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British Plastics

and Rubber

bp&r Jul/aug 2019

THINKING. RETHINKING. LATERAL THINKING. THINKING OUT OF THE BOX. K 2019. THE RETURN REVOLUTION Programme lead for the implementation of a Scottish DRS outlines his ambitions

REALITY ‘CHEK’ The self-assessment kit for cancer that won first prize in the Design in Plastics competition

A PROBLEMATIC PROPOSAL? The restrictions and potential alternatives to the government’s plastic packaging tax


editor’s letter

ALL CHANGE www.britishplastics.co.uk head of content: Leanne Taylor

T: +44 (0) 1244 952 371 E: leanne.taylor@rapidnews.com Assistant Editor: GRACE NOLAN

T: +44 (0) 1244 952 375 E: grace.nolan@rapidnews.com

Assistant Editor: Tom Walker

T: +44 (0) 1244 952 370 E: thomas.walker@rapidnews.com head of media SALES: Lisa Montgomery

T: +44 (0) 1244 952 372 E: lisa.montgomery@rapidnews.com Senior Sales Executive: MANDY O’BRIEN

T: +44 (0) 01244 952 519 E: mandy.obrien@rapidnews.com ART: SAM HAMLYN

T: +44 (0) 1244 680222 E: sam.hamlyn@rapidnews.com SUBSCRIPTIONS:

T: +44 (0) 1244 680222 E: subscriptions@rapidnews.com PUBLISHER: duncan wood

T: +44 (0) 1244 680222 E: duncan.wood@rapidnews.com PRINT SUBSCRIPTION Qualifying Criteria UK – Free Europe – £249 ROW – £249 FREE digital issues available to view and download online British Plastics & Rubber is published monthly (8 times/year) by Rapid Plastics Media Ltd, Carlton House, Sandpiper Way, Chester Business Park, CH4 9QE T: +44 (0) 1244 680222 F: +44 (0) 1244 671074 © 2019 Rapid Plastics Media Ltd While every attempt has been made to ensure that the information contained within this publication is accurate the publisher accepts no liability for information published in error, or for views expressed. All rights for British Plastics & Rubber are reserved. Reproduction in whole or in part without prior written permission from the publisher is strictly prohibited. ISSN 0307-6164 Incorporating Polymer Age and Rubber and Plastics Age.

PEFC Certified This product is from sustainably managed forests and controlled sources PEFC/16-33-254

www.pefc.org

Politics and Brexit aside, the theme of change is one that characterises this issue of BP&R. Our cover story looks at the upcoming K Show, which is changing its focus for 2019 to reflect the move towards a sustainable and circular future with plastics.

W

e find ourselves in changing times. Change in Westminster, with the election of Boris Johnson as the new leader of the Conservative Party and his appointment as the country’s new Prime Minister; change in the structure of the cabinet, with a new Environment Minister now responsible for picking up where Michael Gove left off; and a supposed change in pace in which this new collective aim to get Brexit ‘done’ by October 31 — either with a deal, or without one.

Plastics Federation’s Philip Law on page 22, in which he outlines how the Government’s proposed changes to tax packaging that does not have 30 per cent recycled content could be problematic.

Politics and Brexit aside, the theme of change is one that characterises this issue of BP&R. Our cover story looks at the upcoming K Show, which is changing its focus for 2019 to reflect the move towards a sustainable and circular future with plastics. We also have a feature on page 14 about the highly talented student behind the winning product in this year’s Design in Plastics competition, a self-assessment kit that aims to change the way that breast cancer is diagnosed, communicated and taught about.

So, there’s a lot of change happening – both in this issue and outside of it. And whether or not you are someone that embraces, or fears it, few could deny that it keeps things interesting.

Change too, in Scotland, as the preparations for the implementation of its DRS system are underway. This issue features an interview on page 52 with David Barnes, the programme’s lead, which explores the ways in which this potentially revolutionary model could change collection volumes, recycling rates and behaviour. Also, on the theme of recycling, we have an exclusive feature with the British

Finally, on page 58, materials expert, Mike Boswell, looks at how geopolitical, domestic, seasonal and economic change will impact on the price of polymers as he outlines what converters should be aware of, and plan for, as we enter the second half of the year.

Enjoy the issue. Leanne Taylor, head of content


the big story K2019 BRINGS NEW THINKING

K

AS THE PLASTICS INDUSTRY GETS SET TO DESCEND ON DÜSSELDORF ONCE AGAIN FROM 16 TO 23 OCTOBER, BP&R LOOKS AT HOW GLOBAL SOCIETAL NEEDS, MEGATRENDS AND SUSTAINABILITY ARE THE DRIVING FORCES BEHIND THE SHOW IN 2019.

2019 is fully booked. To the neophyte, this might not occur as significant. However, the statistics tell a different story. A full K show in 2019 means over 3000 exhibitors from more than 60 countries participating, the occupation of the entire Düsseldorf exhibition grounds with some 175,000 m² of net exhibition space, and more than 200,000 trade visitors from all over the world expected to attend. It certainly puts into context why the show is known as the world’s leading event for the plastics and rubber industries. THE MEETING PLACE FOR THE ‘WHO’S WHO’ Messe Düsseldorf, organisers of K, say the show is “the performance barometer for the entire industry”, as well as a global marketplace for innovation, new product launches and connecting with the ‘who’s who’ of the entire plastics and rubber world. K presents an opportunity to demonstrate the industry’s capabilities, discuss current trends and set the course for the future in a setting like no other. However, in times when the industry is experiencing seismic change, the upcoming edition of K takes a distinct angle – one set on addressing the current challenges of plastics for sustainable development, in addressing global megatrends and in the move towards a circular economy. These themes will not only will be among the key topics explored on exhibitors’ stands at K, but ones that will also be covered comprehensively in the supporting programme. PLASTICS SHAPE THE FUTURE For example, there will be a special exhibition named ‘Plastics Shape the Future’, which will host speakers, panel discussions and workshops on crucial topics including packaging waste, marine litter and climate change, as well as resource conservation, energy efficiency and recycling. Messe Düsseldorf says ‘Plastics Shape the Future’ will not only offer an international information and networking platform, but will also provide an opportunity for greater involvement of

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the show is known as the world’s leading event for the plastics and rubber industries.

policymakers and socially-relevant groups in the form of keynote presentations and speed-talks. THE DIALOGUE BETWEEN SCIENCE AND INDUSTRY Other features at K 2019 will be the return of the ‘Science Campus’ which aims to provide a platform for the dialogue between science and industry. It will feature research and teaching bodies, such as universities, colleges and scientific institutions, that will present their latest research for the plastics and rubber industry, with an intensive focus on sustainability and recycling management. Lastly but not least, the VDMA (German Engineering Federation) and its member companies will focus on the circular economy, with an outdoor area providing information about trends and challenges based on data, facts and practical examples as well as offering the opportunity to ask questions. PREPARING A VISIT For visitors planning a visit to K 2019, tickets can be purchased in advance online or on the day from the fair gates. However, the advance tickets are less expensive and allow holders to take advantage of the free travel to the fair by bus or train. Those who are still looking for accommodation for K 2019 may well be hard pushed, however, Messe Düsseldorf advises using the services offered by Düsseldorf Marketing & Tourismus (DMT). In September’s issue of BP&R we will be including a comprehensive exhibitor preview of K Show to help you plan in advance for your visit. www.k-online.de

www.britishPLASTICS.co.uk


Going further with Passion. At ENGEL, we embrace responsibility – both for our own products and for those made using our machines. We are committed to working with plastics responsibly and to increase the use of recycled materials. We support our customers in developing their production processes with the expertise gained over the course of seventy-plus years in the plastics industry. Together we strive to use plastics sustainably, meeting the requirements of the circular economy. Along with over 350 companies, universities and organisations, we have signed the Ellen MacArthur Foundation’s New Plastics Economy Global Commitment – helping to show that together, we can achieve greater things.

engelglobal.com


JULY/AUG 2019

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IN THIS ISSUE 08 INDUSTRY NEWS

ALL CHANGE

“THE HEART OF THE RUBBER SOCIETY BEATS IN LONDON” The renowned International Rubber Conference (IRC) is being hosted in the London next month in what host organisation, the IOM3, says could be the largest rubber conference in the UK this century. To mark the occasion, in a six-page special feature, BP&R highlights the best of what to expect, looks at the significant history of the material in the UK and profiles the latest news from the industry today.

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REALITY CHEK This year’s winner of the Design in Plastics competition has made checking for breast cancer a much more achievable reality thanks to her innovative self-examination kit. Leanne Taylor spoke to the young designer about the product, its potential and her hopes for a future career in plastics.

THE BIG SIX Faced with a decline in the number of domestic toolmakers and production and lead times increasing as a result, UK moulders often look for alternative options overseas. Where this can come with benefits, there’s also potential pitfalls. Jo Davis of Broanmain Plastics writes for BP&R on six ways to find a low cost, high-spec toolmaker that combine the best of both worlds.

on the cover

K2019 BRINGS NEW THINKING As the plastics industry gets set to descend on Düsseldorf once again from 16 to 23 October, BP&R looks at how global societal needs, megatrends and sustainability are the driving forces behind the show in 2019. SEE PAGE 4

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Editor’s Letter

Feature

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Feature

A PROBLEMATIC PROPOSAL? In this special edition of our regular ‘News from the Front Line’ feature, Philip Law, Director-General of the British Plastics Federation answers important questions in relation to the government’s proposal to tax packaging that does not have 30 per cent recycled content, outlining both restrictions and potential alternatives.

