporates a unified colour user interface for the entire range of temperature controllers, with installable option packs. All components are accessible and replaceable for easy maintenance. Furthermore, logging and graphic display of process data, enhanced

We’re committed to supporting the UK plastics industry

Our masterbatches, compounds and roto powders are made at our modern facility in Suffolk. Sustained investment in our site ensures we’ll be manufacturing high-quality products within the UK for years to come. We understand the importance of maintaining short lead times by producing our materials on British soil. We offer accurate plastic colourants, plus products and services to support UK moulders in achieving their commercial and sustainability goals.

Reduce weight, costs and environmental impact. Our new blowing agent masterbatch allows our customers to lightweight their mouldings. This can offer a reduction of up to 10% in material volumes and costs.

Our blowing agent masterbatch was developed by our inhouse technical team and is manufactured at our UK site. It relies on an endothermic reaction. This is safer than exothermic blowing agents which are more widely available. Our product outperformed competitor blowing agents in recent, independent trials. Call us to request a free sample

Rich ‘piano’ blacks with NIR recycling detectability.

Our extensive experience in colour chemistry allowed us to develop black masterbatches to deliver a rich, high-gloss ‘piano’ black finish in PP and PET. These masterbatches are EU food contact compliant.

Our NIR detectable piano black masterbatches maintain a premium appearance, whilst safeguarding the potential for the end component to be sorted in NIR recycling facilities. These masterbatches don’t rely on high levels of carbon black pigments which typically pose a barrier to the recycling of black plastics.

Call us to request a free sample

Fast colour matching, plus an odour reducing additive. We deliver dozens of colour matches for use in recycled plastics every week. Our colour suite provides an option to visit us, to approve colour samples on-site. This free service saves time as several new colours can be approved in a single day. This facility is great when colouring recycled plastics. We can demonstrate exactly how a specific batch of recyclate will impact the end colour of your moulded component. We’ve also developed an odour neutraliser additive to reduce the smells often apparent in PCR material.

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BLOWING AGENT

NIR DETECTABLE BLACK SOLUTIONS FOR PCR

instrumentation as well as event ensure process traceability and data transmission using the open OPC-UA communication standard.

In terms of hot runner temperature control, SISE will also present its new MV3 generation which will be capable of regulating up to 336 zones. It has been deployed in early 2020 on six platforms (XXS, XS, S, M, M, L and XL) with four available power cards (2.5 A, 15A, 15A, 20A and 30A) to adapt the offer to various industries such as packaging, automobile, cosmetics, medical and electrical engineering.

It is sold with 7’’, 10’’ and 12’’ integrated touch panels and a Linux-based software program developed by SISE. Pivoting and detachable side panels facilitate access to power and thermocouple cards. This new generation includes functions such as four soft start modes, zone grouping, PTI function for thermocouple anomalies, ‘Moldscan’ for hot runner system real-time diagnosis, as well as real-time material leak detection. The system is multilingual (up to 12 languages available) with unlimited backup of mould programs.

Lastly, recording and monitoring temperatures in production, and communicating via multiple protocols is in-line with the Industry 4.0 requirements.

MEET THE SPEAKER

Katie Reed Marketing Manager BEC Group

What will you be speaking about at Interplas?

I’ll be taking part in The Big Debate: Reshoring and Contract Manufacturing, a panel discussion between members of the trade moulding industry.

Who should attend your session?

Members of the contract manufacturing community should pop along for a listen. Additionally, many people within manufacturing that could be positively impacted by reshoring might find some useful takeaways for the future of their business.

What will visitors learn?

Attendees will learn about the different factors in the past, present, and future that impact both the supply chain and the contract manufacturing sector as a whole. We will also be exploring the landscape of reshoring for plastics manufacturing and the benefits of bringing work back to the UK both for the customer and the country.

world, have managed our way through disruption caused by limited material supplies through COVID 19, and unprecedented price increases, and now while prices start to ease, the cost of energy is affecting many businesses.”

CJP has been long established as a PVC compound specialist, with many years of experience in the design and development of PVC-based products, offering technical support and training for business that either want to process PVC or already use PVC and a have need to improve processing conditions.

The firm now has a third generation of family management, and will be celebrating 40 years in business in 2025. Benyon added: “Interplas has been an important event for CJP since our first show in 2008 when we launched the UK distribution of Dyna-Purge. Interplas offers the opportunity to meet many of our customers and engage with new businesses. We continue to expand our range of products, as well as improvements to existing product lines.”

The UK supplier of the Dyna-Purge purging compound, the group is always keen to stress that manufacturers don’t need to lose costly materials, energy and production time. Dyna-Purge L has now been introduced to add improved flow when used for injection moulding hot runners with stack tools and fine gates. The high-flow, highly-stable purge has also proved effective for blown film, blow moulding and sheet extrusion process applications with its high nonabrasive, non-chemical scrubbing action suitable for all materials within a 138c–329c range, FDA compliant, non-toxic and simple to use straight from the box.

A VARIETY OF NEW MATERIALS

CJP Sales, a technical stockist of plastic raw materials offering an off-the-shelf service for general polymer grades as well as bespoke stock orders for call off, will once again return to the show.

Technical director Richard Benyon told me: “Our business focus has always been customer service, and it’s important for us to continue adding value for money for our customers. We, like many other businesses around the

The group also supplies Lucofin EBA manufactured by Lucobit AV, which uses the autoclave process to produce a low gel versatile flexible polymer with enhanced polarity properties for compatibilisation. Lucofin can be used as a moulding polymer to produce flexible soft touch parts, or an additive to increase impact.

Lucofin concentrate BA (Butyl Acrylate) content allows producers of film to extrude blends where EBA is added at a lower rate that EVA or other plastomers by increasing the mechanical properties,

ABOVE & BOTTOM: SISE will bring new temp control technology to Interplas

“Interplas has been an important event for CJP since our first show in 2008 when we launched the UK distribution of Dyna-Purge. Interplas offers the opportunity to meet many of our customers and engage with new businesses”

Who are you and what do you do?

Billion was Created by Mr. Léon Billion in 1949, the company has a vast experience in plastics injection moulding machine design and manufacture. In addition to standard thermoplastics IMMs, Billion specialises in multi-injection equipment, and has developed numerous specific plastics processing solutions. Billion is a solution provider and a service partner for plastics processors worldwide. Our headquarters are located in French Plastics Vallée in the heart of Europe, whereas a large network of subsidiaries and agents represent our know-how and expertise on an international basis. Our flexibility, fast response time and extraordinary service create extra value to our customers.

Why is the UK processing market important to you?

The UK market is important to Billion as it has always had a solid manufacturing industry. UK based customers appreciate high quality machinery built in Europe, that not only provides them with a reliable machine that can last for decades, but also a great return on investment.

Ask the experts: BILLION

Hall 4, Stand C4

With customers that require more from machines the UK not only provides us with a significant number of machine sales their quest for innovative features on an injection moulding machine assists us with pushing forward with developments.

Why is Interplas important to you?

Interplas is important to Billion because the number and quality of visitors that attend is vital to ensuring the Billion brand is kept at the fore of the market. Interplas always proves to be a great place to catch up with existing customers and to meet new prospects as well as display new machinery and process developments.

What are the key features of these machines?

One of our many innovations enables the producer to utilise a significant percentage of recycled content in a product but retaining the aesthetics of the component.

Simon Johnson, managing director, Billion UK

What challenges are your customers facing?

Not just our customers, but the industry as a whole is experiencing higher energy costs, higher labour costs along with other increased expenses, on the back of a tough few years. As ever, UK customers are resilient and find ways to carry on and make the best of the situations we all face by adapting and improving their manufacturing processes.

How can your technology help solve them?

Our machines are designed to be repeatable, reliable and energy efficient, especially our all electric Select2 range. Coupled with a Billion robot the package will provide an efficient production cell for our customers that can cost them up to 70% less in energy costs. Along with some of our innovative processes Billion are well placed to assist our customers finding the right solution to their needs.

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INTERPLAS

down gauging the film and increasing line production line speed and pressure, especially in stretch hood applications. CJP’s team will work with processors to formulated blends that will show increased production and cost savings.

Interplas takes place 26-28 September 2023 at the NEC, Birmingham.

MEET THE SPEAKER

Kristen Tapping

Director   GoRolloe

What will you be speaking about at Interplas?

• Cost effective ways of prototyping in-house. Design considerations. Recommended materials and equipment.

• Low volume manufacturing of prototypes for pilot trials

• Design for industrial manufacturing... considerations of polymers, manufacturing method, countries to manufacture in, and variations in tooling and unit costs.

Who should attend your session? Design engineers, polymer manufacturing companies, startups, students, lecturers

What will visitors learn?

How to develop prototypes on a budget. How to validate a product before investing large sums into tooling/ production.

A newbie’s guide to INTERPLAS

Danny Ball, junior editorial content producer for Interplas Insights and BP&R, shares his top ten features to look out for ahead of his first ever show.

With some of the most prominent speakers and exhibitors in the industry set to appear at the event, I’ve been spoilt for choice when getting this list together. With topics such as sustainability and diversity being featured prominently, it’s clear that the industry has a keen eye trained on the future.

DR ROBIN KENT

Net zero is becoming a dominant topic for society and is already driving fundamental changes to our lifestyles. Plastics processing is an enabling industry and will not only supply the products to achieve this transformation but the industry will also need to take action to reduce emissions.

This presentation takes processors through the essentials of net zero from the country level to the processor level and gives an overview of what net zero means in practice for our industry. The seminar covers the essential actions needed to start the process of decarbonisation and getting to net zero.

Visitors will learn:

1. Why net zero is important to the plastics industry.

2. What the transformation is going to mean for plastics processing (and why the plastics industry is an essential partner in achieving net zero).

3. What actions the plastics processing industry has to take to achieve net zero.

WITTMANN

Wittmann will demonstrate its expertise in the areas of LSR processing, and in processing alternative, bio-based materials. A major focus of the machine presentation lies on the processing of special materials. The SMARTlens, will be manufactured with a single-cavity mould supplied by the Austrian company Elmet, made of Dow Corning MS-5002, an injectable two-component silicone, for an adaptive driving beam.

In the second application, the company will display a bio building block, manufactured on anEcoPower 110/350 with the new B8X control system, using an eight-cavity mould supplied by Bioblo, Austria. This raw material is a compound made by Fasal Wood GmbH, Austria, from wood flour and post-industrial polypropylene supplied by Borealis, Austria.

SUMITOMO DEMAG

The IntElect 75 on display has been proven to lower energy consumption for mass-moulders by up to 75%. Additionally, the IntElect series now reportedly accounts for approximately 75% of Sumitomo (SHI) Demag‘s global order intake. For productivity and energy efficiency, the company claims

“This new generation includes functions such as four soft start modes, zone grouping, PTI function for thermocouple anomalies, ‘Moldscan’ for hot runner system real-time diagnosis, as well as real-time material leak detection.”

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The new standardised E 2600 chill vents save you time and money during design, production and procuring spare parts.

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Three sizes available with 3D data

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that the IntElect 75 ticks all the boxes. Customers that have switched from a 100 ton hydraulic machine to the IntElect 75 regularly see their energy consumption fall, according Sumitomo (SHI) Demag managing director Dave Raine.

ARBURG

The centrepiece is a two-component Allrounder More 1600 injection moulding machine, handled by a Yaskawa six-axis robot. Closures are capped and threads unscrewed directly in the mould. The high-end solution aims to eliminate the need for a second mould and additional assembly line. This significantly reduces the manufacturing costs. “We provide our plastics processing customers with efficient technologies to ensure their competitiveness. Especially during these more challenging economic times, not least due to increased energy costs, they can totally rely on us,” said Colin Tirel, managing director, Arburg. “We are seeing a growing interest among our customers in process capability, energy efficiency and digitalisation. Interplas is an excellent platform for showcasing these key topics and our new technology developments.”

6-axis robot arm and ancillary equipment provided by FANUC’s on-stand partner Hi-Tech Automation, the fully automated system will also display live data showing the amount of energy being used, as well as the cost to run the cell, to highlight the efficiency gains offered by the ROBOSHOT.

“As the FANUC ROBOSHOT is all electric, it uses 50-70% less energy than hydraulic machines, and 10-15% less energy than other all-electric machines,” says Martin Grimshaw, ROBOSHOT Sales Manager for FANUC UK. “In fact, it has been proven to be one of the lowest energy consumptions worldwide and one of the lowest total costs of ownership on the market.”

TM ROBOTICS LAUNCHES SHIBAURA INTO UK MARKET

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 will launch its new product offering from the Japanese manufacturer — the full all-electric injection moulding machine range, plus service and maintenance.

TM Robotics says Interplas presents an excellent opportunity to introduce this offering to the market and meet with potential customers in the plastic parts

manufacturing sector. From stand H41, the TM Robotics team will be available to discuss the full range of technologies from Shibaura Machine, including injection moulding machines, industrial robots and integrated solutions that use both technologies.

“The new offering includes the all-electric 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.”

SPEAKERS: WHAT TO EXPECT

With over 40 sessions and 70+ speakers scheduled to present, the conference promises to deliver a captivating line up of sessions that will empower visitors with the latest insights through thought provoking presentations and dynamic panels. The conference sessions will be dived into different themes including ‘Designing in Plastics: Materials of the Future’, ‘The Future of UK Plastics’, ‘A Road to Net Zero and A Circular Economy’, ‘Digitalisation for Sustainable Manufacturing’, ‘Diversity in Plastics’ and ‘Research and Development in Plastics’.

Highlights from this year’s agenda include:

Digitalisation for Sustainable Manufacturing:

DIVERSITY IN PLASTICS

Diversity in Plastics will also feature prominently at this year’s Interplas, with a conference stream on Thursday 28 September. The ambition for the meeting – which is open to all visitors and exhibitors at Interplas – is to announce the findings of the UK’s first survey into the state of diversity in the domestic plastics sector, and identify the key priority areas for recruitment and inclusive action. Diversity in Plastics is the natural evolution of the previous Women in Plastics initiative which was profiled at previous editions of Interplas.

FANUC’S ROBOSHOT

FANUC UK will feature a live on-stand automated manufacturing cell at Interplas 2023 (stand D60, 26-28 September 2023, NEC, Birmingham). Comprising a FANUC all-electric ROBOSHOT injection moulding machine, a FANUC LR-10iA

• The Importance of Industry 4.0 in the UK Plastics Industry to Jaguar Land Rover

• Achieving Sustainable Plastic Products with Data-Driven All-Electric Injection Moulding – Bloom in Box

The Road to Net Zero & A Circular Economy:·

• What the Industry is Doing to Tackle Plastic Pollution – Plastic Bank

• Top Tips for Plastics Processors to Achieve Net Zero –Tangram Technology

The Future of UK Plastics:

• The Big Debate: Reshoring and Contract Manufacturing – Panel in association with British Plastics & Rubber Magazine

• Innovations Changing the Polymer Sector – Panel in association with UK Circular Plastics Network & Innovate UK KTN

The Introducing Stage will complement the Interplas Insights Conference, providing further specialist insights into the future of plastics technology as well as technical know-how. There will be a wide variety of subjects covered from moulding and forming, materials, automation, software, testing, inspection, and more.

SUPPORTING THE UK MANUFACTURING INDUSTRY

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A 3D-PRINTED HOT RUNNER, and problem-solving nozzles

The Streamrunner is a hot runner from Hasco, made using additive manufacturing, for ‘maximum design freedom.’ While not new to the market, the firm has been developing the product for greater efficiency gains. Hasco claims that with this technology the flow channels can be optimally designed in rheological terms by completely avoiding sharp edges and areas with poor throughflow properties. This gentle passage of the melt leads to considerably lower shear rates and consequently to better quality of the injection moulded parts. Colour changes can also be carried out faster through the flow-optimised design because the material can be guided via large deflection radii.

Through the free threedimensional design of the runners, new possibilities are also created in multicomponent moulding, according to Hasco. Different plastic components or colours can be spread over a very small space and the runners can be intertwined. Hasco claims that this allows product designers to overcome existing restrictions in the design of plastic mouldings and to utilise new design options.

Because the hot runner gets by without separate diverting elements, very small nozzle gaps can be achieved.

A machine is only as good as the sum of its parts. Here’s a couple of recent innovations that caught our eye.

Depending on the chosen nozzle size, cavity-to-cavity distances (pitch) from 18 mm can be deployed. The manifold height can also be made 20-30 mm lower than with conventional manifold blocks.

The company says that the Streamrunner can be adapted individually for the respective application, and not just with regards to the form and size. If desired, it is also available as a fully wired modular system or as a completely assembled hot half with precisely coordinated control technology.

The technology may also prove to be cost-effective. The compact design requires smaller mould sizes and thus smaller injection moulding machines for production. In addition, the low mass of the manifold block reduces energy consumption, thus achieving an additional cost saving.

Hasco reports that it keeps a close watch on the rapid developments being made in the field of additive manufacturing and ‘constantly’ updates the manufacture of the Streamrunner to take the latest innovations into account. New developments are tested in-house at the company’s technical centre.

Meanwhile, in a recent realworld example, a manufacturer of an inhaler housings from Asia was struggling with colour streaks in its injection moulded components. The result was an above-average reject rate and high costs for quality control, since each housing had to be checked for possible defects. A common solution for this type of defect, brought only a slight improvement while resulting in longer cycle times and, as a consequence, lower productivity. After installing a Promix Solutions mixing nozzle however, the firm has reported

that the colour streaks were eliminated, with the cycle times changed back to normal settings and even shortened by a further four seconds. This resulted in an overall productivity increase which the customer puts at 12.5%.

“The investment costs for the Promix mixing nozzle were paid back within two months, thanks to the quality improvements and cost savings achieved,” according to the plant manager.

“Not only that, the higher homogenizing capacity in the mixing nozzle allowed the back pressure to be reduced from 280 bar to 80 bar, which corresponds to a reduction of around 70%. As a result, it was possible to significantly reduce wear on the gearbox and thus maintenance costs.”

“If you look closely, you will find machines in a lot of injection moulding companies that are not running optimally and injection moulded parts that are causing problems,” said Rolf Heusser, CEO of Promix Solutions. “You can think of increased cycle times, part warpage, colour streaks, high masterbatch consumption or weak points in flow seams, the challenges are adamant. But, often these problems can be solved simply and costeffectively. Our mixing nozzles can be delivered ready for connection within a few weeks and in many cases help to eliminate quality problems, increase productivity and reduce the CO2 footprint.”

Promix Solutions will showcase its mixing nozzle and other key components for saving raw materials, increasing productivity and solving quality issues at the Fakuma show in Friedrichshafen, Germany, from 17 to 21 October 2023, in hall A2, stand 2105.

26 - 28 SEPTEMBER 2023

NEC | BIRMINGHAM | UK

Be challenged and inspired

TO TRANSFORM YOUR BUSINESS

Interplas will bring together some of the brightest minds and thought leaders from the UK plastics industry. Get ready to immerse yourself in a captivating line up of sessions that will empower you with the latest insights.

2 Stages 50+ SESSIONS 70+ Speakers 500+ EXHIBITORS

View the full agenda and book your FREE pass today

ERIC BAYLE Business Development Director, EMEA PLASTIC BANK

ROBIN KENT Managing Director TANGRAM TECHNOLOGY

VICTORIA BERNADO Team Leader CELLMAT TECHNOLOGIES

ANNE HITCH Business and Project Development Lead RECOUP

ROSIE LAWTON Applications Scientist M&I MATERIALS

PHILIP LAW Director – General BRITISH PLASTICS FOUNDATION

IAN RAY SME Materials, Injection Moulding & Process JAGUAR LAND ROVER

TERRY COOPER CEO ARGO GROUP INTERNATIONAL

CERIS TURNER-BAILES CEO WASTEAID

KATHERINE FLEET Head of Sustinability RECOUP

KRISTEN TAPPING Founder and Director GOROLLOE

STANLEY MITCHELL Head of Business Development XAMPLA

OPINION

We have all read the doom-laden headlines these past few years about how our planet is drowning in plastic litter and microplastics. It would seem that every other day some environmentalist around the world is spouting words on just how evil and nasty it is.

And while you can’t argue about some of the hard evidence out there, namely that plastic pollution has been found in even the most remote of places; including Mount Everest, the Mariana Trench and the Arctic, one British engineer thinks plastic does not deserve the bad rap it’s been getting. In fact, he argues that part of the problem lies more with misinformation and how people use the material.

Meet Richard Pike, (pictured). His company Gemini, based just outside Oxford, is in the business of prototype design and manufacturing. By its very nature it operates using predominantly plastic on an industrial scale – and has been since he formed it with his wife back in 1999 – so Richard understands just how complex the situation is and that you can’t really blame one person or organisation; nothing is black and white. Case in point: despite his profession, he actually cares about the environment and goes diving in his spare time.

“I’ve been diving for eight years, and I love it. It helps me to relax,” Richard commented. “When you’re down there, you only think about what’s in front of you, nothing else, it’s amazing. Another reason why I love it is that you get to see how marine life interacts with its environment, like how a shipwreck has changed over the years.”

Despite being a keen diver for this amount of time, and is a member of PADI (professional association of diving instructors) and BSAC (British sub aqua club), he said that he hadn’t seen any clear indication of plastic pollution in the sea – but admits that plastics and other litter in the sea, like discarded fishing nets, are obviously a problem.

“The reason fisherman discard nets is that, over time, they become more opaque and more visible to the fish so their yields go down – not because of the nylon degrading.”

Richard then pointed towards the issue of infrastructure around recycling the nets. “Another reason some fishermen are throwing away old nets is that in many parts of the world there simply isn’t anything in place for recycling the nets, probably because of

economic factors, so we need to look at this and at the cost of recycling.”

Interestingly enough, two UK-based organisations have been set up in recent years to help combat this situation, which, according to the United Nations, has seen over 640,000 tonnes of nets, lines and pots used in commercial fishing dumped in the seas globally.

Odyssey Innovation’s Net Regeneration Scheme has been running since 2016 – and has been responsible for over 200,000 kilograms of endof-life nets being recovered and recycled back into the circular economy, with most harbours around the British Isles involved. This operation has gone from strength to strength and has seen major backing from supermarket chain Morrisons, plus, since 2020, Exeter City Council has been playing a key part with providing a sorting facility.

The other major UK marine recycling operation is the Ocean Recovery Project. This involves environmental charity Keep Britain Tidy –they’ve teamed up with plastic processing experts Multispeed and have recycled over 40 tonnes of trawl net into plastic pellets that can be resold to the market. To date, Brixham harbour has been one of the biggest contributors, however Scarborough, Whitby and Dunbar in Scotland are also part of the project.

Alongside these relatively recent marine recycling schemes, other exciting developments have been happening including one that Richard’s Gemini company first noticed and wrote about on their social media just before the Covid-19 pandemic.

Polymateria was founded in 2015 at Imperial College

Why one engineer thinks we need to change our attitude towards plastic

WORDS Dan Perrin

Your Trusted Healthcare Polymer Partner

London and was the first organisation to achieve certified biodegradation of the most commonly-littered forms of plastic packaging. By adding a special additive called Lyfecycle into the plastic processing, a lot of packaging material that escapes refuse streams can now fully break down into an environmentally friendly wax-like substance. Sounds like science fiction? Well, you better believe it, because it’s definitely happening and Richard is “100 per cent onboard with this new technology”.

Keeping abreast of all the latest technological developments is essential for a major company like Gemini. After all, they are not the only prototype manufacturer in the UK, far from it. But what exactly do they build? Well, to put it simply, if you want a product designed and prototyped quickly, they are your ‘one-stop shop’. Offering a wide range of specialist services, Gemini’s team of talented 22-strong workforce can produce 3D design concepts, CAD design, traditional hand-carved models, high-tech blow moulding and injection moulded prototypes.

Working within automotive, big pharmaceuticals and fastmoving consumer goods industries, their client list is just as impressive as the services they offer. Jaguar, BMW, Airbus, Bacardi, 3M and KraftHeinz are just some of their regulars. They have these impressive clients simply because they deliver great results every time. “People like using us,” Richard commented, “and we always try to be associated with projects that benefit humanity.” Working with Cambridge University in producing HIV diagnostics, as well as electric motors for YASA Motors perfectly demonstrate this.