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SPECIAL PREVIEW

Feature

25 TEMPERATURE CONTROL 31 RUBBER 35 MOULD MAKING AND TOOLING

Feature

52

19 PACKAGING

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THE RETURN REVOLUTION As Scotland looks to become the first UK country to implement a nationwide Deposit Return System (DRS), Tom Walker spoke to Zero Waste Scotland’s David Barnes, the Programme Manager for DRS, who is at the forefront of the scheme’s introduction.

www.britishPLASTICS.co.uk

41 PIPE AND PROFILE 45 IN-MOULD LABELLING 51 RECLAMATION AND RECYCLING 54 SOFTWARE 55 BUYERS’ GUIDE 58 POLYMERMAN


www.ultrapolymers.com | Your partner from design to production

INDUSTRY | NEWS KraussMaffei and Netstal to combine under KraussMaffei brand

Hans-Ulrich Golz

KraussMaffei and Netstal are to combine into a single company under the KraussMaffei name. The new joint company will start presenting these changes initially in its medical technologies and packging portfolios. Hans-Ulrich Golz, President of the Injection Moulding Machinery segment at KraussMaffei, said: “Under the single, strong KraussMaffei brand, we are combining our injection moulding expertise from all application areas. “We will be pushing ahead the world of injection moulding more than ever, in keeping with our new, shared motto, Pioneering Plastics.” Tobias Daniel, Vice President Sales IMM at KraussMaffei, said: “The common sales organisation, which is global and oriented to cover entire areas, is an important milestone in our effort to get even closer to our customers and markets. “This way, we are the partner who can always provide our customers with the right solutions to make their businesses more successful.”

Make UK appeals to Boris Johnson to avoid no-deal Brexit The head of Make UK has urged Boris Johnson to rule out the possibility of a no-deal Brexit, citing the damage it could cause to the UK’s manufacturing sector. The call follows the new Prime Minister’s appointment of prominent 8

Biesterfeld expands collaboration with ExxonMobil Chemical in UK and Ireland Biesterfeld is strengthening its long-standing collaboration with polymer supplier, ExxonMobil Chemical, by commencing distribution of Vistalon ethylene propylene diene (EPDM) rubber in UK and Ireland. “By expanding our distribution rights to include the UK and Ireland, we are enhancing our offer of high-performance polymers,” commented Guy Payne, Managing Director, Biesterfeld Petroplas Ltd. “We are pleased to be strengthening our collaboration with ExxonMobil Chemical. The outstanding properties of Vistalon EPDM will provide our customers with competitive advantages, reinforcing our market position within the synthetic rubber industry.”

Vistalon EPDM rubber offers good ozone and UV stability and is highly resistant to chemicals and heat. It provides high flexibility when cold, it has good electrical insulation and compression set. Vistalon EPDM is ideally suited for a wide variety of applications, including automotive and consumer goods products. It can be processed using injection and extrusion moulding and can be calendared into sheets for roofing products. Due to the combination of its properties, Vistalon EPDM is also used in interior and exterior gaskets, as well as in cable insulation and flexible hoses. Depending on the grade, it is available in the form of pellets or bales.

pro-Brexit politicians to key Cabinet positions. Stephen Phipson, CEO of Make UK, said: “We welcome the new Prime Minister to Downing Street and have written to him today congratulating him on his appointment. “We have also set out the critical importance manufacturing plays to the economy. British manufacturing

is a great national success story employing millions of people and contributing billions of pounds to the GDP. “A no-deal Brexit would damage our sector beyond repair. We look forward to working together with the new administration to make sure we move quickly to a deal which delivers Brexit and keeps manufacturing in a world leading position.”

www.britishPLASTICS.co.uk


www.ultrapolymers.com | Your partner from design to production

Hillenbrand to acquire Milacron Milacron has been acquired by US-based industrial company, Hillenbrand, for a cash-and-stock transaction valued at approximately $2 billion USD (£1.6 billion GBP). Hillenbrand, which also owns ancillaries group, Coperion, says the transaction represents a “pivotal step in [its] vision to become a world-class global diversified industrial company” by

adding new strategic businesses in hot runner systems and injection moulding to its portfolio through Milacron’s brands, including MoldMasters and Milacron injection moulding. Together, the combined company will have increased scale and product diversification, which Hillenbrand says will enhance its ability to serve customers through complementary technologies across the plastics value chain, including plastic base resins production,

compounding, processing both extruded and injection-moulded products and recycling. Joe Raver, President and CEO of Hillenbrand, said: “This transaction meaningfully transforms our portfolio and product offering by adding Milacron’s leading technology solutions and sizable installed customer base to help us drive long-term growth.” In May, Milacron also sold its Uniloy Blow Moulding division to Osgood Capital Group.

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www.ultrapolymers.com | Your partner from design to production

Valpak and RECOUP join for educational programme RECOUP and environmental compliance firm, Valpak, have joined forces to deliver a plastics recycling education programme directly into schools. Pupils from Diss High School in Norfolk took part in recycling games to help them understand what they can recycle locally, as well as the journey plastic packaging takes once it is recycled. Steve Gough, CEO of Valpak, said: “Plastics are on everyone’s mind at the moment, and these workshops do an amazing job at helping the children to understand how plastics are made, how to identify the different types, and to give them ideas on how to keep plastic packaging out of the natural environment by recycling. “We have supplied a dedicated bin to collect plastic bottles, so the pupils can recycle easily at school.” Anne Hitch, Citizen and Stakeholder Engagement Manager at RECOUP, said: “It was encouraging to have so many questions and so much input from the students, and they were really keen to understand what happens to plastics packaging when recycled.”

Government to invest £60m in sustainable plastics in drive to net zero New forms of packaging and plastic made from plants, wood chippings, and food waste could be a step closer, thanks to new business and government investment. Business are expected to jointly invest up to £149 million, alongside a £60 million government investment, to help to move away from single-use plastics. The funding could be used to find ways to cut waste in the supply chain, develop new business models and create new sustainable recyclable materials. This could include using plants instead of oils to make plastic,

which will help reduce their carbon impact. This forms parts of the government’s ‘Clean Growth Challenge’, and follows the UK becoming the first major economy to legislate to end its contribution to global warming by 2050. Greg Clark, former Business Secretary, said: “This government and business co-investment clearly demonstrates that when it comes to cutting plastic pollution there is a shared ambition. This is unique opportunity for our worldleading businesses and innovators to develop the materials of the future with the potential to transform our economy as well as our environment.”

The Plastribution UK team with Mike Boswell (far left)

“As this is our 40th anniversary year, the recognition is especially poignant.”

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Plastribution wins performance award UK polymer distributor, Plastribution, has won an award from its parent company, the Itochu Corporation.

The awards are made on an annual basis to Itochu businesses that have performed exceptionally well. Plastribution is the only business in Itochu’s Energy and Chemicals Division to receive an award this year. Mike Boswell, Managing Director of Plastribution, said: “Whilst this award is classed as a management award, I am dedicating this achievement to the outstanding contribution from all members of staff and I am delighted that their collective efforts have been recognised in this way. “As this is our 40th anniversary year, the recognition is especially poignant.”

www.britishPLASTICS.co.uk


www.ultrapolymers.com | Your partner from design to production

New management team announced for Wittmann Battenfeld UK Barry Hill, Managing Director of Wittmann Battenfeld UK, is to retire from his role on January 1st, 2020. Hill has been instrumental for Wittmann Group business in the UK for well over 30 years. Michael Wittmann, Wittmann Group General Manager, said: “Barry will be sorely missed within the Wittmann family. No anniversary celebration, trade exhibition, or conference will be the same without him.” In 2020, Wittmann Battenfeld UK will be jointly run by Daniel Williams and Tracy Cadman, responsible for sales and finance respectively. Hill said: “I have every confidence in passing the baton on to Daniel and Tracy. Like myself, Dan has come up through manufacturing via the apprentice route and therefore has a solid grounding in the issues and principles of industrial life.

L-R Barry Hill, Daniel Williams and Tracy Cadman

“Our customers are in very good hands. It has been a pleasure and privilege to serve the Wittman Group through my career. It is rare indeed to work today for a global business that adheres so faithfully to true family values.

“Over the transition period of the next six months I am looking forward to steadily handling over the UK reins and to seeing many old friends and customers on site at K 2019 in Düsseldorf.”

None of the drawbacks... • TECHNICAL SUPPORT BY OUR OWN EXPERIENCED ENGINEERS • SPARES HELD IN THE UK • DEMO SHOWROOM • STOCK MACHINES

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Alan Turing to be the face of new £50 polymer note

Mathematician Alan Turing will appear on the new £50 polymer note set to enter circulation by the end of 2021. Bank of England Governor, Mark Carney, said “as the father of computer science and artificial intelligence, as well as war hero, Alan Turing’s contributions were far ranging and path breaking.” The Bank is currently in final preparations for the launch of the polymer £20 in 2020, with over one billion new notes being printed. markets.

Manchester Polymer Group releases agenda for next Plastics Seminar The Manchester Polymer Group (MPG) has released the agenda for its next plastic seminar, ‘Plastics and the Environment’ taking place on 31 October. The group says the ever-growing concerns of the environmental impacts of plastic, combined with the increasing focus on the Circular Economy model is the driver for the full day of presentations and discussion on this highly topical theme. The ‘Plastics and the Environment’ seminar will cover wide and varied aspects of the issues involved, including collection, sorting and recycling; standards developments; legislation and testing; new developments in environmentally friendly plastics; and post-consumer waste. The event will take place on at the Macdonald Kilhey Court Hotel, Standish, Near Wigan.

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ARRK injects significant investment into new Midlandsbased moulding facility ARRK Europe says it is experiencing continued growth of its range of services, including its newly established injection moulding centre in the Midlands, following significant investment at the site. ARRK secured the 40,000 sq. ft facility in Kings Norton, Birmingham, back in October 2017, as part of its continued growth, which now includes a strategic alliance with neighbour, Paintbox. ARRK has made significant investment in this site with the installation of six Krauss Maffei injection machines, ranging from 80T to 1600 tonnes, robotic arms, material handling systems and a CMM machine. The new site has also created around 45 new jobs in quality, programme management, production and logistics with more opportunities on the horizon.

General Court of the European Union rules BPA as substance of high concern The General Court of the European Union has dismissed a challenge from PlasticsEurope and has upheld that BPA is a ‘Substance of Very High Concern’ under REACH legislation. BPA was added to the list of Substances of Very High Concern in January 2017, but PlasticsEurope took the European Chemical Agency to court over the matter. However, the General Court has “dismissed the action in its entirety.”