One particular Gemini customer, Unilever, is keen to promote their planet-friendly credentials and is using the Lyfecycle technology, alongside another huge client, Reckitt Benckiser. However, both firms play out their business model on a global scale and involve investors who have had their fair share of controversy over the years – however, to be a major prototype firm like Gemini, you have to realise there are many moving parts to the industry and not get bogged down with forces that are beyond your control.

Richard is quick to comment it’s far from straightforward, that companies are being mindful about how ‘ecofriendly’ they are perceived to be and this is probably being driven, in part, by the mainstream rhetoric on plastic pollution. They themselves are currently in talks to obtain an approved ISO environmental standard called “Environmental management ISO 14001”.

“It’s getting more and more prominent in the clients’ brief, in fact, it might come to the point where a client will say, ‘until you have that environmental standard, you can’t supply to us,’” Richard explained. “They’re going down this route because they have to be seen as being responsible for taking an environmental stance. If you’re not green, you’re unethical.

He further commented about companies using lighter grade plastics and the cost factor.

“There’s been this apparently recent move to using more lightweight plastics, but this is nothing new, we were doing this 20 years ago; shaving out half a gram of plastic from our moulding. If you can imagine the scale of some of these production plants, we’re talking billions, not millions

OPINION

of units therefore, if you can shave off a small amount of plastic then the savings are going to be huge.”

And these facts further highlight what makes this whole global pollution situation so complicated, in that you have these huge industrial and economical forces essentially steering everything – with there being no one quick-fix to a more eco-friendly world.

So, Gemini’s stance on plastics for the foreseeable future is that there’s no substitute to support modern living. “It’s a marvellous material but it’s been taken for granted,” Richard explained. “It’s what you do with it afterwards...we need to value it more, because good luck trying to get through another pandemic without it, plastic is the main raw material in PPE.

Misinformation on how you should substitute plastic is another key factor that needs addressing, according to Richard. “As much as I admire Greenpeace, they have demonised plastic to a point where people are using alternatives that are even worse for the environment. Like switching to paper pulp, much of which can’t even be recycled. Any thermoplastic can be recycled, but what happens to cardboard after use? It rots down and produces methane which is a very harmful greenhouse gas.”

Despite everything, Richard remains optimistic. “The best role the UK can play is be innovators.

We’ve got some smart people here and we can develop materials that we can give to countries like China. Change will come through innovation, and making sure the consumer is informed of what the facts are.”

ON

THE COVER

THROUGH THE DOORS AT STV MACHINERY

As the British plastics industry gears up for an Interplas to remember, BP&R takes a look through the doors at one of the UK’s leading independent machinery suppliers.

To understand the extent of STV’s resources and capabilities, a visit to their Northamptonshire HQ is recommended. Here’s a brief overview of what’s on offer:

12,000ft workshop

In addition to supplying new machines and ancillaries, STV Machinery has offered a carefully controlled machine refurbishment service for over a decade, which Richard Perry

believes is unrivalled in terms of attention to detail.

With up to 40 machines from a variety of different manufacturers in the workshop at any one time, it’s a busy environment, in which STV’s engineering team has gained huge knowledge and experience of moulding machines from different manufacturers, as well as moulding processes. This unique technical resource underpins the company’s offering across all its services, from new machine sales to ongoing service and support.

Working Showroom

Adjacent to the company’s workshop is a large and impressive working showroom, packed with moulding technology including new Yizumi machines and ancillaries from the company’s other partners: Virginio Nastri, SML and Enmair Automation.

This allows potential customers to get ‘hands-on’ with the machines before any purchasing decision. “Photos, specs and videos are always useful when considering a new machine”, said Richard Perry, “However, getting close up to the machines and seeing them in action, gives a deeper understanding of what’s on offer. We can also carry out mould trials if required.”

Spares stores

During any visit to STV’s premises, a look around the spares store will illustrate the point that the company is committed to providing as near ‘full factory’ support as possible, to all its customers. Like all areas within the building, it’s clean, well organised and linked to a computerised stock control system.

Offices and meeting room

STV Machinery is an ‘all under one roof’ business, despite its size. The offices follow the same level of attention to detail as in the workshop and showroom – and close proximity to these areas brings a sense of unity and teamwork throughout the business. Here, the team carries out all sales support and service management functions, as well as administering the company’s successful and well established STVConnect machinery brokerage service.

STV MACHINERY

The UK market for moulding machines and ancillaries has seen some big changes over the last few years, with an influx of new products from Asian countries vying for position with the established European manufacturers.

The European machines are generally available in the UK through subsidiary companies of the manufacturing businesses. Whereas availability of the Asian machines tends to be through local UK distributors.

This being the case, STV offers the quality Asian-built Yizumi range of machines, with full, UK engineering and service support, as well as carrying UK stocks of spares and consumables. Managing Director Richard Perry believes that this is the ‘ace card’ that makes Yizumi such an attractive proposition to UK moulders. He commented: “Any major capital purchase like a moulding machine, will only deliver a return on investment if it’s working at full capacity. Our customers understand the need for reliable, expert local engineering support – and this factor is key in any assessment of value-formoney”.

There are two comfortable meeting rooms, each with a large TV monitor for presentations and videos.

Complete moulding solutions

The group provides a wide range of machines and ancillaries for all kinds of moulding operations. These include:

New moulding machines from Yizumi

The Yizumi machine range is broad, ranging from 30t to 9,900t. Yizumi is one of the world’s largest machine manufacturers and its IMMs are characterised by class leading tie bar space – a feature that STV says its customers appreciate. Typical Yizumi machine specification includes: low energy servo hydraulic system, test certified at 0.29kw/kg; four 3 phase sockets; double UK socket; dosing socket; double core pull; double air blast; robot interface; caterpillar water supply to moving platen; bypass oil filtration; centralised lubrication; European components; tool kit, mould clamps; mounting feet and first emergency spares. STV says it can offer highly competitive prices, plus a comprehensive three-year warranty.

Refurbished moulding machines from other manufacturers

STV also supplies high quality refurbished

“We’re engineers who supply moulding machines and ancillaries.”

ABOVE: STV’s working showroom for Yizumi machines at its Northamptonshire headquarters.

ABOVE: STV’s engineering team provides outstanding technical support.

moulding machines from Boy, Arburg, Engel, Negri Bossi, KraussMaffei and other manufacturers. An initial 2500 cycle test is carried out to evaluate each machine, which is then thoroughly cleaned, repainted and subjected to over 100 checks, with any worn parts being replaced. Finally, another 5000 cycle test is undertaken with a mould. This results in a refurbished machine which is as close to new condition as practically possible.

A complete range of ancillaries from around the world

STV’s ancillaries range covers the complete spectrum of equipment for productive moulding operations, backed by application and service support:

• Enmair granulators, mould heaters and volumetric dosers

• SML chillers, hot air & desiccant dryers and hopper loaders,

• Yizumi beam robots and sprue pickers

Conveyors and automation solutions from Virginio Nastri

As part of the company’s continual growth plan, STV has recently established a partnership with Virginio Nastri, one of Europe’s best-known conveyor and automation manufacturers, with a great reputation for quality and innovation.

The range spans every kind of parts handling, from standard and bespoke conveyors to complete, customdesigned automated systems.

Experience

Current managing director Richard Perry has been with the business since its inception in 2009 – taking over the reins as managing director on the death of his father, the well-known plastics industry entrepreneur Karl Perry, in 2022. “My dad always ran a tight ship and I’m sure he’d be proud to see how we are taking the company forward”, he said. “Our approach has always been to provide high quality machinery and personal service, backed by a strong core of engineering expertise. When we sell a machine, we see it as the start of a relationship, not the end of a sales process. Having said that, a large proportion of our sales these days are to repeat customers. I’m proud of that fact.”

STV’s senior management team has combined experience of over 80 years in the business. Fellow long-standing members are Sales Manager Steve Lacey, Technical Director Lee Parkins and Operations Director Steph O’Meads. Steve’s experience has been gained from positions within a toolroom, then onto production, Spaceminster Group, Demag, Hallam Plastics, Negri Bossi and STV Machinery. Lee started his engineering career as an apprentice at Spaceminster as a BOY engineer, before moving into a position as an in-house maintenance engineer and then working through the ranks at STV Machinery. Steph joined the Company as an administrator in 2018 and became a Director in 2022. She oversees the day-to-day management of the business: engineers, spares, finance, haulage and other key functions.

Perry said: “Buying a moulding machine is a big decision. You need to be sure of the company behind it, as much as the machine itself. My aim for STV has always been that we offer the best of both: great machines and a team you can trust”.

BELOW: Machine refurbishment at STV’s Northamptonshire workshop.

“Any major capital purchase like a moulding machine, will only deliver a return on investment if it’s working at full capacity.”

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YOUR MOULDING PARTNER | FROM CONCEPT TO PRODUCT

Plastic injection moulder BEC Group is well versed in helping inventors and entrepreneurs to take their ideas from design to reality. Often working with design agencies, product designers or clients directly, BEC becomes involved at different stages of the journey, but typically are consulted once an initial product design has been prepared. One such product design agency, Simple Design Works approached BEC to work together on a design for manufacture for a golf training product.

Simple Design Works provided 3D CAD drawings of the initial design for BEC to produce a design for manufacture. A design for manufacture is one of the most important aspects of the design to production process for tooling and injection moulding. It involves both the toolmaking and injection moulding departments coming together to make recommendations to the client. These recommendations are crucial in optimising the part for moulding, and reducing timescales and costs for the client.

The design for manufacture highlighted several design elements which were unachievable for tooling, chief amongst them was complex interior detailing. These recessses and fine details were removed or redesigned in order to mould successfully. Additional features such as an extra ring on an alignment stick were removed to reduce costings, and a cheaper solution to prevent slippage of the stick implemented. Once these and other recommendations were passed over to the team at Simple Design Works, and a full design was completed, Mitchell opted to continue working with BEC to injection mould his product.

BEC Group scores HOLE-IN-ONE with golfing aid

The BEC tooling department produced a suite of four tools (and five parts) for the V Plane project; the main body which works to connect the alignment stick to the club, two rubber sleeves which fit between the main body and the rear lock arm to grip the golf club, the rear lock arm which screws into the main body and the horizontal alignment stick which ensures the golfer’s club stays in a parallel straight line to the golfer’s body when hitting the golf ball. A set of anodized aluminum screws holds the part together – initially these were proposed to be stainless steel, but proved to be too heavy.

Due to thin wall sections on many of the injection moulded parts, cooling, ejection, and a suitable finish were of concern. BEC were eventually able to design onto the core of the tool a small amount of draft angle to achieve the desired finish. This was an unusually shaped sliding core tool that required over lapping shut offs on the top of one core to mate with the second core.

Several detailed trials took place to achieve a material grade that give stability, strength, and high flow speed as well as the required gloss finish. Both the main body and rear lock arm were produced in black ABS. The front and rear rubber sleeves were produced in a two-cavity tool to reduce costs. Moulded in black santoprene, this TPE was used to increase friction (over the ABS of the main body) and therefore give an improved grip to the golf club.

The alignment stick was produced in a two-cavity tool in a bright orange ABS after colour sampling.

Initial samples were tweaked slightly due to slight distortion in the alignment stick, due to the coring out of the

V PLANE

The brainchild of keen golfer and entrepreneur Mitchell Bligh, V Plane is a golfing aid aimed at improving one’s short game. This versatile bit of kit can be used both on the course or at home to improve putting, chipping, and pitching for the amateur or more experienced player alike.

An alignment stick (and other commonly used drill sticks) can be secured to the golf club with the help of the V Plane, improving alignment and muscle memory to get those great shots.

alignment stick on one side but not the other. To prevent this from occurring a cooling jig was implemented to cool the stick evenly.

In order to screw the rear lock arm onto the main body, inserts were required. These were manually heat staked as a secondary operation postmoulding. The alternative of manually loading inserts was ruled out due to the complexity of the tool making it incredibly difficult.

In initial designs, the V plane logo was indented into the moulding. For reduced cycle times when moulding, BEC suggested it would simplify toolmaking to change the logo to stand proud of the tool and from the final moulding. This also allowed the opportunity to make the V Plane branding stand out further by adding hot foiling. This decorative process involved pressing a layer of metallic foil onto a raised element of the moulding with a heated stamping die, quickly transferring the foil onto the moulding. This resulted in more obvious branding; and provided highquality, long-lasting results.

Once all necessary design and tooling alterations had been executed and Mitchell provided sign off for all samples, an initial production run began. Mouldings were extensively quality checked and once passed, were shipped to an ecstatic Mitchell.

Mike Tharme, toolroom manager at BEC Group, reflected on the V Plane project and working with both a design agency and an entrepreneur to successfully produce the golfing aid.

“Working with Simple Design Works to make alterations and improvements on the V Plane design was an easy process, with all our recommendations taken on board. Despite the fine detailing on the main body of the part causing a few tooling issues, we managed to alter some of the interior recesses for succesful moulding. Mitchell’s enthusiasm for the product at every stage made the entire process all the more rewarding-it’s why we do what we do,” said Mike Tharme, Toolroom Manager at BEC Group.

INJECTION MOULDING

BEC at 45

This year, BEC Group is also celebrating its 45th anniversary – here’s a potted history of one of Britain’s innovative moulders:

1978 The beginning of BEC, as founder Geoff Elvy put it “three engineers gambled all they possessed, it was exciting and terrifying at the same time”. The trio formed the company in New Milton, where it remains (albeit in slightly larger premises than those pictured!) to this day. Initially, the company started in the press tooling industry, before moving into the plastics game as they became ever more popular.

1981 At the start of the 1980s BEC began working on a pivotal project for the business – the very first payment terminal for Barclays bank. These terminals allowed financial transactions to be made from credit or debit cards at point of sale; revolutionary! Working with Racal Transcom to develop tooling and mouldings was a vast project, once signed off, we produced hundreds of them every month.

1982 1982 signalled the beginning of filter manufacturing at BEC. We were approached by Phillips to design and build a two-cavity mould tool for tumble dryer filters – these filters are still available today. The success of this initial filter lead to future filter manufacturing for household brands such as Hotpoint, Creda, Richards and Kenwood and propelled us into the world of filter manufacturing.

1986 (ish) “I began at BEC nearly forty years ago (no one can remember quite when!). Back then the team was a bunch of young lads, we worked up to 55 hours a week, including Saturday mornings when we’d all have a bacon sandwich together for breakfast. Over the last thirty odd years we’ve had interesting projects, brilliant team members and crushing recessions. It’s certainly never been boring working for BEC” Paul Holland, Head of Design & Innovation.

1988 1988 was a rollercoaster of a year at BEC. Proudly the three partners were able to buy the buildings that BEC occupies to the present day. Tragically in the same year, founder Barrie Cox passed away, leaving a large hole at the company.

1993 “I started working at BEC in 1993. I made some of the 1st filters for BEC when the filters building was just an old greenhouse type storage area. I was also involved, although in a minor way, in securing the British Standard accreditation for BEC Filters. There were many great characters over my time at BEC and I always had a good relationship with Geoff and Graham. I am still in touch with a few of my ex-colleagues from BEC” -Aron Walker, former BEC employee.

2000 Mudeford Lifeboat Funday: This local event that continues to this day began as a fun way to support the local RNLI Mudeford lifeboat. In the year 2000 the BEC toolroom and mouldshop teamed up to develop a seaworthy craft “Stella” from repurposed barrels to take on several other makeshift boats in a race along Mudeford Quay. Whilst the team didn’t quite cruise their way to victory, they weren’t far off, and went on to take part in two further fun days.

2010 After previously producing tooling for eco petrol filters, BEC were approached by a well-known automotive company to produce tooling and mouldings for reducing diesel emissions. The team set to work developing the design and tooling of a 3-part bespoke mesh filter. Once trialled and tested production began. In a typical month BEC still produce around 25,000 of these filters every month.

2011 “I started out at BEC around twelve years ago. Prior to that, I made filters for BEC in my own business, but after the big financial crash in 2008 Geoff and Graham kindly offered me a job at BEC. They’ve been good to me over the years, and I’ve been lucky to work with a great team that make the job fun!” – Danny Golden, Production Coordinator, Filters

2020 In the midst of the Covid-19 pandemic, BEC worked with Protecting heroes and JNDC to produce rapid tooling and injection moulding for critical PPE face shields. From receipt of approved CAD to BEC, we produced first offs within eight days. Once these first offs were approved, we jumped straight into 24-hour production.

“Despite the fine detailing on the main body of the part causing a few tooling issues, we managed to alter some of the interior recesses for succesful moulding.”

The British Plastics Federation: A SHORT HISTORY

As befits the longeststanding plastics trade federation globally, the British Plastics Federation (BPF) is unique in covering the entire industry in one organisation: raw material suppliers, equipment suppliers, plastics processors, recyclers and service suppliers. When the BPF was created 90 years ago, in 1933, raw material producers were also converters. This facilitated a technical dialogue between them which characterises the BPF today.

1933 was portentous. ICI’s discovery of polyethylene prefigured the BPF’s role in fostering innovation. Adolf Hitler’s rise to power in Germany, perhaps foresaw that the BPF would always be in the eye of the storm.

Government Dialogue

Throughout its history, a central BPF role has been to act as the industry’s interlocutor with government.

During the Second World War, the government needed the BPF to advise on the potential contribution of plastics applications ranging from radar installations to hand grenades. The BPF also negotiated the industry being within the ‘reserved occupations’, exempt from military service to maintain production. A BPF panel also advised the Government Controller of Steel and Iron on the provision of special steels for toolmakers.

Post-war, the BPF continued to interact with government. This was sometimes on a daily basis, particularly during the Covid pandemic, when it helped coordinate the supply

Celebrating 90 years since its creation, the British Plastics Federation has achieved its highest recorded membership, with over 550 member companies. BPF Director General Philip Law provides a brief history of the world’s first trade association for the plastics industry.

By the 2020s the BPF was responding to around 50 government consultations per annum.

An International Footprint

The BPF has built a very strong brand in the global plastics marketplace. It has guided member firms to high potential export markets, helping them secure initial footholds.

The BPF’s first overseas exhibition venture was at the International Exhibition of Industrial Arts in Paris in 1937. Post -war, the BPF mounted its first stand at the Kunststoffe Fair in Dusseldorf in 1959. By 2023 the BPF had represented the UK plastics industry in all five continents. A true pioneer, it first exhibited at Chinaplas in 1985.

1992, as well as intensifying support for the Association of Plastics Manufacturers in Europe.

To assess the industry’s competitiveness, the BPF has led groups of members on overseas study tours. The Moulders Group visit to ten West German plastics moulders in 1981 resulted in me writing a comparative study of the UK and West German plastics moulding industries, drawing important conclusions on the supply of tools and the organisation of training. This was preceded by a Moulders Group tour of plants in the United States, taking place over six weeks in 1952. The Rotational Moulders Group visit to view northern Italian industry in early 2023 maintained this tradition.

Brexit wasn’t the first BPF intervention in the mechanics of international trade. At the creation of the European Free Trade Area in 1960, the BPF was heavily involved in resolving the plastics-related issues on product and process definitions and rules of origin.

of plastics Personal Protective Equipment (PPE) to the NHS and disseminate safety guidance to the industry.

The BPF also successfully managed government investigations on clingfilm and in cot mattresses, both subject to ‘scare stories’ in the 1980s. The BPF’s crisis management skills were quickly deployed to great effect: undertaking research, formulating actions, handling the media, dialogue with government, representing industry at public inquiries.

The federation has strong ties with its fellow plastics associations worldwide. I, Philip Law, served as Director General of the International Plastics Association Committee from 2014–2019.

The creation of the Single European Market in 1993 required the harmonisation of product characteristics including environmental attributes. A more professional approach to the industry’s representation in Brussels was needed and the BPF became a leading force in the creation of the European Plastics Converters Association in

The BPF also won international acclaim when it produced a film, ‘The Shape of Plastics’ in 1962, the 100th anniversary of ‘Parkesine’. This won a gold medal at the Bilbao International Film Festival and became the official British entry in the Moscow Film Festival.

Innovation

The BPF grew with the industry’s innovative capacity. A succession of BPF groups were created to foster nascent sectors. The BPF Windows Group was founded in 1981. PVC windows were new to the

BPF logos through the years

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BPF

UK market sand there was a dire need for an industry forum to agree commercial and technical standards, including joint work on fire safety. The BPF filled these needs in a legal framework.

Likewise, a Packaging Group was formed in 1962 at the dawn of supermarket expansion in the UK, with plastics arguably making further expansion possible. Also in 1962, the Pipes Group was launched in the face of unduly conservative building regulations and what was then a sluggish BSI.

A Veteran of Sustainability

‘The circular economy’ has a surprisingly long track record with the BPF. It established an authoritative Environment Committee in the early 1970s, publishing in 1974 ‘Plastics and the Environment’, edited by JJP Staudinger, even back then highlighting the potential of chemical recycling. The BPF even directly managed a Materials Reclamation Centre in Sheffield, Sheffield Reclamation, and from 1980 a bottle collection scheme with supermarkets in West Yorkshire, the PET-A-BOX project.

The BPF ‘s role in the Voluntary Commitments for PVC, Vinyl 2010 and VinylPlus, with increases in PVC recycling is impressive. Coordinated activity on PVC was assisted by the creation of the Vinyls Group in 1992, uniting all the PVC interests

within the BPF. The group won cases of misrepresentation at the Advertising Standards Authority and broke new ground in its collaboration with The Natural Step, a highly respected Swedish sustainability organisation.

The BPF’s Recycling Group was established in 2011, completing the full industrial circle within the BPF’s structure.

Present at the Creation

The BPF’s 90th anniversary coincides with the anniversary

BELOW: Still from The Shape of Plasics 1962

of Interplas. The BPF had a critical role in the emergence of Interplas. The BPF’s earlier management of the Plastics Section of the British Industries Fair reached its apogee during the Festival of Britain in 1951, when the BPF stand hosted a royal visit. But due to the financial risk involved, the BPF decided against organising its own trade fair and instead to cooperate with Associated Iliffe Press. The result was the British Plastics Exhibition at Olympia. Judged a success with 26,000 visitors in 1951, further editions were planned on a two-year cycle, ultimately evolving into the Interplas of today.

Medieval Links

The BPF’s history is even linked with a much earlier era. Making articles from horn, a natural polymer, was a well-established craft in medieval London, regulated by The Worshipful Company of Horners, which still exits. In 1943 the livery company decided to adopt the plastics industry as its contemporary

trade. It also presented the BPF with the opportunity to deliver the Horners Award for Polymer Innovation and Design, competed for annually. An early reference to the livery company in 1284 marks almost 750 years’ recognition of plastics as a distinctive trade! ‘Sustainability’ indeed!

To Unsung Heroes

It is impossible to name all those who have contributed to the BPF since its creation. But there are two individuals who stand out as being absolutely critical to the postwar BPF, richly deserving posthumous praise. One is Geoff Stanley, a Normandy veteran, who, during two stints as ‘General Manager’, held the organisation together during very difficult times, 1956-70 and 1973-74. The other is his assistant, Basil Aldis, who between 1947-62, deemed ‘years of explosive growth’, was responsible for the whole of the BPF’s Technical, Publicity and Exhibition work. Let this short history be dedicated to them.

Philip Law at BPF Annual Dinner 2022

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If we look at this through the climate change lens, it is worth noting that 1.6 tonne/1.8 ton of CO2e could be saved if we were to use food-grade recycled PP versus using virgin PP resin.

With this in mind NEXTLOOPP has been addressing the key roadblocks to closing the loop on post-consumer foodgrade PP. This has meant deep-diving into the specific sorting and decontamination requirements for the recycling processes for PP.

Up until now the residual contamination levels of postconsumer PP packaging have been an unknown area. The lack of data showing the misuse rate within PP feedstocks has meant there was no reliable way of defining the residual levels that could potentially migrate into food as well as understanding which molecules to target via a decontamination processes.

Nextek’s study aimed to identify substances that might cause samples to be outliers from the expected input stream which could represent challenges to the final safety of the recycled plastics. Key was to check whether the substances observed could potentially be genotoxic. This is critical criteria for EFSA safety evaluations given that the substance could be derived from the mis-selection of an item of non-food PP packaging, which is not necessarily a case of misuse.