ARRK European MD, Tony Lowe, commented: “With this geographical advantage close to the heart of the UK automotive industry, ARRK are well placed to support customers. “In addition, our partnership with Paintbox offers a very competitive ‘one stop shop’ with moulding, fully automated robotic painting, assembly, EDI and logistics. This package is one we feel our customers have been looking for and one we are fully committed to providing.” As the Kings Norton site continues to grow its operations it is anticipated that the company will host an open day towards the end of the year.

PlasticsEurope said: “We already note that the court’s conclusion is in clear contradiction to the express provisions if the REACH Regulation. “PlasticsEurope continues to consider that the REACH Regulation exempts intermediates from the entire authorisation title of REACH, including their inclusion on the candidate list for eventual inclusion in Annex XIV as SVHC. “In any event, the General Court’s judgement does not affect the current situation, which is that BPA, whether an intermediate or not, can be lawfully and safely placed on the EU market in compliance with all relevant legislation.”

www.britishPLASTICS.co.uk


www.ultrapolymers.com | Your partner from design to production

Q: Which marginal conditions are important when choosing a material loader?

IN THE LATEST INSTALMENT OF OUR ONGOING SERIES ANSWERING THE MOST FREQUENTLY ASKED MATERIALS HANDLING QUESTIONS, THE EXPERTS AT MOTAN COLORTRONIC EXPLAIN THE CONFIGURATION OF MATERIAL LOADERS.

In addition to the throughput and local conditions, numerous other criteria are important for the conception of material supply that can affect the configuration of material loaders. This affects the form of delivery and properties of the material to be conveyed. For example, one needs to consider whether granulate and pellets, regrind, flakes, or powder is going to be conveyed. Another deciding factor is whether the material is dusty, whether it tends to form angel hair, or whether it is very abrasive due to its fillers or reinforcement materials. For particular requirements, there are specific material loaders e.g. for regrind with a specific cleaning filter, flake material loaders with particularly large material outlet flaps, or abrasion protected material loaders with reinforced, hardened surface deflectors. Ideally, a material loader line is set up modularly, in order to adapt to changed production requirements. This applies, for example, to the material inlet pipe as well as the material inlet flap. The material inlet can be fitted to the container either radially straight or angled. A special form is a tangential material inlet in combination with an air outlet with cyclone effect. This is used for fine, dusty material that tends to form angel hair. The material inlet flap has two important functions: on the one hand, it minimises abrasion, because it functions as a deflector at the material

inlet and so protects the filter sieve and casing of the material loader from abrasion. For extremely abrasive materials, an angled material inlet or a glass covered impact plate would be sensible. On the other hand, the inlet flap ensures that multiple material loaders can work together in a system. The moment one material loader of the system starts working, the vacuum in the system causes the flaps of the other material loaders to shut. For high-grade applications where fine dust must be avoided, the use of a dedusting unit, which is installed directly on to the material loader, is recommended. The then dedusted material can be processed without delay, because the dust is sent to the central filter with the air flow. High-grade material loaders often have a spring damper at the material outlet, which prevents the flap closing completely when it is not under vacuum. If there are granules on the outlet flap during conveying, they will first be sucked away. With increasing vacuum, the flap is pushed against the spring and eventually closes completely. This prevents trapped material leading to a loss of vacuum.

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Reality Chek WORDS: LEANNE TAYLOR

A

T THIS YEAR’S WINNER OF THE DESIGN IN PLASTICS COMPETITION HAS MADE CHECKING FOR BREAST CANCER A MUCH MORE ACHIEVABLE REALITY THANKS TO HER INNOVATIVE SELFEXAMINATION KIT. BP&R SPOKE TO THE YOUNG DESIGNER ABOUT THE PRODUCT, ITS POTENTIAL AND HER HOPES FOR A FUTURE CAREER IN PLASTICS.

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university student has been praised for her vision and outstanding product development after the judges awarded her top prize in the 2019 Design Innovation in Plastics competition. Daniella Kaligorsky, a third year Product Design student from Technological University Dublin, came up with ‘CHECKKIT’, a kit which shows how to conduct a self-examination for breast cancer. It includes models that simulate the breast and the physical symptoms of breast cancer and it also has a brochure to explain what to do and how to recognise 12 possible symptoms, along with a notebook to log results. Kaligorsky chose translucent silicone for the outer layer of the breast models, with the replica tumours and back plate produced from ABS. The silicone was chosen for its ability to replicate the texture of human skin accurately, as well as being easily processed, whilst ABS’ qualities as a tough, hard and rigid material with good chemical resistance and dimensional stability that is effectively injection-moulded made it ideal for the rigid plastic components. “It was daunting choosing the materials initially, as I hadn’t worked with plastics before,” Kaligorsky explained. “However, it was surprising to discover how much can be done with polymers and the variety of properties that they possess. The ability for these materials to replicate skin and tumours so accurately is incredible. It made me realise just how large the opportunities using plastics in design are.” MARKET READY The longest running student plastics design competition of its type, DIP is held every year to encourage university students to come up with brand new products made primarily of plastic. Competition organisers, the Institute of Materials, Minerals and Mining and the Worshipful Company of Horners, this year set the challenging brief of ‘Healthy Body – Healthy World’ inviting ideas for improving health, wellbeing or encouraging exercise, with a product that could demonstrate longevity and sustainability. Commenting on the winning product, chairman of judges, Richard Brown, said the panel was extremely impressed with Kaligorsky’s thorough research into the medical and practical need; her comprehensive review of materials to get the right texture and touch for her product, along with her analysis of manufacturing methods, costs, end user experience and sustainability. She had also given due consideration to competitor products. “We felt very strongly that this was a product that would enhance wellbeing and was market-

ready to meet Daniella’s vision for it,” he added. Another member of the panel, technical engineer, Mike Stuart, formerly of Covestro, said the well thought through manufacturing and practical presentation would help de-stigmatise the subject of breast examination and make it useable even in schools. “This product could be put into production fairly quickly, and we feel a possible future application could be a similar kit for testicular cancer,” he explained.

I’ve learned a substantial amount about both plastics and the manufacturing process. Although there is still so much to learn, I am excited to take a step further to discover more about the world of plastics and the benefits that it can provide. Plastics are amazing. They are the future.”

RAISING AWARENESS Kaligorsky said losing a member of her family to breast cancer had inspired her to look deeper into this subject and try to address the problem. “It is a great opportunity to be able to pursue product design and be acknowledged by such a great competition and I am proud that the significance of the problem with cancer is recognised,” she said. “The subject of cancer is avoided and is unspoken, which seems to only make the problem more prominent. As discovered, cancer survivors and patients can feel exceptionally lonely due to the lack of awareness and fear of discussing the illness. That inspired me to look deeper into the subject to address this problem. “As soon as I began my research, I realised how big a problem it actually was and how many people are affected by it. After conducting interviews, I was surprised to discover how little people know about breast cancer and the self-examination process. This has ultimately inspired me to come up with a product that raises awareness and teaches people self-examination.”

www.britishPLASTICS.co.uk


“PLASTICS ARE THE FUTURE” Thanks to taking part in the competition, Kaligorsky is now keen to pursue a career in medical plastic product design and hopes her products will make a difference in the field of health and wellbeing. She will hone her skills during upcoming placements at both Covestro and PDD London, both part of the winner’s prize package. “I have realised that I am interested in helping people through design, specifically in the medical field,” she explained. “I’ve learned a substantial amount about both plastics and the manufacturing process,” she added. “Although there is still so much to learn, I am excited to take a step further to discover more about the world of plastics and the benefits that it can provide. Plastics are amazing. They are the future.”

The new Seprobot solution

HEALTHY COMPETITION The other finalists in the competition also produced worthy and impressive products.

Kai Wang, of Brunel University, came second for his product ‘Potluck’, a combined cooking and storage device that encourages and simplifies the production of nutritious stock cubes using avoidable food waste. Third place went to Christopher Kay from De Montfort University for ‘EnviroJect’, a

re-usable syringe system, providing a safe and sustainable method of administering medications. Highly commended places were awarded to Louis Farnworth for his breathing aid product ‘Air’ and Namgyun Ryu for his ‘Tri Walker’ mobility aid. All finalists receive work placements and cash prizes, along with further help to develop their products should they wish. The theme announced for next year’s competition is urban living.

www.britishPLASTICS.co.uk

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22-May-19 2:01:01 PM


PACKAGING | NEWS GROUP COLLABORATION PRESENTS prototypes of food packaging made from 100 per cent recycled material

Unilever launches “game-changing” packaging refill system

BASF, Borealis, Südpack, and Zott have come together on a pilot project that has seen multilayer food packaging made from 100 per cent recycled materials. The project was made possible thanks to the collaboration between the three, with BASF supplying chemically recycled polyamide, Borealis providing sustainably produced polyethylene and Südpack using these materials to produce multilayer film for a specially sealed packaging for Zott Gourmet Dairy. The raw materials for the polyamide and polyethylene were produced in very small quantities as part of the ChemCycling project, and the pyrolysis oil derived from plastic waste was supplied by a partner and fed into BASF’s Verbund production site in Ludwigshafen as feedstock. Maurits van Tol, Borealis Senior Vice President for Innovation for Technical and Circular Economy Solutions, said: “What is special about this pilot project is that both components of the packaging, the polyamide and polyethylene, are made from chemically recycled material. “This innovative solution came about thanks to the selection of special polymers. In addition, the collaboration between the companies involved made it possible for the first time to consistently certify each step up from the raw material to the finished packaging.”