Although PP has very similar properties to HDPE being olefinic, the packaging format of PP may reduce the chances of it being in a consumermisuse scenario. A large proportion of PET packaging is relatively durable, with a tight closure, making it a container of choice when used for the storage of hazardous materials.

Likewise HDPE packaging is also in bottle form with a

Ground-breaking study defines the residual contamination level of post-consumer polypropylene packaging

Polypropylene (PP) is one of the world’s most prolific polymers, accounting for more than 20% of global plastics production. 55% of PP rigid packaging is used for food-contact packaging, yet according to Plastics Recyclers’ latest report , whilst the net demand for PP in Europe alone is 10.5 Mt., PP recyclate from postconsumer rigid product applications only meets 3% of this demand.

closure meaning it too may be used in such a scenario. PP food containers, on the other hand, are less likely to come in bottle form and much more likely to be pots, tubs, or trays with limited closure capability.

Characterising the residues in post-consumer packaging that have been sorted into mono-polymer fractions was done by analysing and testing multiple batches of food/non-food samples to see what molecules are present and if there are any areas of concern.

To achieve this Nextek’s team of scientists worked on a 20tonne batch of PP bales sourced from a UK-based materials recovery facility (MRF). Using automatic optical sorters to separate colour fractions of natural (clear), white and coloured articles, each colour fraction was hand sorted into articles from food applications and articles from non-food applications.

The analytical study involved 700 tests, which represented approximately 17,500 different PP packs based on 25 significantly sized flakes per test. This was estimated to be a cross-sectional representation of 7% of the packs from the combination of batches of 260,000 packs.

Following this contamination study Nextek characterised the contamination levels in PP and concluded that they are in the

order of 10x less than what we expect in HDPE milk bottles and 100x less than expected in PET.

These results further validate Nextek’s global multi-participant project, NEXTLOOPP, as it breaks through the final barriers to closing the loop on food-grade recycled PP.

By deploying innovative technology to effectively sort post-consumer PP packaging, the project is now harnessing these study findings to fast track the production of INRTgrade and food-grade rPP.

The growing need to recycle post-consumer PP packaging into a suitable material for primary food contact packaging is driven by the European Union policy to include at least 10% recycled content for all packaging, increasing to 50% by 2040.

Understanding the sorting and decontamination requirements needed to enhance the recycling processes, is a major step forward. More importantly this data is essential towards enabling food-grade PP packaging to be recycled into high-value recyclates that can safely be used in new foodcontact packaging, and this takes us back to the climate change debate.

To effectively reduce the world’s CO2 emissions, we must flip our perspective on recycling. If we are to simultaneously reduce our waste and our reliance on virgin resources then we must pivot from recycling to re-looping. In other words me must focus on turning used products back into equal value products. Instead of recycling plastic packaging to achieve commodity resins we should re-loop plastic packaging into the highest quality resins possible. This study now gives us the leverage to work towards this.

WORDS: Professor Edward Kosior and Paul Marshall of Nextek and NEXTLOOPP

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POLYMERMAN

Destockingversusdemand; asupplychallengeinthemaking?

Mike Boswell, MD, Plastribution examines the factors that may lead to an undersupply of polymers with the likely consequences of a sharp recovery in prices and the challenges of supply shortages.

In order to appreciate why this situation may occur, a review of recent events and commercial strategies merits consideration.

Prior to April 2020 (Pre-Covid)

Markets were largely stable and purchasing strategies were JIT (Just in Time)

April 2020 – June 2020 (Covid Phase 1)

Due to the economic uncertainties that Covid-19 brought supply chains emptied and prices fell. JIT continued.

July 2020 – December 2020 (Covid Phase 2)

After destocking supply and demand stabilised. JIT continued.

January 2021 – February 2022 (Covid Phase 3)

Prices increase rapidly as demand exceeded supply. Supply is restricted through a combination of shipping restrictions and polymer feedstock availability. Purchasing strategies move to JIC (Just in Case)

March 2022 – May 2022 (Russian invasion of Ukraine – Phase 1) Prices escalate to record levels as concerns of security of supply escalated. JIC continued.

June 2022 – (Russian invasion of Ukraine – Phase 2) Fears of a global economic slowdown overtook security of supply concerns and demand quickly fell away. Purchasing strategies moved back to JIT based upon the following:

1. Availability is good.

2. Price deflation.

3. Borrowing costs going up.

4. Cash is preferable to inventory in times of economic uncertainty

3. Tendency towards substituting plastics in ‘single use’ applications

4. Slowing rates of construction

The more credible explanation, for the fall in demand, is the move back to JIT from JIC, and the influence of this factor is now greater as more supply of polymer originates outside of Europe and supply chains lengthen.

The real risk comes from the difference between underlying and actual demand. Polymer producers for reasons of:

1. Physical storage capacity

2. Working capital requirements

3. Interest expense have cut back supply to match with actual demand, but when supply chain levels have return to normal will face the challenge of meeting underlying demand either through imports and/or ramping up domestic production. When sudden increases in demand have occurred previously, European polymer production has been beset by plant reliability issues, a situation which is typically made worse by colder winter weather conditions.

The market can change quickly, with the most recent example being a shortfall in Styrene Monomer in July, due to a planned and unplanned European outage combined with restricted imports, causing contract prices to increase and spot prices inflating to meet them.

What is the supply side concern?

Except for North America, polymer consumption is down by some 20% to 30%. This applies to every converter and application. However, according to the International Monetary Fund1 global GDP is expected to grow by 3.0% in 2023 and historically polymer demand has grown faster than GDP. Whilst some reduction in demand may be explained by factors such as:

1. Accelerated demand during the Covid-19 pandemic for durables including white goods and home improvements

2. Reduced demand in the automotive sector resulting from the IC chip shortages

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

PLASTICS 101: Polyurethanes

Polyurethanes

Polyurethanes are one of the most versatile plastic materials, with an enormous potential for applications within the manufacturing industries. What follows is a technical summary of the key considerations when formulating a compound.

History of polyurethanes

Polyurethanes were discovered by Otto Bayer in 1937, were commercialised in the 1950s and have since been used in a variety of applications that impacted the manufacturing sector in the 20th Century.

The reaction between a Polyol and an Isocyanate plus additives such as catalysts and surfactants and blowing agents which can be used withing the formulation results in a polyurethane material that is fit for purpose.

Question: polyurethane system houses

The starting point for the choice of polyurethanes and its end applications/product, is utilised, is a polyurethanes system house. Polyurethane formulators are usually the second or third tier in the manufacturing chain but will have a very good knowledge of the end application and the relevant specification the end product must meet.

A few factors to consider in the choice or for the choice of a polyurethane system

• Exposure to UV radiation.

• Exposure to elevated temperatures

• Exposure to water

• Cycle time

• Exposure to humidity

• Gel rise profile

• Abrasion resistance

• Free rise density and moulded density

Pravin S Mistry, global CEO, PREA, gives a technical overview of polyurethanes: their processing methods, characteristics and uses.

• Insulation properties

• Stability of PU system

• Comfort

• Sustainability

• Protection

• Recycling

• Sound absorption

• Exothermic reaction

• Wear resistant

• REACH compliance

• SVHC free

• Adhesion

• Continuity of supply

• Fire resistance

• Repeat and ease of manufacture

• Dispensing machine type and outputs

Typical processing of polyurethane systems

• Hand mix - carried out using a small impeller and a hand drill

• Low pressure mixingutilises mechanical mixing in a chamber under low pressure chemical feed

• High pressure mixinginvolves impingement mixing forcing the chemicals together under high pressure

Polymer choice

By careful choice of polymer and its termination and

hydroxyl value together with the choice of Isocyanate will affect the end application of the polyurethane greatly.

Catalysts

Are used to control the reactivity of the polyurethane system whether the system needs to be fast or slow in cure and the desired physical characteristics can be manipulated.

Surfactants

Control the cell structure with the polyurethane and can influence the final physiacls properties of the polyurethane.

Fire retardant

The incorporation of fire retardants will improve the ability of the polyurethane to resist a fire and also improve the safety of the final application.

Blowing agents

Next generation blowing agents can be utilised to minimise any damage to the atmosphere by careful choice of type in relation to both the formulation and end application.

Fillers

The use of fillers reduces the cost of Polyurethanes but can also add strength and additional properties.

Pigments

A whole variety of pigments are available that can provide a spectrum of different colours.

UV stabilisers

Chemicals that improve the UV stability of the PU system.

Ozone protection

Chemicals that aid the ozone protection of elastomers, especially when near the world’s oceans.

Antistatic additives

Additives that are incorporated into the PU system to help dissipate static build up.

A few dos and don’ts for the use of polyurethanes to be aware of:

• Do - Fully research both the PU system and PU dispensing machine in respect of final application.

• Don’t -Take shortcuts with tooling designs.

• Do - Ensure that the moisture content of the PU system and associated plant are known and controlled.

• Don’t - Use a PU system that has the wrong gel rise profile for your application.

• Do - use a compatible release agent for your PU system.

• Don’t - Purchase inferior raw materials for your PU system.

• Do - ensure that you have the required PU mixing on your PU Dispenser

• Don’t - contaminate the foam system with chemicals that will cause foam collapse.

• Do - Use a fully accredited test house to verify your product complies to the local regulations.

• Do - Have good process controls and quality systems in place.

• Do - Consider protype and proof of concept.

• Don’t -Try producing parts/ materials without carrying out research into the PU systems available.

Summary

As now can be seen by using the right polyurethane system, many factors must first be taken into consideration before formulating a product. Most importantly the end application and specific for must be clearly defined in order that the product is manufactured to the correct specifications and costings. Formulating the right polyurethane and the careful choice of mixing technology will have a distinct impact on the desired physical properties of the polyurethane.

Technical support Always ensure you can receive technical support. PREA can offer excellent technical support in all aspects of Polyurethane machinery, processing, Polyurethane system choice and tooling to enable your company to produce quality product repeatable within budget and on time.

In addition, PREA can also help with root cause analyse of Polyurethane processing issues and PREA have a comprehensive knowledge of all aspects of machine designs, tooling manufacture, formulations, and quality and processing improvements.

ABOUT THE PLASTICS CONSULTANCY NETWORK

The Plastics Consultancy Network (PCN) is a professional network of the best independent polymer consultants in the world. With over 30 years of service to the industry globally, now may be the time to call in the experts to help achieve your business goals.

Whether it is Plastics, Composites, Rubber, Polyurethanes, Adhesives, Textiles and other polymer materials, the members of the PCN can assist.

Established in 1988 the Plastics Consultancy Network has been serving the global polymer industry for over 30 years

Every PCN Consultant is an independent, highly qualified, and experienced polymer consultant considered an expert in their field. All PCN members have a proven track record in polymer consultancy and can bring decades of experience to your company, at a fraction of the cost of hiring internal resources.

In times of trading be it difficult/demanding conditions, improving efficiency, increasing margins, and reducing downtime are more vital than ever. PCN’s focus on the polymer sector involves sharing the knowledge and information generated from many years of experience in all areas of the polymer businesses. PCN’s commitment is to help clients find effective solutions, actively, quickly, creatively, and at a minimal cost.

Consultants can form a vital part of any management team, a valuable resource that can be used whenever required. Without the significant overhead cost of full-time staff, they are a variable and controllable cost, used only when required. The PCN operates in the UK, Europe, Nordics, Middle East, North America and Asia.

CASE STUDY:

Southbourne Rubber invests in Zünd digital cutting technology

Founded in a small village between West Sussex and Hampshire, from where its name derived, Southbourne Rubber (SBR) has been prominent in the manufacture of industrial rubber (precision rubber and silicone components) since the 1970s.

Southbourne Rubber’s reputation is built around flexibility, technical ability, customer service, high-quality products, and solutions. Its component portfolio is made up of a large range of both standard and make-to-print products.

Stephen Wilde, Managing Director at Southbourne Rubber said “With over 40 years of experience in the aerospace sector, we provide specialist industry and product knowledge in order to support our customers’ platforms. Critical to this is our knowledge and ability to manufacture from highperforming materials which provides quality reassurance to each of our customers. Our specialist and standard products are found across a range of applications including avionics, actuation, landing gear, interiors, fuel control, and engine systems as well as other hydraulic and pneumatic applications for many major OEMs.”

With sustainability and renewable energy being hot topics, Southbourne Rubber was keen to lessen their impact on the planet and looked into new ways to achieve this. In 2021, Wilde visited the Advanced Engineering tradeshow at the

NEC in Birmingham, where he came across the Zünd exhibition stand. Wilde said “I was very impressed with the Zünd Cutter, especially the footprint, flexibility and ability to cut a wide range of materials with just a simple tool change. Furthermore, the Zünd cutter would support our ongoing efforts of reducing our carbon footprint by minimising the amount of rubber and silicone material wastage. The Zünd digital cutting system uses sophisticated nesting algorithms, programmed to

maximise material yield, which in return reduces the amount of waste. I decided to follow up with Zund UK and book a product demonstration, so we can test our own materials.”

Following a successful demonstration, Southbourne Rubber ordered their Zünd G3 L-2500 digital cutting system straight away. Stephen said “During the demonstration, we could really see the benefits of digitising our workflow and the ROI was clear to see over a short period of time. The speed, accuracy, and quality

output were amazing. We could also envisage the cutter freeing up our resources to support other areas of the business. Southbourne Rubber are growing at a rate of >35% per year and we could clearly see how the Zünd will support this growth and enhance it.”

Southbourne Rubber took delivery of their Zünd G3 L-2500 digital cutting system earlier this year. Reflecting on the purchase, Stephen said “The Zünd digital cutter brings a new string to Southbourne Rubber‘s bow, enabling the participation of exciting new RFQs (Request For Quotation). Southbourne Rubber has now won new business it would never have been able to quote against or complete for, without the Zünd. The acquisition of the Zund will further support and enhance Southbourne Rubber’s continued, dynamic growth.”

Southbourne Rubber has invested in the latest Zünd G3 L-2500 digital cutting system for processing custom, precision-engineered gaskets.

“During the demonstration, we could really see the benefits of digitising our workflow and the ROI was clear to see over a short period of time.”

Advantages of customisable thin-wall hybrid composite tubes for OEMs

When it comes to thin-wall tubes for applications requiring high stiffness and robustness, metals were traditionally the material of choice because of their high stiffness and relatively low price.

Historically, composites were not the first choice because glass fibre composites, while lighter, may not have the necessary stiffness, and carbon fibre, while stiff enough, is often too expensive for most common applications.

Generally, thin-wall composite tubes are those with thicknesses between 0.5 mm (about 0.02 in) and 2 mm (about 0.08 in) and are used for various applications across diverse industrial applications, such as camera tripods, window cleaning poles, IMR equipment, telescope poles, medical applications, sporting equipment and even camouflage netting support poles.

Sustainability trends and light-weighting are now pushing manufacturers to improve operational efficiencies by reducing weight without sacrificing mechanical properties. We are often asked could composites replace traditional materials in these applications?

Tune mechanical properties to the application

Aluminum, which has been the traditional material of choice for many, has a stiffness of 70 gigapascals (GPa). Glass fibre, which is often the first choice for composite solutions because of its great performance to cost ratio, provides the desired weight savings compared to aluminum for tubes of equal dimensions but only has a stiffness of 35 GPa. Therefore, to match the stiffness of

Marc Tagher, Area Sales Manager for the US for Exel Composites, on why he feels composites are now the best material for the job and discusses customisable hybrid composite products, tailored to the user’s needs.

aluminum, usually thicker tubes are needed, impacting existing design specifications and reducing weight savings.

Carbon fibre composites tick all the boxes in terms of mechanical properties as they are much lighter than metals and boast much higher stiffnesses. Basic carbon fibre tubes have a stiffness of 120 GPa and high-modulus carbon fibre tubes have stiffnesses up to 210 GPa. However, carbon fibre composites are also more expensive than metals. This is where hybrid composites come in, providing the best of both worlds.

Hybrid composites, made from a combination of glass and carbon fibres, allow manufacturers to tailor mechanical properties for any given application without changing the specified dimensions of the tubes or poles by adjusting the ratio of glass fibre to carbon fibre in the structure. For example,

for window cleaning poles, a customer might require a pole predominantly made from glass fiber for cleaning two-story buildings but need something with a higher ratio of carbon fibre, providing extra stiffness, for poles intended for cleaning five-story buildings. This is a simple task for an experienced composites partner to produce composites tailored for your specific application.

Benefits of volume pullwinding manufacturing

For high volume costcompetitive composite production, continuous manufacturing processes, such as pultrusion and pull-winding, are advantageous because they ensure consistent high-quality production and high levels of repeatability. Pull-winding is particularly useful for

manufacturing hybrid composites because it allows for cross-directional control of mechanical properties and selective reinforcement of the thinwall composite tubes, meaning there is optimal use of material and costs are kept as low as possible.

Pull-winding combines the unidirectional alignment of fibers with the helical winding of reinforcements, resulting in the ability to control unidirectional fibers and helical winds, from a few degrees up to 90 degrees.

Manufacturing thin-wall composite tubes is possible using other manufacturing techniques, such as filament winding, however these require more manual steps and are more suited for thick tubes with large diameters. Furthermore, because they involve more manual steps and smaller manufacturing volumes, it is often the case that thin-wall composite tubes manufactured using filament winding are more expensive.

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FACTS & FIGURES

RECYCLING: knowing the facts

When discussing plastics and recycling outside of the industry, it’s essential to know the facts. Helpfully, Close Brothers Asset Finance has provided a guide to the intersectionality of these two industries.

Taking a global view first, Germany is the world’s largest exporter of plastic waste with 743k metric tonnes, followed by:

HOUSEHOLD WASTE

On average, every household in the UK throws away 3,432 items of plastic packaging, with food and drink packaging making up 83% of the total, made up of:

In 2022, 12% of plastic waste in the UK was recycled while 46% was incinerated; 25% went to landfill, and the rest was exported.

There are around 2070 local authorities in the UK, all of which provide a kerbside collection service that includes plastic bottles. Between 2010 and 2021, the share of UK local authorities collecting plastic pots, tubs, and trays at the kerbside increased from 28% to 88%.

Although the collection services for most types of plastic packaging materials has increased over the past decade, the share of local authorities collecting plastic film has been decreasing in recent years.

In terms of targets, under the UK’s resources and waste strategy, the country aims to recycle 50% of plastic packaging by 2025, with the target increasing to 55% by 2030. The overall recycling rate target for all packaging has been set at 70% by 2030.

In 2022, approximately 1.15 million metric tonnes of plastic packaging waste generated in the UK was sent for recycling in 2022. Of this, 54% was processed in the UK, with the remaining amount exported for processing abroad. By contrast, in 2010 70% of the UK’s plastic packaging waste was shipped abroad.

“Although the collection services for most types of plastic packaging materials has increased over the past decade, the share of local authorities collecting plastic film has been decreasing in recent years.

”

A complete guide to Neoprene rubber

This guide, by Seals Direct, details the history of Neoprene and explains the main advantages and disadvantages of using this rubber compound for manufacturing bespoke sealing solutions.

What is Neoprene Rubber?

Neoprene rubber, also known as Polychloroprene, is a man-made synthetic rubber used for a wide variety of sealing applications. With over 70% of the rubber used for manufacturing rubber products being synthetic, a large proportion of this is Neoprene. It is available as solid Neoprene or expanded Neoprene (open-cell sponge or closed-cell sponge) in a range of hardnesses and densities. Neoprene is one of the most versatile rubber compounds available for manufacturing rubber seals as it demonstrates good chemical stability and resistance to UV and weathering. It is also tough, abrasion resistant, and can operate in a wide temperature range making it an excellent material for manufacturing seals, trims and gaskets.

How is Neoprene Rubber Made?

When demand for natural rubber exceeded supply, scientists looked to develop a low cost synthetic alternative. In 1930 DuPoint purchased a patent focused on acetylene chemistry. This research discovered that a jelly-like substance called divinyl acetylene, when combined with sulfur dichloride, set into an elastic compound similar to natural rubber. DuPoint continued this research and later developed the synthetic rubber compound known as Neoprene.

Today, the process of manufacturing Neoprene remains almost completely unchanged. Neoprene is created using a process called polymerisation which is a chemical reaction that creates by-products. These by-products are melted, mixed with carbon pigments and foaming agents and then baked. This process creates a Neoprene rubber compound.

The raw compound can then be used to create rubber Neoprene seals, such as extruded profiles or moulded gaskets. The extrusion process pushes the rubber compound through a tool (known as a die) which, together with pressure and temperature, extrudes the required shape. This compound can also be used to produce rubber strip or sheet for sealing, edging and cushioning applications. Large calendar rollers squash the raw compound into flat sheets which are then cut to the required thickness, width and length.

Although the Neoprene rubber compound is initially semi-solid, it can be made into both solid and expanded sponge rubber products. During manufacturing, nucleating agents such as nitrogen or carbon dioxide are added to the compound to create a cellular structure. The gas injection rate can be adjusted to help achieve different densities and properties. This process creates what is known as expanded Neoprene, a closed-cell sponge that is often used to create watertight seals.

Advantages of Neoprene Rubber

Neoprene is a popular general purpose material that has been reliably used to manufacture Neoprene seals, trims and gaskets for many years. It demonstrates an excellent resistance to weathering, most substances and extreme environments making it the material of choice for sealing solutions in most industry sectors. These properties include;

Weathering: Neoprene has superb weathering properties which make it an excellent material for seals and trims used in outdoor environments. These properties make Neoprene waterproof and resilient to UV when exposed to direct sunlight, and suitable for use in the marine environment where products need to demonstrate excellent ozone resistance. Neoprene, in both its sponge and solid forms, also has a low oxidation rate so will not absorb moisture.

Chemical Resistance: Although harsh chemicals will degrade the rubber with prolonged exposure, Neoprene demonstrates a fair resistance to splashes and light contact with most chemicals, fuels and oils. It can also withstand contact with some alkaline solutions and methyl or ethyl alcohols.

Temperature Range: Rubber seals manufactured from Neoprene maintain a similar hardness and flexibility in low and high temperature environments. Although these products will provide a good sealing solution in temperatures between -20°C to +90°C without deforming, cracking or splitting, it is recommended that seals manufactured in Neoprene are used in temperatures above 0°C. During a test which heated Neoprene to 70°C for 70 hours, there were no changes to the materials hardness or elongation. There was only a minor (+9%) change to its tensile strength.

As well as demonstrating excellent weathering and good general resistance, a Neoprene seal displays exceptional functional characteristics which make it an ideal material for a wide

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selection of automotive, marine and industrial sealing applications. These characteristics include;

Resilient: Unlike some other synthetic rubber compounds, rubber seals manufactured in Neoprene are incredibly durable and less prone to tearing or abrasion. The material does not easily stretch reducing the chance of damaging the seal during installation. These factors, in addition to Neoprene rubbers’ general weathering and resistance, allow you to purchase a long lasting sealing solution that will not need replacing for a considerable amount of time.

Cost Effective: As Neoprene is used as the base material for a diverse variety of products, it is manufactured in high volumes at a relatively low cost.

Compared with other rubber compounds such as natural rubber and Nitrile, Neoprene is an affordable alternative with similar operating properties. As rubber seals manufactured in this material are strong, hardwearing and resistant to abrasion they need to be less frequently replaced. The initial low production cost together with the extended durability makes Neoprene an affordable option for most sealing solutions.

Self-Extinguishing: Neoprene rubber is self-extinguishing which allows it to burn when in direct contact with a flame but instantly self-extinguishes as soon as the flame is removed. It can also be manufactured in a fire retardant compound with low smoke and toxicity characteristics.

Vibration Dampening: Rubber seals and gaskets manufactured in Neoprene are able to dampen vibrations and shock. The structure of the material can flex when force is applied dissipating

and absorbing the vibration. This allows the rubber to be used in applications containing equipment that needs to be protected from vibrations caused by impact.

Closed-Cell: One variant of Neoprene is expanded sponge Neoprene which is a closed-cell sponge that does not absorb water. In a similar way to compressible foam, it can be used to create watertight seals on hatches, doors and lockers. Similar to solid Neoprene, expanded Neoprene can be extruded or cut into an endless variety of shapes and sizes.