The packaging made from recycled materials (Credit: Zott)

Unilever has announced the launch of a new technology that allows consumers to refill and reuse its Cif spray bottles at home. The new Cif ecorefill concept sees a refill attachment ‘twist and click’ onto the top of an existing Cif bottle, which has been filled with water by the consumer. The technology delivers a 10x concentrated formula into the water, providing the same cleaning product as the original. The ecorefills, which use 75 per cent less plastic than the bottles, are 100 per cent recyclable once the plastic sleeves are removed. By the end of 2020, Unilver says its ambition is for all Cif ecorefills and spray bottles to be made from 100 per cent recycled plastic. The ecorefill’s space-saving design also comes with a smaller price tag, retailing less than the

Iceland “open about the challenges” after initial failure of plastics-free trials Richard Walker, Managing Director at Iceland, has admitted the group still has a “mountain to climb” on its plastic-free pledge after two key trials failed. After its paper band replacement failed to live up to hopes, the supermarket has had to reintroduce plastic packaging across its bananas this summer. In May, Iceland also scrapped a plastic-free greengrocer trial that was running in Liverpool after three months following a 20 per cent plunge in sales as loose produce and alternative packaging failed to resonate with local shoppers. From July 24, Iceland is launching its latest efforts for new plastic-

price of Cif spray bottles. “The launch of Cif ecorefills is a game-changer when it comes to reducing plastic waste in the products we use to clean our homes,” said Gemma Cleland, Vice President, Homecare, Unilever UK & Ireland. “By keeping a bottle of Cif and refilling and reusing it over and over again, consumers can reduce their consumption of single use plastic.”

free banana packaging, with a trial across 20 stores. The supermarket chain is also planning a new plastic-free greengrocer initiative that will run across more than 30 stores later this year, which will be focused on pre-packed produce rather than loose items in response to customer feedback from the failed trial. Walker admitted the group’s initial efforts to replace plastic packaging on the bananas ended up causing up to 20 per cent shrinkage of the fruit and they would snap off or go rotten. He told PA: “This is all part of the process – we’ve got to keep experimenting. It’s good to be upfront and open about the challenges. “We’ve still got a mountain to climb – and we’re still all on our own. No other supermarkets are following our lead.”

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Amcor enters into agreement for the sale of three flexible packaging plants in the UK and Ireland

Wales to develop new packaging measures following UK-wide EPR consultation Hannah Blythyn, Wales’ Deputy Minister for Housing and Local Government, has welcomed the outcome of a joint-governmental consultation to introduce Extended Producer Responsibility (EPR) for packaging. The consultation, which ran from February until May this year asked residents of Wales, England, Scotland and Northern Ireland for their views on EPR. A further consultation on proposals for a

Deposit Return Scheme for drinks containers in England, Wales and Northern Ireland was also carried out at the same time. “I’m pleased to see such public interest and enthusiasm for action in response to the consultation and to tackle the problem of single use plastic pollution in general,” Blythyn said. “Taking forward these important proposals will not only support our ambition and action to radically reduce waste and transition to a circular economy but also the realisation of our commitment to decarbonisation.” Wales will now work with the other UK Governments to develop the proposals.

Amcor has announced it has entered into a binding agreement with Kohlberg & Company for the sale of three former Bemis plants located in the United Kingdom and Ireland for cash consideration of $394 million (approx. £317million GBP). Collectively, these three plants generate annual sales of approximately $170 million (approx. £137million GBP) from the sale of flexible packaging for certain healthcare products. The sale remains subject to customary approvals including European Commission approval of Kohlberg & Company as the buyer and is expected to close in the coming weeks.

Europe’s flexible packaging market worth over €16 billion by 2023 A Wood Mackenzie Chemicals report has found that Europe’s flexible packaging market is predicted to achieve an annual compound growth rate of two per cent over the next five years. This will mean it will reach over €16bn euros (approx. £14.45bn GBP) in 2023, according to the ‘Flexible Packaging Europe Supply Demand Report’. Paul Gaster, Wood Mackenzie Chemicals Principal Analyst, said: “The European market for converted flexible packaging showed modest growth in 2018, increasing by just over two per cent to reach €14.5 billion last year. Sales in the European region, comprising 28 countries across Western and Eastern Europe, including Russia and Turkey, accounted for 16 per cent of total global sales in 2018. “There are still a number of smaller markets, largely in Eastern Europe, showing dynamism in the region. The European region as a whole exports nearly ten per cent of total production to non-European destinations,” he added. 20

Michael Gove has backed an ‘all-in’ DRS (Credit: Ian Davidson Photography)

MICHAEL GOVE backs all-in deposit return system Before the cabinet reshuffle under Boris Johnson’s premiership, former Environment Secretary, Michael Gove, backed a comprehensive ‘all-in’ model for a deposit return system (DRS). In a speech at Kew Gardens, Gove said such a model would give consumers “the greatest possible incentive to recycle.” The Government announced in February it was exploring two versions of a DRS, with the alternative on-the-go model attracting criticism from environmental groups due to it being restricted in the types of

containers it can take. Recent research from the Campaign to Protect Rural England (CPRE) suggested that the all-in model could generate £2 billion for the economy in ten years, compared to just £250 million for the on-the-go scheme. Gove said: “We need to work with business to make deposit return schemes as effective as possible and I believe an all-in deposit return scheme will give consumers the greatest possible incentive to recycle.” Maddy Haughton-Boakes, from the Campaign to Protect Rural England (CPRE), said: “We welcome Michael Gove’s support for an all-in deposit return system.”

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EXCLUSIVE NEWS FROM THE FRONTLINE

A problematic

proposal? IN THIS SPECIAL EDITION OF OUR REGULAR ‘NEWS FROM THE FRONT LINE’ FEATURE, PHILIP LAW, DIRECTORGENERAL OF THE BRITISH PLASTICS FEDERATION, ANSWERS IMPORTANT QUESTIONS IN RELATION TO THE GOVERNMENT’S PROPOSAL TO TAX PACKAGING THAT DOES NOT HAVE 30 PER CENT RECYCLED CONTENT, OUTLINING BOTH RESTRICTIONS AND POTENTIAL ALTERNATIVES.

DO YOU THINK THAT THE PROPOSED TAX WILL BE A POSITIVE THING, IN THAT IT WILL RAISE TAXES WHICH RESULT IN MUCH NEEDED IMPROVEMENTS TO THE RECYCLING INFRASTRUCTURE? It is clear that in the UK there is a need for huge investment in our recycling infrastructure to reduce our dependence on exports. A tax, however, only guarantees money for the Treasury. The industry believes that instead of a tax, refining Extended Producer Responsibility (EPR) obligations can achieve so much more and guarantee that money is invested in improving our recycling and waste infrastructure. BUT WOULD REFINING EPR OBLIGATIONS ACHIEVE THE AIMS SET OUT BY THE GOVERNMENT? We feel this would not only significantly increase the amount of plastics that are recycled, but it would also enable us to maximise recycled content in applications where it is possible, without generating more waste. ARE THERE AREAS WHERE THE 30 PER CENT TARGET IS NOT ACHIEVABLE? We estimate that around 25 per cent of packaging on the market cannot legally include recycled content due to food contact legislation. Medical packaging, for example, is not permitted to contain recycled content. Some plastics are perfect for packaging particular food products and are widely collected, easy to recycle and have thriving end markets such as the construction industry — but cannot legally incorporate recycled content when used for packaging. Other products would need to be made thicker and probably multi-material — a retrograde step that introduces problems for recyclers as well as using more plastic. Taxing companies in cases such as these could arguably be deemed unfair and is likely to result in extra costs for consumers. WITHOUT THE TAX AS A LEVER, WOULD THE INDUSTRY BE ACHIEVING THESE GOALS ANYWAY? Research carried out by Ernst & Young showed that 85 per cent of packaging companies planned to increase the recycled content in their packaging and, regardless of the tax, it is estimated that 50 per cent of companies would reach the 30 per cent target anyway. With the tax, this would be 62 per cent.

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DO YOU NOT FEEL THAT THIS INCREASE WOULD BE WORTH IT? Whilst we feel that the tax may increase the amount of recycled content in some packaging applications, in many cases this would not necessarily be the best environmental solution. In order to avoid paying the tax, it is likely companies would have to use more plastics. This could be for technical reasons in terms of strength or tensile properties or for food safety reasons. This could ultimately result in more plastic waste, not less, and could also cause problems for recyclers by creating packaging which is harder for them to process. DO YOU SEE ANY UNINTENDED CONSEQUENCES WITH THIS TAX? The UK is not currently able to recycle all of its waste and there is also a lack of recycled plastic available, potentially disadvantaging smaller businesses that will need to compete for material alongside large brands. Currently, 60 per cent of our recycled plastic for food packaging is imported. If 30 per cent recycled plastic is suddenly demanded, this may leave the UK overreliant on overseas markets. The tax, as proposed, would also exempt prefilled packaging, which we estimate accounts for around a third of all packaging on the shelves at supermarkets. This puts UK companies at a disadvantage and could result in £120m of business every year being lost to overseas companies. DO YOU THINK THAT THE TAX COULD LEAD TO JOB LOSSES IN THE INDUSTRY? The plastic packaging industry currently employs 27,000 people in the UK. We estimate that the tax as currently proposed could result in up to 4,600 jobs being lost, with 1,500 of them going overseas as a result of exempting pre-filled packaging, disadvantaging UK businesses. This could ultimately cost the economy £320m per year.

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This is a rare opportunity to properly tackle the problem and we want to avoid unintended consequences. However, we feel that this tax is not the best way of reducing plastic waste. Instead, refining wider extended producer responsibility (EPR) obligations, which are currently also being reviewed by the government, provides a better approach.

IF YOU DO NOT FEEL THE TAX IS THE WAY FORWARD, WHAT DO YOU THINK THE GOVERNMENT SHOULD DO TO TACKLE THE ISSUE OF PLASTICS WASTE, AN ISSUE WHICH IS SERIOUSLY DAMAGING THE REPUTATION OF THE INDUSTRY?

WHAT DOES THE BPF FEEL NEEDS TO BE DONE TO IMPROVE THE DOMESTIC SUPPLY OF RECYCLED MATERIAL? We welcomed the government’s consultation on the standardisation of household collection schemes and we very much hope the ridiculous situation we currently find ourselves in — with 38 schemes across the UK — is dealt with sooner rather than later. In an ideal world, all plastics would be collected for recycling across the UK to establish a stable supply of material for recyclers, as it is in many European countries. All plastics can technically be recycled, and work is being done around the world to scale up new recycling technologies.