Disadvantages of Neoprene Rubber

Although Neoprene is an excellent material for most sealing applications, there are occasions where it would be better to use an alternative rubber compound such as Silicone or Nitrile. These include;

Extreme Temperatures: Whilst Neoprene seals can be used in temperatures between -20°C to +90°C, the optimum temperature range is 0°C to +70°C. This makes it unsuitable for freezer cabinets, ovens and autoclaves. Sealing solutions for these products should be manufactured from a material such as Silicone which can withstand much lower and higher temperature ranges.

Chemical Resistance: Constant contact or submersion with certain hydrocarbons, strong oxidising acids or esters and ketones will cause the rubber to

degrade. For applications where the rubber seal will be in contact with these substances, you should use a Nitrile or Viton extrusion or gasket.

Types and Grades of Neoprene

Rubber

Neoprene rubber is available in a selection of types and grades suitable for different uses and industries. As a material that can be manufactured into both sponge and solid variants, Neoprene offers a solution to most sealing applications. It can be blended with other rubber compounds, such as SBR and EPDM, to reduce the cost and improve resistance and stability.

Commercial Grade Neoprene

Rubber: Commercial grade Neoprene rubber is a general purpose product that offers all of the properties of Neoprene, including a good general resistance to most substances and weathering. It is often blended with other rubber compounds, such as SBR to reduce the price. It is available in a range of hardnesses from 40°sh A to 80°sh A.

Neoprene Rubber to British Standards BS2752: Neoprene is also available in a grade compliant with British Standard BS2752 specifications. This compound uses a higher content of Neoprene rubber

to improve its weathering properties and chemical resistance. It is available in a selection of shore hardnesses, including C40, C50, C60, C70 and C80.

Expanded Neoprene / EDPM Closed-Cell Sponge

Rubber: Neoprene is also available as a closed-cell sponge which can be used to create watertight seals to stop water ingress. Expanded Neoprene is often blended with EPDM to reduce the price and improve its UV stability and chemical resistance. It can be purchased in a range of different extruded profile shapes in hardnesses between 50kg/m3 to 190kg/m3.

Fire Retardant Neoprene

Rubber: Although fire retardant Neoprene (EN45545-2) is more expensive than commercial grades, it is often a requirement for mass transport systems. This material has low smoke and low toxicity characteristics which help provide a safe environment in enclosed environments. Seals Direct is a supplier of Custom Rubber Seals for most industry sectors. The firm can manufacture bespoke extrusions from an existing sample or technical drawing in a range of materials including Neoprene, EPDM, Silicone and PVC.

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SABIC resin is first polymer to earn a UL verified mark for thermal runaway protection

SABIC has announced that its STAMAX 30YH570 resin has earned the UL Verified Mark from Underwriters Laboratories. This 30 percent glass fibre-reinforced copolymer resin, a featured product offered under the company’s BLUEHERO electrification initiative, is the first polymer used in electric vehicle (EV) battery systems to receive UL Verification for marketing claims of thermal and mechanical performance.

The vast majority of EV batteries perform without issues throughout their useful life. Although thermal runaway incidents are extremely infrequent, the safetyconscious automotive industry is highly focused on ensuring that the design and performance of EV battery systems prolong the time available to exit a vehicle by delaying

the propagation of a fire beyond the battery pack for as long as possible. A key consideration is the proper selection and deployment of fire protection materials used for battery pack components, including enclosures and covers, trays, thermal barriers that separate cells into groups, etc.

According to Venkatakrishnan

MOULDFLO ANNOUNCES CHESTERFIELD BASED FERROMATIK UK AS SALES AND SERVICE PARTNER

Danish flow monitoring and mould validation specialist ‘MOULDFLO’ has officially announced Chesterfield-based plastic processing equipment and ancillary supplier FERROMATIK UK as its official Sales and Service partner for the UK and Ireland.

Following a lengthy search and evaluation process supported by the Danish Trade Council in the UK, Ferromatik UK was shortlisted and then finally selected as MOULDFLO’s preferred partner of choice. MOULDFLO’s Head of Sales Anjum

Parwaiz said: “Building on strong sales growth and the up and coming launch of complementing products for the monitoring, testing, validation, and maintenance of injection moulds, we recognised the need to strengthen our

Umamaheswaran (UV), SABIC’s global Automotive Marketing director: “UL Verification for the thermal runaway protection of STAMAX 30YH570 resin is a significant milestone

in our development of polymer materials for today’s rapidly evolving EV battery systems. This recognition not only underscores the exceptional performance and safety features of

our polymer, but also reinforces the importance of our BLUEHERO initiative. By providing costeffective, lightweight plastic solutions, SABIC is helping to advance EV technology.”

worldwide reseller network.

We were looking for a reseller in the UK who had the capability to install, integrate solutions and handle

the past our resellers were suppliers of tool and maintenance components, retailers of DIY products and mould consumables, but our customers also

need our knowledge of cooling and polymer processing. This is a prerequisite when asked to design a flow monitoring solution or mould validation system. Ferromatik have the capability and capacity to do training on top of installation, service, and support”.

Anjum added: “Our market research study showed that customers speak highly and value the service provided by the team of sales and service engineers at Ferromatik UK. This was clearly significant when selecting and finally appointing our new reseller for UK and Ireland”.

BIFFA PRODUCES GUIDE TO EXTENDED PRODUCER RESPONSIBILITY

Sustainable waste management company Biffa has released a guide to Extended Producer Responsibility (EPR) to help UK businesses meet new obligations for packaging waste.

EPR is one of a group of changes to deliver 2018’s 25Year Environment Plan, Circular Economy Package and UN Sustainable Development Goals.

It holds producers (rather than taxpayers) responsible for the collection, sorting, recycling, or disposal of any product packaging brought into the UK market and destined for households.

They must report their data from 2023, then EPR fees will be introduced from

October 2025. Obligations differ depending on business size, but those with an annual turnover below £1million and handling less than 25 tonnes of packaging are exempt. The new rules aim to inspire a circular economy for packaging in the UK. In time, EPR could facilitate a wider transition towards a carbon-based hierarchy for waste management in a domestic supply chain - an essential step in creating a more sustainable future as highlighted in Biffa’s

Manchester based Duo celebrates 35 years in packaging

Blueprint for Waste Net Zero.

‘A practical guide to Extended Producer Responsibility: what businesses need to do and why it’s important’ by Biffa outlines who is responsible, the timeline (with deadlines) and how to prepare. This is underpinned by insight from leading business waste experts at Biffa on how EPR will impact important areas like packaging design, recycling and the UK’s wider sustainability strategy.

Pledge2Recycle, RECOUP and Fun Kids collaborate to launch educational podcast

Pledge2Recycle Plastics and RECOUP has announced a collaboration with Fun Kids, a UK radio station for children, that aims to introduce an engaging and educational programme, “Sort it out,” designed for children during the summer holidays and beyond.

“Sort it out” aims to inspire young minds to learn about recycling plastics and sustainability in a fun and interactive way. With the support of Pledge 2 Recycle Plastics mascot, ‘Monty’, Fun Kids has produced a series of podcasts that aim to ‘captivate’ children and foster their understanding of environmental responsibility. Gregory Watson, Managing Director at Fun Kids, said:

“In today’s busy world with many competing things distracting children, it can be hard to get important messages across. We had great fun working with Pledge 2 Recycle Plastics and RECOUP to create audio content to help open children’s ears and eyes to plastic recycling in a fun and accessible style.”

Carly Dadge, Communications and Marketing Manager at RECOUP, said: “We believe that fostering environmental awareness from an early age is essential for building a sustainable future. Collaborating with Fun Kids allows us to reach a wide audience of young learners and instil in them a passion for plastic recycling and protecting our planet.”

Staff and their families were served Manchester-themed refreshments and invited to watch artist and performer, Dave Sharp speed paint a ‘masterpiece’ of King Charles in under ten minutes. The inspiration behind the royal painting and one of Duo’s proudest moments to date was winning the Queen’s Award – now named the King’s Award - for Enterprise in Innovation for its DuoOptipac mailing bag in 2020. The commemorative art will be hung in their community room, The Hive, alongside their award.

Zoe Brimelow, Brand Director at Duo, said: “Reaching our 35th year in packaging is a milestone we’re honoured to have achieved. The business started out with a humble 17 employees and minimal machinery

its

and equipment. Now, the business is thriving with 106 members of staff and some of the UK’s leading brands as loyal customers. The event was a fantastic way to honour our successes over the decades and give special focus to the awarded DuoOptipac product, which was designed and patented by our team. It’s a brilliant example of packaging innovation and the combined effort that goes into developing our leading solutions - a true team endeavour.”

Ten of Duo’s employees were also selected to take part in a speed painting masterclass with Dave, learning step-by-step how to craft a piece of art. One of the ten chosen was John Zlupko, a Conversion Operative and one of the company’s longeststanding employees.

Packaging consultancy and manufacturing company, Duo has commemorated

35th anniversary with an event at its premises in Manchester.

See you in 2026

Interplas will be back in 2026, bringing with it the opportunity for you to experience the UK’s largest plastics industry exhibition showcasing the full spectrum of plastics processing machinery, materials, so ware, services and ancillaries in one place.

It’s also the only plastics event in the UK where visitors can see working machinery LIVE on the show floor and where they’ll come to compare, contrast and buy.

With an expected 12,000+ attendees across the three-day event, as well as new features and an expanded floorplan, now is the time to position yourself as a company that can o er solutions, showcase innovation and o er expertise to an audience known for its quality and purchasing power.

Berry Global develops ‘next generation’ of FormiFor insulation

Berry Global’s European flexible films division has launched a ‘next-generation’ version of its FormiFor insulation compression film that now incorporates up to 30% post-consumer recycled material.

Berry claims that this latest addition enables companies to benefit from the many existing advantages of FormiFor while also being able to demonstrate a stronger environmental profile through the increased use of circular polymers. The film also demonstrates the commitments made in Berry’s Impact 2025 sustainability strategy to develop solutions that minimise a product’s environmental impact.

The new version of FormiFor, which has received RecyClass accreditation to confirm

An Egg-cellent development: Spark Sourcing gains eco certification for egg shell based compound

the authenticity of the recycled content, contains up to 30% of Berry’s Sustane premium recycled polymer. It is claimed that Sustane polymers provide high levels of technical performance, consistency, traceability, and quality. This ensures that FormiFor continues to offer its high weld and holding force characteristics and can be printed in up to eight colours for high-impact and colourful decoration that maximises brand awareness and on-shelf appeal.

Spark Sourcing, a distributor of sustainable packaging solutions, has announced that its product, eco-shell, has received EN 13430 certification for recyclability . This adds to a growing list of certifications that includes SGS eco-certification for plastic, waste, and carbon reduction, as well as EU RoHS and REACH certifications. These distinctions firmly establish ecoshell as the ultimate choice for brands and manufacturers dedicated to achieving a circular economy for plastics.

eco-shell is a bio-calcium compound derived from eggshells through a patented seven-step process that involves calcination. Patents have been granted in the USA, UK, Taiwan, Australia, and China .

PLA, as well as recycled plastic, ocean-bound plastics, and bio-plastics. Additionally, eco-shell holds both antibacterial and high FIR emissivity certifications, further enhancing its value and applications.

The possible applications of ecoshell are vast, spanning various industries and products: Jars and bottles for the cosmetic, pharmaceutical, wellness (supplements and powders) and cannabis industries (up to 30%

Geofabrics enhances manufacturing capabilities with support from Ridat

The company claims that this ‘versatile’ material is compatible with a wide range of plastics, including PP, PE, HDPE, PET, EVA, PS, ABS, rubber, PVC, UK-based thermoforming equipment manufacturer Ridat has supplied Geofabrics with a Model 8040AVF Vacuum Forming Machine with Duplex Heater, after being tasked with supporting the company in increasing its production capacity.

The 8040AVF has been designed for consistent production of all commonly used thermoformable material

of up to 12mm thickness. It provides an automatic vacuum forming cycle and features top and bottom heating with PID control for accurate zone temperature control. Geofabrics of Leeds, UK, specialises in the manufacture of geotextiles, cuspates and cuspate composites, and geocomposites, which are supplied into a wide range of high risk civil engineering applications.

It manufactures cuspates from high density polyethylene, which is extruded into a range of different thicknesses.

The sheet is formed in an extrusion process: semi-molten polymer is extruded through a flat die and these impermeable membranes are then vacuum formed into cuspated cores. Geofabrics’ cuspates are commonly used as a component in

a geocomposite, in conjunction with a geotextile filter, in applications such as gas protection systems, cut off walls around contaminated land, rear of bridge abutments and retaining walls, etc. The installation of the 8040AVF is helping Geofabrics to increase production of its cuspate products.

It has supplied a number of thermoforming machines to Geofabrics in the past. Dipak Sen Gupta, Director of Ridat, said: “We are

plastic reduction) Foam mats and gym flooring that are 40% less plastic, cheaper, and anti-bacterial Trays and industrial packaging with 50% eco-shell Bags made form 30% eco-shell and 70% recycled plastic. eco-shell + PLA for reduced plastic and biodegradable straws, utensils, etc. Industrial buckets, bins, and barriers with a 30% plastic reduction. * Pallets made of recycled plastic and eco-shell that pass stringent strength tests.

proud of our longstanding relationship with Geofabrics, which has been built up over several years, and were delighted to support the company once again with our technical expertise and innovative vacuum forming technology.”

Kingsmoor Packaging claims its recent collaboration with Mypower, a solar energy solutions provider, has resulted in an extensive PV solar panel investment for their Somerton manufacturing facility. Once installed, the company claims that the system will mark a significant step forward in the thermoformed packaging specialist’s commitment to sustainability, as the company aims to achieve 50% of its annual energy consumption from onsite renewable sources by the end of 2023.

Following the recent announcement of Kingsmoor’s brand refresh and their new strapline, “Forming A

Kingsmoor packaging lays down marker for sustainable future with solar panel collaboration

Better Future”, this renewable energy project aims to serve as testament to the company’s dedication to this vision.

With the integration of technologies

AQUAPAK POLYMERS APPOINTS DUDLEY JONES AS SALES DIRECTOR- AIMS TO DRIVE SALES OF HYDROPOL POLYMER

Aquapak Polymers Ltd, which specialises in polymer-based material technologies that the company claims delivers both performance and environmental responsibility at scale, has announced the appointment of flexible packaging expert Dudley Jones as Sales Director to drive end applications of its polymer, Hydropol.

Jones’ role will concentrate on promoting end applications for Hydropol, a highperformance polymer that the company claims enables product design to provide its muchneeded functionality,

whilst increasing recycling and reducing plastic pollution, with a focus on paper and barrier applications through extrusion coating, casting or lamination onto other materials.

Commenting on the

such as a free air chiller system and smart compressor systems, Kingsmoor says it has taken substantial strides to reduce its carbon footprint during the manufacturing process.

The latest investment in on-site renewable energy further strengthens their mission to minimise environmental impact. By harnessing the power of solar energy, Kingsmoor Packaging aims to significantly contribute to the production of their own energy needs.

In addition to the focus on energy sustainability, Kingsmoor remains dedicated to utilising materials with high recycled content, ensuring all products are ‘100% recyclable.’

The company claims its R&D team is continuously exploring innovative packaging designs that prioritise lightweight construction and reduced plastic usage, exemplified by their ‘Cirrus’ packaging solution.

role and enormous potential for Hydropol, Dudley Jones said: “Aquapak has developed a unique technology in HydropolT, which is recyclable, marine safe, does not form microplastics* and can deliver barrier and functionality to paper.  This makes the potential applications for Hydropol far reaching and very exciting. From beverages and confectionary to personal care and

home improvements, Aquapak’s technology has the potential to transform flexible packaging as we know it.”Commenting on Dudley’s appointment, Mark Lapping, Chief Executive Officer, Aquapak, added: “Dudley is joining Aquapak at a time when the demand for new, environmentally friendly but functional packaging is huge. There are many market segments where Hydropol can provide end-customers with a solution which isn’t available today and help them improve their environmental footprint without compromising product quality or the end-user experience.”

AIMPLAS has carried out chemical and biotechnological pretreatments to turn synthetic plastics into biodegradable bioplastics. The goal of the project is to develop sustainable and environmentally friendly alternatives to traditional petroleumbased plastics.

The project used a cascade process by applying and combining chemical and biological methods to turn fossilbased plastic waste into natural, biodegradable substitutes to be used in the packaging and pharma industries.

The role of AIMPLAS in the project involved the pretreatment of plastics using microwave-assisted thermochemical degradation. This new technology provided promising

AIMPLAS’ BioICEP Project turns

non-biodegradable plastics into new biobased materials

extrusion technologies that made changes to the structure of the polymeric chains to improve biodegradation of these plastics.

AIMPLAS is also the coordinator in charge of dissemination and exploitation of results, as well as communication activities.

results by turning non-biodegradable plastic waste (such as low-density polyethylene) into easily biodegradable materials. AIMPLAS claims that they

Arburg brings 100th anniversary celebrations to Ireland

Following the success of ARBURG’s ‘Anniversary Days’ celebrations in Lossburg Germany, and what the company says was a successful open day event at ARBURG UK in Warwick, ARBURG brought the celebrations to Athlone, Ireland, on 7th September 2023.

As previously covered by Interplas Insights, 2023 marks a special anniversary for ARBURG as the company commemorates 100 years of the Hehl family business. To celebrate, ARBURG is hosting a series of anniversary events, providing industry peers with an opportunity to

celebrate, socialise, learn and explore industry topics.

ARBURG says it was delighted to extend an invitation to all within the Irish plastics sector to visit the First Polymer Training site in Athlone, Ireland, on Thursday 7th September 2023, for a day of celebrations, insights and networking.

achieved total degradation in less than 28 days. Another technique used was the depolymerization of polyamides to obtain the monomers of these polymers.

Microorganisms are then able to degrade these monomers so they can be turned into products of interest such as bioplastics.

Likewise, AIMPLAS says it used reactive

BioICEP met the goal of developing processes to reduce the amount of plastic waste in the environment. With this in mind, the project was made up of partners from different countries and areas of knowledge who were able to address the challenge of developing alternative processes to improve recycling based on a multidisciplinary approach, which was essential for project success.

Visitors to the event could look forward to exploring topics of the Irish plastics market, with presentations and discussions focusing on improving sustainability, energy efficiency, digitalisation and maximising your OEE, specifically within the medical and healthcare sectors.

ARBURG’s 370 A full-electric Allrounder with GESTICA operator platform was also on display throughout the event.

Dr Robin Kent of Tangram Technology was the

day’s keynote speaker, and ARBURG gave away a limited number of signed copies of his book “Sustainability Management in Plastics Processing,” recently published in collaboration with the BPF.

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David Raine COLUMN

PMMDA Chairman Dave Raine senses optimism in the air ahead of two of the industry’s major upcoming events.

Seizing the opportunity

ith Interplas just around the corner, and Fakuma following closely on its heels, September looks like it’s going to be a bust period for the industry, and many people will be wondering what attendances are going to be like. The latest information would suggest that Interplas is set to be the best attended by both visitors and exhibitors for some time, which is all good news. With this in mind, the opportunities for manufacturers and suppliers alike to engage in good meaningful conversations about how to remain competitive should be grasped firmly with both hands, and in order to do this, some thought needs to be given to what we as an industry are trying to achieve.

Traditionally, the plastics industry has sat within the engineering sector, and this has been viewed sometimes as a ‘dirty, hands on’ working environment. Although a visit to any one of the many clean rooms currently producing componentry within the UK and Ireland would immediately dispel this myth, there is still a large sector of the industry that sits outside of these specific requirements, and in most cases, these are exactly the businesses that need to attract a younger generation of would-be experts and engineers. As an industry, we have an aging workforce, and every effort needs to be made to create better working environments, with adoption, of automation & IIOT-

Wtype reporting and integration top of the list of priorities. Interplas and Fakuma are the ideal forums for this, with industry experts aplenty available to everyone. One final thought before these exhibitions is the green angle. Consumers, and indeed prospective employees, especially those of a younger generation, are thinking carefully about where they work and who they spend money with, and transparency regarding environmental progress and plans need to be clear and visiblesimply disclosing net zero as a target or aim in the future is not enough, and proof of action will be required.

The above points will mean that suppliers and customers alike will need to plan visits carefully to get the most out of their precious time, and the sad truth is that these plans will need to be considered and implemented against a backdrop of UK, EU and indeed global uncertainty. Therefore, my hope and wish is that the upcoming events provide a forum for positive and meaningful discussions, and that we as an industry embrace and seize this opportunity to converse with peers, and develop a ‘resilient, best practice’ approach to the coming months and into 2024.

“

The opportunities for manufacturers and suppliers alike to engage in good meaningful conversations about how to remain competitive should be grasped firmly with both hands, and in order to do this, some thought needs to be given to what we as an industry are trying to achieve.

”

Philip Law

The BPF’s director-general Philip Law on a summer of mixed messages from government – and their impact on the plastics industry.

Stop-Start-Stop for industry, as government rows back on legislation

Once upon a time August was commonly dubbed ‘the silly season’, not for the antics of our public figures, but for the simple fact that most people took their holidays at a time of year which promised sunshine and, you just couldn’t get hold of your business contacts because they were ‘hors de combat’ sunning themselves on a lilo in Spain, or sprawled over a rock on a Greek island.

Not so today! The pressure is pretty continuous. I dare say that the Brussels Eurocrats cleared their desks and pulled down the shutters long ago but here in the UK mobiles are chirping, the Central Bank is still uttering baleful pronouncements on the cost of money, and the PM is gamely dodging the bouncers and googlies being bowled at him from disaffected backbenchers.

This sense of pressure has a lot to do with the fact that London is the epicentre of global news distribution. We just can’t escape it at any time of the day or month! This is compounded by the fact that news is money and the search for, production of and interpretation of news is constantly intensifying as the range of media widens.

An interesting and very relevant feature of the last month or so is the ‘rowing back’ on several pieces of environmental legislation, at least partly the result of the anti-Ulez vote which led to a Tory victory at the Uxbridge by-election. We have seen signals that there might be

a re-think of Net Zero Carbon and Defra has even announced it has stopped talking to Greenpeace. Also Zac Goldsmith has abandoned the government in desperation at its climate change policy.

Close to home, the government (together with the devolved administrations) has decided to defer Extended Producer Responsibility for packaging payments from October 2024 – October 2025. The government announcement carried the telling comment that it ‘recognises that there is a risk that the programme could contribute to inflation, on which it is essential that we continue to bear down’.

What does all this mean for the plastics industry? StopStart-Stop is never helpful as business requires continuity to plan and invest but on the other hand the introduction of a far from perfect system would have caused chaos. There was clearly more to the announcement than it just being counter inflationary. Much more work really needed to be done on the substance. Which means yet more serious deflection of expert management time and a re-run of old issues.

With Net Zero Carbon there appears to be a growing realisation of the costs of transformation and indeed the impossibility of ultimately reaching a Net Zero situation, globally and indeed nationally, especially when imports from potential free trade partners are weighed into the balance. Boris As the coming months unfold and we approach an election,

both Conservatives and Labour will be restating their ambitions in their manifestos. Nevertheless the plastics industry’s products in use remain powerful savers of energy and assist significantly in mitigating the effects of climate change, a point we will continue to make strongly with politicians of all hues.

BPF’s preparations are rapidly advancing rapidly for a crowded September and beyond. The BPF will be at Interplas (September 26th–28th) celebrating the Federation’s 90th Anniversary, and it will play a full part in the adjoining conference programme. We will also be exhibiting at the RECOUP Conference on September 28th. Our Annual Dinner on October 12th is already sold out and will feature former Shadow Chancellor of the Exchequer, Ed Balls, as guest speaker. Along the way we will be attending the Labour Party Conference on October 9th in Liverpool, pressing the plastics industry’s huge role in economy and society. High points of the year end will be our annual Parliamentary Reception at the House of Commons to be addressed by Minister Nusrat Ghani MP and meetings with Labour’s Shadow Business Minister Bill Esterson MP. An Enterprise Forum meeting with Defra’s Head of Waste to Value and Circular Economy will take place at the BPF’s offices on November 9th.

In the meantine, see you at Interplas!

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