This is a rare opportunity to properly tackle the problem and we want to avoid unintended consequences. However, we feel that this tax is not the best way of reducing plastic waste. Instead, refining wider extended producer responsibility (EPR) obligations, which are currently also being reviewed by the government, provides a better approach. Recycled content should be maximised where it delivers the most benefit to the environment and where food safety regulations allow it to be used. An incentive also needs to remain for manufacturers that make products capable of including significantly more than 30 per cent recycled content. We believe that recycled content is better evaluated in line with Wrap’s Plastic Pact, which states that the average amount of recycled plastic across all packaging should be 30 per cent by 2025. Instead of the proposed tax, increasing the plastic industry’s obligation towards meeting the costs of recycling is better met through refining the existing Extended Producer Responsibility System, which could be modulated to take into account a total resource efficiency approach, which includes the amount of recycled content as well as recyclability. This would help ensure we reduce plastic waste and that any extra money raised is invested in the UK’s recycling and waste management infrastructure, while remaining aligned with the government’s Waste Strategy.

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www.motan-colortronic.co.uk | Technology for challenges of the future

TEMPERATURE CONTROL | NEWS Frigel expands with new Polish subsidiary

ICS Cool Energy highlights importance of preparing for seasonal temperature rises

ICS is advising manufacturers to be prepared for warmer weather

ICS Cool Energy is urging plastics and rubber manufacturers to prepare for unexpected summer temperature spikes that could adversely affect the running of a plant. The company says that where temperature control equipment is a fundamental manufacturing tool for both process-specific cooling or moderating a site’s ambient air temperature, it is important to take precautionary measures to enable systems to avoid downtime when weather spikes over and above 30˚C. This, it says, is particularly important for ageing, underspecified or poorly maintained equipment, where consequences of not preparing for seasonal temperature fluctuations can result in not only short-term production downtime, but potentially full mechanical failure and the replacement of equipment. In order to help manufacturers avoid such outcomes, ICS Cool Energy has released an information guide outlining the short and longterm contingency measures that can be put in place to mitigate any negative seasonal effects on production processes. “Often the British summertime is laughed off as an underwhelming

period of overcast days peaking around 22˚C,” explained ICS Cool Energy’s Richard Metcalfe. “Yet, the fact of the matter is there are usually two or three days where the ambient air temperature exceeds the nominal specification for much of the pre-existing cooling equipment in operation across the UK’s manufacturing industry. It is these two or three days which can cost manufacturers hundreds of thousands of pounds in production downtime and remedial work.” He continued: “Flaws, which in 95 per cent of operating conditions go unnoticed, come to the fore when an industrial cooling system is placed under real strain. Equipment with a nominal specification in the mid-tolate twenties will start to struggle, and mechanical functions which are six, seven, or more years of age will again find it difficult to generate the level of mechanical cooling required to prevent overheating. “Crucially, these problems can – for the most part – be avoided by simply planning ahead. Not everyone will need to make wholesale changes or purchase new equipment, but acknowledging the issue exists is the first step.”

Frigel has opened a new subsidiary for its process cooling solutions in Poland. The company says the move is an important step for its global strategic growth by providing direct access to Polish market demand for intelligent process cooling solutions in the plastics, beverage and die casting industries. “We have always considered Poland as one of the top industrial markets in Europe. Thanks to its large population, a growing economy and a very friendly business climate, we believe Poland has the potential to expand business further in the future years and become a leader country within the central/eastern European territory,” said Frigel CEO, Duccio Dorin. “This subsidiary will allow us to improve operations and better serve our customers in Poland, guaranteeing a continued and much faster local support and services”. The new subsidiary is based in Wielgolas Brzeziński, Poland, and will support local sales and after sales services including installation, training and a local technical service, as well as a complete machine and spare parts stock.

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www.motan-colortronic.co.uk | Technology for challenges of the future

Flow control retrofit “simple and inexpensive” says Wittmann

WFC retrof it kit carried out for two f low circuits in this illustration

Piovan’s Easytherm mould temperature control unit wins IF Design Award A mould temperature control unit (TCU) for plastics processing has been awarded the IF Design Award for 2019. Piovan’s ‘Easytherm’ TCU from its Aquatech range was chosen from a field of 6,400 entries from over 50 countries as winner of the coveted IF (Industrie Form) award. A collaboration between Piovan Group’s R&D team and Italy-based strategic design consultancy, MM Design, the Easytherm is designed to fulfil all the necessary functional processing requirements of a temperature control unit, whilst incorporating new innovative features relating to usability, mobility and human-machine interaction. These features include a tiltmounted control panel so that operators can read key data easily; tempered glass for protection; six touch keys for instant access to

Wittmann has introduced a retrofittable flow control that it says can turn a simple flow controller into a low-cost, high-grade control system. The company says with a WFC retrofit, both existing and newlypurchased flow controllers from its 101, 301 and 200/300 series can be equipped with automatic control of flow quantity and temperature without major expense. As standard, the Wittmann flow controllers from these series’ come only with a simple visual flow control system (floats) and a bimetallic thermometer. With this standard equipment, it was not previously possible to collect the relevant flow quantity and temperature data digitally and pass them on to the injection moulding machine. However, with the new WFC retrofit-kit, this is now achievable. The conventional flow tubes used for the above-mentioned series’ can now be replaced easily by the

new measuring units. Wittmann says special adapter elements made of brass are inserted inside the flow controller housings in the top and bottom parts, in which the measurement units the liquids flow through are anchored. Here, the method of vortex flow measurement is applied, which makes digital analysis of both flow quantities and temperature development possible. The manual adjustment valves installed in the flow controller enable optimal adjustment of the flow quantity and a tolerance margin can be set on the control unit. The status of this margin can be passed on to the injection moulding machine. This can also be carried out using a special interface available as an option. In this way, targeted digital monitoring and analysis of the flow parameters are ensured. If the actual value falls below, or exceeds, the set tolerance margin, the control unit will issue an alarm signal if desired. The WFC retrofit kit also has an optional mains adapter, making it easy to use as a standalone solution.

“From the outset we concentrated on man-machine interaction, with correct positioning of a clear, legible display and with a handle for easy mobility. Every detail has been carefully styled, defining a new design language for the brand,” Piovan’s Easytherm commented Alex Terzariol, Owner TCU has won a coveted of MM Design. design award Easytherm operates with temperatures up to 90°C, but main functions; and an integrated Piovan says the range will soon be handle to allow the easy manoeuvre expanded up to 180°C. of the unit from one moulding “We are proud of this award, machine to another. There are achieved through our determination additional communication ports for to be constantly innovative, even Industry 4.0 connectivity. in choice of materials and in the The unit itself features two steel design of our solutions. Easytherm shells designed to protect the derives from in-depth analysis of temperature control unit from the market’s needs, with the aim impacts and accidental knocks at of producing a product that would the sides and also help to disperse successfully combine outstanding the heat accumulated on the performance with quality of internal components. At the front, materials and modern design,” said there are sheet metal covers and a Peter Dal Bo, Piovan’s Group Chief polycarbonate display mounting panel. Commercial Officer.

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www.ultrapolymers.com | Your partner from design to production

International Rubber Conference Organisation

T THE RENOWNED INTERNATIONAL RUBBER CONFERENCE (IRC) IS BEING HOSTED IN LONDON NEXT MONTH IN WHAT HOST ORGANISATION, THE IOM3, SAYS COULD BE THE LARGEST RUBBER CONFERENCE IN THE UK THIS CENTURY. TO MARK THE OCCASION, OVER THE FOLLOWING PAGES, BP&R HIGHLIGHTS THE BEST OF WHAT TO EXPECT, LOOKS AT THE SIGNIFICANT HISTORY OF THE MATERIAL IN THE UK AND PROFILES THE LATEST NEWS FROM THE INDUSTRY TODAY. WE BEGIN BY LOOKING AT THE CONFERENCE IN MORE DETAIL.

The heart of the rubber society

beats in London

The International Rubber Conference in 2019 (IRC 2019) will be held in London, UK, where delegates from all over the globe will descend on a city steeped in the material’s history. Held at the Kia Oval, home to Surrey County Cricket Club, from 3 – 5 September, the event marks the 200th anniversary of the work of Thomas Hancock on his pioneering pickling machine for the mastication of rubber. You can read more about this history on page 30, where BP&R’s Tom Walker looks back at the way in which this invention paved the way for the industry and resulted in the production of many of the products still familiar to us today. The IRC, however, will put aside these historical aspects by looking forwards to the emerging new innovations in elastomers, materials and products across three days of technical papers and presentations. The event will play host to rubber scientists, academics, technologists and industrialists to name but a few, as the industry gathers to learn, share and network.

A global gathering During the event, delegates will have the option to attend the presentations that they are most interested in, covering keys topics themed around engineering application of elastomers; polymer innovations; process and manufacturing advancements; filler and additives developments; and additional sessions on sustainability, material characterisation and modelling. In addition, on Tuesday 3rd and Wednesday 4th September, delegates will be able to attend plenary sessions given by two of the industry’s renowned experts. Tuesday will see Professor Dr Manfred Kluppel, Head of Department Materials Concepts and Modelling at the German Institute of Rubber Technology, give an address on ‘Modelling and Design of Elastomers – From Molecular Mechanisms to Industrial Applications’, which will focus on a broad overview of reinforcement mechanisms and modelling approaches with applications for FEM simulations. Kluppel will also be giving the Rubber Foundation Lecture as his plenary talk as the most recent IOM3 Colwyn Medal winner. Ahead of the conference, Kluppel said: “It’s important for me to attend the IRC 2019 in London since the rubber experts from all over the world are present there. I can get distinct information on all kind of problems regarding rubber and elastomer parts, be it theoretical questions or practical applications. The heart of the rubber society is beating at the IRC in London, so don’t miss it.”

Coolflow DTX Process Cooling Solutions

for Extrusion & Moulding Systems

Hydratech specialise in the manufacture of heat transfer fluids, glycols, antifreeze solutions, inhibitors and cleansers - for use in cooling and heating systems in manufacturing processes.


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On Wednesday, Professor Judit E Puskas AIMBE and IUPAC Fellow, Biomaterial and Biopolymer Engineering Program at Ohio State University, USA, will present a talk on ‘Natural Rubber Biosynthesis: Still a Mystery.’ Puskas, who received a PhD in plastics and rubber technology in 1985, and an M. E. Sc in organic and biochemical engineering in 1977, has been involved in polymer research and development in the microelectronic, paint and rubber industries. Of the event, Puskas said: “Being a Rubber City Girl, it is imperative that I come to this conference, listen to the latest research and news and meet experts.” A forum for learning Ahead of the start of IRC 2019 there will be an additional opportunity to attend various training courses on Monday 2 September. Held by the Rubber Division, Lord and Rubber Consultants within the Kia Oval, these courses aim to give attendees the opportunity to learn more about the rubber industry and help to improve knowledge. The Rubber Division will be holding their course on basic rubber compounding, focused on providing an overview of rubber compounding and testing and the process techniques. Lord will host a half-day

contact us tel: 01792 586800 www.hydratech.co.uk

training around LORD Corporation Chemosil and Chemlok substrate-to-metal bonding agents through theory and experiment. There will also be another half-day training focused around Sipiol Weatherstrip Coatings, Flocksil and Flocklok Adhesives and Chemlok Glass Encapsulation. Rubber Consultants will be hosting a full day course on the use of rubber in design of engineering components with a combination of theory and a hands-on workshop. Scoring a century In addition to the plenary talks, concurrent conference tracks and optional training courses, the event will also feature a large exhibition, host a student prize and hold taster events provided for local schools. Commenting on the upcoming conference, Professor James Busfield, Head of Materials Division at Queen Mary University of London and Co-Chair of IRC 2019, said “we look forward to welcoming delegates to IRC 2019, which we anticipate will be the largest rubber conference in the UK this century.”

Turn the page read more about the significant history of rubber in the UK as well as the latest news from the industry.


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International Rubber Conference Organisation

T

2 0 NOT OUT

THE YEAR 2019 MARKS TWO CENTURIES SINCE INVENTOR, THOMAS HANCOCK, FOUNDED THE BRITISH RUBBER INDUSTRY. AHEAD OF THE INTERNATIONAL RUBBER CONFERENCE (IRC) 2019 AT THE OVAL CRICKET GROUND, LONDON, BP&R LOOKS AT THE HISTORY OF HANCOCK, AND THE DEVELOPMENT OF RUBBER AS A MATERIAL AT THE FOREFRONT OF THE 19TH CENTURY. WORDS: TOM WALKER

The Charles Macintosh and co. factory in 1918

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In 1815, Thomas Hancock was in partnership with his brother, Walter, as a coachbuilder in London. The beginning of his foray into developing rubber came from the aim to keep passengers and drivers on his coaches dry. By 1819, he began experimenting with production.

This led to rubber being made waterproof, as in 1823 Macintosh patented his method for making waterproof garments by using rubber dissolved in coal-tar naphtha for cementing two pieces of cloth together, which led to the famous Macintosh coat being named after him.

In 1820, Hancock patented a number of elastic fastenings for items like gloves, suspenders and shoes, but found himself wasting large amounts of rubber in the process of making it.

Macintosh’s rubber still encountered problems, most notably that it was easy to puncture when seamed, and that the natural oil in wool caused the rubber cement to deteriorate, while the fabric became stiff in cold weather and sticky in hot weather.

“THE PICKLE” To avoid wasting rubber, Hancock invented a machine called a masticator, which shredded waste rubber using a hollow cylinder studded with teeth. Hancock said of the masticator: “Pieces with fresh cut edges would perfectly unite, but the outer surface, which had been exposed, would not unite. It occurred to be that if minced up very small the amount of fresh-cut surface would be greatly increased and by heat and pressure might possibly unite sufficiently for some purposes.” Instead of patenting the masticator, Hancock instead decided to refer to the machine as “the pickle”, choosing a name that would keep his process secret. The pickle could initially by operated by hand by one man and could hold 85 grams, and by 1821 a two-man machine was produced that could hold 450 grams. ENTER THE MAC This further evolved from the previous wooden model to a steam-driven variant, and in 1821, Hancock joined with Scottish chemist Charles Macintosh, to supply the Macintosh factory with masticated rubber.

Despite the problems, Hancock and Macintosh continued together, and founded Charles Macintosh and Co. in 1834, based in Manchester. PATENT SUCCESS In 1837, Hancock finally decided to patent his masticator, which allowed his masticated rubber to be used in applications such as mattresses and pillows, tubing and tyres, and packaging, which led to Hancock and Macintosh becoming the largest manufacturer of rubber goods in the world. The final form of the masticator came in 1841, with a machine that could hold up to 91 kilograms of rubber – over 100 times the amount of the original machine. ACCIDENTAL DISCOVERY The period saw further developments in the rubber industry, with American Charles Goodyear creating vulcanised rubber in 1839. This came about by accident, with Goodyear heating up rubber with sulphur and white lead and finding that the new rubber could withstand temperature changes without a change in performance. Vulcanised rubber was patented by Goodyear in 1844, and this led to a dispute with Hancock, who had copied and improved on Goodyear’s process, and tried to patent it himself in 1843. Despite the death of Macintosh in 1843, the new vulcanised rubber was successfully used by Hancock in the evolved Macintosh coat, and the process was so effective that the Mackintosh and Hancock Vulcanised Articles companies, both of which evolved from the original Charles Macintosh and Co. company, still make the coats today using the same techniques and procedures used in the 1840’s.


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RUBBER | NEWS Tarmac expands asphalt range in UK first Tarmac has launched a new rubberised asphalt which uses recycled waste tyres. The sustainable building materials and construction solutions business is the first in the UK to develop a new asphalt technology capable of recycling end-of-life tyres (ELTs) into roads. With 40 million waste tyres produced every year in the UK, the company has created an innovative asphalt mix using granulated rubber. Tarmac estimates that it will be possible to recycle and reuse up to 750 waste tyres for every kilometre of highway surfaced with the new material, depending on the thickness of the road, which would help to reduce the 120,000 tonnes of rubber waste exported from the UK annually. The company believes there is also significant scope to recycle and reduce the UK’s dependence on the export of ELT’s to other countries. Brian Kent, Technical Director at Tarmac, said: “While plastic

UK-made rubber fenders help protect historic canal dock An innovative project to help protect a section of a historic canal in Southern England is being realised thanks to the use of rubber fenders. The specially-designed rubber fenders (Image: SPC Compounding)

recycling has attracted media headlines, used tyres remain a significant and overlooked waste stream and our new innovative rubber modified asphalts offer a more sustainable option for our industry and the environment. “Rubber is used in asphalt across the USA, but in the UK there is a lack of the necessary industrial infrastructure required to allow manufacture of this type of material. Against the backdrop of major investment in the strategic road network there is now an opportunity to leverage this technology and unlock the benefits of this circular economic approach.” As part of recent trials of the new material, Tarmac supplied asphalt with rubber in Coventry. Rob Little, Senior Engineer, Highways Technical, Coventry City Council, added:“Coventry City Council is delighted with the rubberised asphalt trial; we hope we can use more of the product across the city in the future to help divert waste tyres from landfill and incineration to reduce the carbon footprint for road construction projects in Coventry.”

The fenders are produced in a collaboration between Avon Impact Management (AIM), a part of Melksham-based Avon Rubber plc, and Westbury-based SPC Compounding, and are designed to replace the wooden railway sleepers originally installed to protect the sides of the canal from damage by boats. The wooden fenders, now over 50 years old and are beyond repair, will be replaced with the speciallytailored rubber alternatives by a team of volunteers from the Canal and River Trust. In total 38 rubber fenders, at a length of 60m, will be supplied to the Trust, bringing a longer life expectancy and excellent impact properties. Commenting on the project, Steve Manzi, Canal and River Trust volunteer development co-ordinator, said: “The Kennet

Tarmac estimates that it will be possible to recycle and reuse up to 750 waste tyres for every kilometre of highway surfaced with the new material

and Avon Canal is arguably more popular than any time in living memory. It essentially relies on the technology that was used to build it 200 years ago, so we are constantly making improvements so that it can continue to be used. “This is a great project with so many benefits. Avon have supplied us with the custom-designed fenders, and with the volunteers leading and managing the project it means that we can replace the old fenders and protect this part of the canal for many years to come. Without Avon and the volunteers, we would really struggle to get this important repair work done.”

SPC Group is exhibiting at the International Rubber Conference (IRC) 2019

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RUBBER CONSULTANTS TO OFFER NEW TESTING SERVICES FOR LARGE RUBBER STRUCTURAL AND SEISMIC COMPONENTS Rubber Consultants has opened a new Rubber Engineering Laboratory in Brickendonbury, Hertford, that will provide the global earthquake community with a research and testing resource that will support manufacturers of large seismic rubber bearings. Within this new laboratory, Rubber Consultants’ engineers have designed and built a large rubber component test machine that can test full-scale bearings under actual earthquake conditions, as well as having the capability to test other large structural rubber-based bearings and other large rubber products. Rubber Consultants is the commercial unit of the Tun Abdul Razak Research Centre (TARRC), the UK- based laboratory of the Malaysian Rubber Board (MRB). TARRC engineers have played a pioneering role in the development of laminated natural rubber-metal bearings for civil engineering applications for more than sixty years and are regarded worldwide as experts in the principles of design of rubber engineering components for shock, noise and vibration control. This expertise can be applied to components as diverse as small automotive mounts and bushes through to anti-seismic devices and large marine fenders. Rubber Consultants says this exciting development puts it at the forefront of providing anti-

seismic and structural bearings testing to manufacturers worldwide. Commercial testing will be offered from August this year, and ISO 17025 accredited testing for seismic isolation to EN15129 will be available from January 2020. The new machine is unique and has the versatility to be able to test large engineering components such as laminated metal-rubber seismic and structural bearings with dimensions up to 1000mm diameter. For these kinds of safety critical components, stringent testing is required that subject the bearings to a range of demanding and complex conditions similar to those experienced in-service. No other machine of its kind in the world has the capability of complex combined testing of components in axial, shear and tilting modes of deformation. The laboratory will provide CE marking testing services for manufacturers of these components to access the European market. This is one of the most powerful test machines of its kind, capable of providing 10MN compression load and a shear load of 1MN with a stroke of 1m. The actuators are under servohydraulic control, that can deliver any time-history command within the capacity of the 600kW hydraulic powerpack system. The purpose-built Engineering Laboratory, an area of some 216 sqm, is also home to a range of other state-of-the-art test equipment for dynamic and multiaxial testing of smaller components including tyres, as well as a range of test pieces for material properties characterisation and performance modelling.

TARRC/Rubber Consultants are exhibiting at the International Rubber Conference 2019 (IRC)

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Management buyout marks new chapter for UK rubber reprocessor A Cheshire-based company that has developed a process for converting vulcanised rubber material waste into virgin compounds is starting a new chapter after a management buyout. HS Polymer Reprocessing Ltd, based in Hyde, has been acquired by Stephen Crompton, the company’s General Manager, from its previous owners Douglas Hodgson, Quentin Hartley and Jeffrey Savage. Established in 2006, the company has developed a process that can convert vulcanised rubber material waste back into a form that is clean and easy to incorporate back into virgin rubber compounds, with little or no loss of physical and mechanical properties. The process returns ‘vulcanised’ rubber compounds to a ‘devulcanised’ state, where the rubber flows like the original, virgin rubber compound, without the use of additional ingredients or additives. “I am delighted to acquire ownership of HS Polymer Reprocessing Ltd, where I have worked as the General Manager for four years,” commented Crompton. “We are an established, known business within the polymer industry and I am committed to growing the business further. We have also cemented our position locally within the last two years, forging new and lasting relationships with other fellow small businesses. We’re also currently the proud owners of the title of Tameside Micro-Business of the Year 2018. Moving forward for both our employees and customers, it’s very much business as usual.”

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International Rubber Conference Organisation

WHEN TWO BECOME ONE

R RICHARD BAKER HARRISON AND HUBRON SPECIALITY HAVE MERGED TO FORM A NEW, REBRANDED COMPANY THAT AIMS TO BECOME A SIGNIFICANT FORCE WITHIN THE WIDER MARKET. AHEAD OF IRC, BP&R SPOKE TO THE MANAGING DIRECTOR ABOUT THE IMPORTANCE OF THE MERGER, THE POTENTIAL OF THE NEW ORGANISATION, AND WHAT IT MEANS FOR THEIR CUSTOMERS.

WORDS: TOM WALKER

Bringing together decades of expertise, the merger of Richard Baker Harrison and Hubron Speciality creates a new company that, according to Martin Cicognani, Managing Director, sets out a new path for continued growth in the rubber and plastics industries.

“Our much broader portfolio of products touches upon each element of our customers’ formulation, whilst our UK technical centre provides the quality assurance and testing capabilities to support new customer development projects,” he continued.

The new company, which will be known as RBH and operate within the OBG Group, will pool the products, services and resources of two long-standing UK suppliers to the rubber and plastics industries that will provide a much broader offering.

“With the sales team having doubled, there is also a much bigger pool of knowledge available to our customer base, and having come from technical backgrounds themselves, they can offer formulation guidance and real application experience.”

“The legacy businesses were both long established suppliers to European manufacturers. Each offered broad portfolios, technical support and maintained an absolute focus on customer service,” Cicognani explained. “Recognising these strengths, RBH retains many of the core values of these successful businesses and has a vision that sets the organisation for continued growth within their specialist markets.”

The merger has also brought together packaging and blending capabilities, meaning RBH can now offer additional production flexibility and environmental control to the end user, with a range of pack sizes and process dispersible packaging available.

BACKED UP Now backed by a larger group, Cicognani says that having combined portfolios, supply chains, European warehouses, laboratories and repackaging facilities, means the company is now equipped to succeed in helping manufacturers overcome challenges in the production of complex formulations.

A CHANGE FROM THE NORM Mergers and acquisitions have been part of Hubron Speciality and Richard Baker Harrison history, which date back to 1934 and 1858 respectively. However, Cicognani says that this merger is a departure from their traditional acquisition and growth structure. “The significance of this merger has been the retention of those values that make RBH quite special, and relevant for the future. Bringing these elements together, we believe we have the correct blend of materials and services, which can enhance performance and inspire change across our core markets.”

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MOULD MAKING & TOOLING | NEWS Meusburger launches configurator for hot runner moulds

Gas Venting Inserts

Meusburger in collaboration with its sister business, PSG, have launched a new configurator for hot runner moulds, which allows a complete mould base including hot runner manifold to be customised with just a few clicks. The company says the new FH configurator offers high flexibility, immediate creation of the 3D data and immediate price display and is a world first on the market. It also offers the possibility of selecting the hot runner manifold as well as the flexible positioning of the nozzles and the entire manifold in the manifold plate. The thickness of the FH 63 Manifold plate and the nozzle length are automatically calculated on the basis of the various parameters entered in the configurator. The display of the mould size shows the manifold plate relative to the manifold. During configuration there is a live display of the manifold. This way, Meusburger says individual adjustments can be tracked and edited directly on the screen. At the end of the process, the 3D data is created immediately and is available to download straight away. Another advantage is the immediate price calculation, saving time in the overall process. In addition to the hot runner mould, the required components and accessories can also be ordered from Meusburger. This way the customer receives everything from just one source and with only one order. “Following the takeover of PSG in 2016, this is a further step towards standardisation in the hot runner sector,” said Managing Director, Guntram Meusburger. “There is very good cooperation within the Meusburger Group, [and this] has resulted in an expansion of projectrelated business.”

Innovation from OGM eliminates gas traps in injection mould tools Oxfordshire-based plastic injection moulding company, OGM Ltd, has developed an innovative new solution to eliminate the problems caused by gas traps in injection mould tools. Gas traps are a common problem in injection moulding, leading to scorching, pinholes and poor finished part quality. They are caused by gas pockets forming as the ‘melt fronts’ of the molten plastic, which is injected under pressure into injection mould tool cavities, come together before the gas has escaped naturally through the split lines of the tool; this traps the gas within the plastic. Best practice in part design, tool design and the use of mould flow simulation alleviates the risks of gas traps, but they can still occur. OGM says the proactive solution, where exact location of a trap is unknown, is typically to fabricate the tool with inserts made from specialised porous materials in the critical areas, or retrospectively to add vent pins (fixed ejector pins) to the exact site of the problem. The company says neither of these options,

The new FH conf igurator from Meusburger

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however, is ideal, principally on the grounds of cost and time. The solution developed by OGM uses the company’s latest hybrid metal additive manufacturing technology. This has been adopted to produce a wide range of mould tool inserts, quickly and at competitive cost. Using newly developed techniques, OGM says it is now able to build inserts layer by layer that incorporate large numbers of micro-pores, each just a few microns in diameter, through which gas can escape, without adversely affecting the quality of the finished part. The inserts are 3D laser sintered in steel or other metals, to match the exact requirements of each injection mould tool. The dimensions and characteristics of the gas escape channels are optimised to reduce cycle times and boost productivity, while maintaining high levels of part quality, even for extremely complex designs. Marcel Gowers, Additive Manufacturing Applications Engineering Manager at OGM, said: “The process we’ve developed exploits the potential of 3D laser sintering, to create precise and carefully controlled vent channels through carefully selected areas of the injection mould tool. OGM’s porous inserts can be manufactured into any 3D shape, both quickly and efficiently, enabling us to reduce lead-times to a minimum; just as importantly, we can help customers eliminate the problems caused by gas traps while maintaining moulded part quality and productivity.”

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WWW.QUICK-MOULD-CHANGE.COM | QUICK MOULD CHANGE SOLUTIONS

Paddy McGrath (left) with Simon Pugh

The company has a GF Cut 600E large capacity EDM Wire machine with integrated CAM (Fikus AC Cam) built into the machine’s touch screen control system.

area. “Thanks to our Wire EDM capabilities we successfully cut away the cracked section of the main Die,” Pugh added. “We then designed and manufactured a bespoke insert and successfully fitted it into the original mould tool cavity die. This tactic helped minimise production down time overall and kept the cost to our customer to an absolute minimum.” Linear Plastics has continuously invested in its tool making and machining capabilities, primarily in order to complement and support its primary injection moulding business. The company has a GF Cut 600E large capacity EDM Wire machine with integrated CAM (Fikus AC Cam) built into the machine’s touch

screen control system. The machine is also hard wired into the Linear Plastics main server. This enables the company to have a direct link to the design and programming team. In order to further complement the EDM work Linear Plastics has two manually operated die sink machines; a Charmilles 4lc for large capacity work and a Charmilles Form 20 for the smaller and more intricate work. Pugh added: “The EDM Wire machine enables Linear Plastics to manufacture detailed and intricate electrodes required for the EDM Die Sink process, which is used during the manufacture and repair of mould tooling and also allows us greater manufacturing freedom at tool design stage.”

by representatives of the British Government. Over the past three years the event has grown to become one of the most significant dates in the calendar for the leading providers of metrology, inspection, machine tools, workholding, cutting tools, and CAD/CAM/PLM manufacturing software and ancillary products and services providers on both sides of the Irish Sea. For the first time in its three-

year history, the event, hosted by the GTMA and the Limerick Institute of Technology, was attended by Catherine Page, the Chargée D’affaires for the British Embassy, and representatives from the embassy’s Department of International Trade. Local suppliers and manufacturers also took part in up to 190 sit down one-to-one meetings with larger companies such as Stryker Medical, Cook Medical, Ascent Aerospace, and Bombardier in the inaugural ‘Meet the Manufacturer’ event. Julia Moore, CEO of the GTMA, said: “Manufacturing Solutions Ireland 2019 opened up new possibilities within the supply chain to customers and suppliers from both Ireland and the UK, advancing stronger trading relationships between both. “Every year we see new ideas, new technologies, materials and processes on display, allowing us to share knowledge as well as do business during the event.” “It certainly highlights the innovation of our SME engineering community, who need to be responsive, fast, flexible, and have the ability to innovate as well as to be competitive in a global market.”

Linear Plastics helps avoid a mould tool “fatal failure” with EDM skills Linear Plastics has helped a customer avoid what it says would have been a “fatal failure” of an inherited mould tool. The South Wales-based firm said the quick thinking and technical skill set of its toolmaking department, together with the capabilities of its Charmilles-based Electrical Discharge Machining (EDM) investments, provided a solution to the potentially costly problem. “Linear Plastics was presented with a ‘fatal’ failure in one of our customer’s inherited mould tools, where poor tool design at conception meant over time the main cavity die had cracked through a water circuit in an area which would have rendered the die a total loss, necessitating the costly remanufacture of a new one,” explained Linear’s Process Improvements Manager, Simon Pugh. Using the expertise of its tool design team, however, Linear was able to redesign and provide a robust solution to the damaged

British Government representatives attend Manufacturing Solutions 2019 UK and Irish trade relations were central to Manufacturing Solutions Ireland 2019, as up to 750 visitors, exhibitors, manufacturers, and business owners met at the manufacturing supply trade exhibition event at LIT’s Moylish Campus, which was also attended

Julia Moore (second from right) praised the event’s success 36

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The

F FACED WITH A DECLINE IN THE NUMBER OF DOMESTIC TOOLMAKERS AND PRODUCTION AND LEAD TIMES INCREASING AS A RESULT, UK MOULDERS OFTEN LOOK FOR ALTERNATIVE OPTIONS OVERSEAS. WHERE THIS CAN COME WITH BENEFITS, THERE’S ALSO POTENTIAL PITFALLS. JO DAVIS, OPERATIONS DIRECTOR AT BROANMAIN PLASTICS, WRITES FOR BP&R ON SIX WAYS TO FIND A LOW COST, HIGH-SPEC TOOLMAKER THAT COMBINE THE BEST OF BOTH WORLDS.

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Big Six

Toolmakers are an essential part of the plastic manufacturing process, creating precision tools such as moulds that are used to create high quality components. However, UK toolmaking has recently been in decline. With fewer operating on home turf and production lead times and costs increasing as a result, companies have been looking further afield to Eastern Europe and, more commonly, China, for their toolmaking solutions. Despite the relatively cheap and quick services on offer, language and cultural barriers often prove challenging for some customers, resulting in the production of poor-quality components that are not fit-for-purpose. Faced with the choice of quality or speed, many UK moulders wonder if a middle ground exists. Industry experts believe that it does, noting the potential for anyone to find reliable, highspec tools within a reasonable timeframe at an affordable price.

OUTSOURCING ELEMENTS Outsourcing elements is fine – in fact, this can often help to keep down costs and lead times. But, it’s important to find out from the start what these are and how they will be managed to ensure any outsourcing doesn’t impact the final tool quality. It can be a good idea to find a company to manage the toolmaking process from start to finish. However, they need strong bonds with reputable workshops for the design and manufacturing processes of the tool and inserts. The company should oversee any final modifications before the finished tool is shipped to the UK, ensuring it’s of the highest quality. This way, the process is retained inhouse. Yet, by outsourcing certain elements, considerable cost savings can be realised and the production process is sped up.

1

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Faced with the choice of quality or speed, many UK moulders wonder if a middle ground exists. Industry experts believe that it does, noting the potential for anyone to find reliable, highspec tools within a reasonable timeframe at an affordable price.”


5

MATERIAL CHOICE There are two material choices to consider when it comes to the production of a tool: the material of the tool itself and the material of the final component. It’s important to use the right kind of steel for the tool so it can be fully hardened. Nickel-chromium alloy (grade 2767), for example, is ideal. As far as the material for the injection moulded components is concerned, this is critical because different materials have different shrinkages. An ABS or polypropylene composite will react differently to a material containing glass fillers, for example. This needs to be considered when making calculations for a tool.

3 6 4 2 HIDDEN COSTS Hidden costs are another key area to consider, especially if you’re importing your tool from overseas. A reputable toolmaker should offer you an all-in price, covering design, modifications, manufacture, shipping costs, import taxes, customs duty and VAT. This way there will be no unwelcome surprises.

EXPECTED TIMEFRAMES Due to a decline in the number of UK toolmakers and the fact that one tradesperson usually works on the same item from start to finish, extremely long waits of up to a year for a finished tool are not uncommon. By contrast, Chinese toolmaking firms have several people working on different stages of the same tool, so the timeframes can be swifter. A typical UK company that works alongside a trusted Chinese toolmaking partner can take between one and four weeks to finalise the design. This is followed by four to six weeks for the manufacturing process and another week to test the tool. Finally, there’s a six-week shipping time for the final tool. This, however, can vary greatly. So, it’s essential to clarify the expected timeframe with your prospective toolmaker early on in the process to avoid any misunderstandings and delays.

PRODUCTION KNOWLEDGE While it is possible to design and manufacture a tool in isolation, toolmakers aren’t moulders and so without understanding the moulding parameters for the production of the final component, it can result in a tool that is not fit-for-purpose. Therefore, it’s a good idea to get a component production team involved in the prototype to consider what the final component will look like, the materials it will be made from and even the machines it will be made on. This helps to ensure that the final tool will deliver the desired result.

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PROJECT PLANNING For optimum quality of the tool and moulded components, it’s advisable not to push forward the timescales. Instead, factor additional time into the project planning to avoid having to rush at the end.

A rushed tool will make for a lower quality moulded component and is a false economy in the long run. A wellmade, high-quality master tool will enjoy a long and successful service life, running at least half a million components. In fact, figures upwards of four million moulded components are not uncommon. It’s worth getting it right first time, every time.

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PIPE AND PROFILE | NEWS Naylor Plastics joins BPF Pipe Group

First EN standard for PVC-O pressure pipes published The first European EN standard for oriented unplasticised poly(vinyl chloride) (PVC-O) pipes has been issued after an extensive four-year development process. Initiated by The European Plastic Pipe and Fittings Association (TEPPFA), the new standard, named ‘EN 17176 PVC-O Piping Systems for Water Supply and For Buried and Above-Ground Drainage, Sewerage and Irrigation Under Pressure’ has been adopted in the 28 EU member states and another six member countries. This creates a new Europewide voluntary standard for those manufacturing PVC-O pipes, where previously there had been a variety of non-aligned national standards. This new standard allows specification for PVC-O piping systems intended for water supply use, pressurised (up to 25 bar) drainage, sewerage, treated waste water and irrigation systems, either underground or above-ground where protected from direct sunlight. It applies to drinking water piping systems under pressure, up to and including 45°C, as well as to pressurised waste water and irrigation. Monica de la Cruz, Chair of CEN/TC 155, the European Standardisation Committee for plastic piping systems and ducting systems where this new standard was developed, said: “TEPPFA has been instrumental in helping to bring this new standard into being and it will provide reassurance to specifiers that PVC-O pipes and fittings defined within the standard are of a good quality and fit for their designed purpose. Oriented PVC is

a remarkably strong material and ideal for a wide variety of applications under pressure to contribute to improve Europe’s water supply and waste water infrastructures.” TEPPFA is a partner organization of CEN/TC 155 and has been involved in the development of many of the 221 CEN/TC 155 standards currently in use, as well as over 40 projects that are presently being worked on.

Naylor Plastics has recently joined UK’s plastic pipe manufacturers’ association, the BPF Pipes Group. Together, BPF Pipes Group members account for a UK workforce of around 6,300 and a joint annual turnover of almost £9 billion. They install around 288,000 km of pipes every year, 198,000 km of which is above ground, such as plumbing and underfloor heating and 90,000 km of which is below ground, including water, wastewater and gas pipes. “We are delighted to be joining this influential group within the industry; it works hard to encourage best practice in all areas of pipework,” said Richard Edwards, Naylor Plastics’ Managing Director. “As a company we are expanding in both volume and product range and are looking forward to enhancing our growth and participating in future product standards for the benefit of the industry.”

Plastic Pipes 2020 International Conference now accepting abstract submissions The Plastic Pipes Conference Association (PPCA) has issued a call for papers to be presented at its next conference and exhibition, Plastic Pipes XX, which will be held in Amsterdam from September 21 - 23, 2020. Held every two years, the event is hosted by the PPCA members PE100+ Association, Plastics Pipe Institute, and The European Plastic Pipes and Fittings Association. Sarah Patterson, Technical Director of the Plastics Pipe Institute, said: “The main programme will comprise approximately 100 presentations relating to the design and development, testing, installation and operation of plastic pipe systems. “The papers will detail technical solutions or developments addressing engineering issues using plastic pipes systems or components. Also, papers identifying market trends for future growth of plastic pipes and components will be accepted for consideration.”

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In 2018, more than 400 delegates from 40 countries attended PPXIX in Las Vegas to review 93 technical papers, network and connect with the 33 exhibiting companies. “The PPCA conferences are the forum to connect to those in the plastics pipe industry. Presentations were of high quality and the forum provided a genuine technical transfer of knowledge and experience from the entire global industry,” Patterson added. Alternating between the United States and Europe every even numbered year, the three-day Plastics Pipes Conference and Exhibition is the largest event of its kind which is focused solely on plastic pipe systems and applications. 41


Sica launches new haul-off for extrusion lines of large dimension and thickness HDPE pipes Sica has launched a new haul-off system for large-diameter thickwalled pipes in response to growing interest in HDPE pipes for the transport of pressurised fluids. The new P3500/24 Plus multicaterpillar haul-off is capable of hauling pipes up to 3.5 metres in diameter. Despite being able to achieve maximum pulling force equal to 900,000N using all its 24 caterpillars, Sica says it still guarantees reduced energy consumption thanks to high-performance mechanical transmissions and a minimum level of maintenance required. To confront the oily behavior of polyolefins, all rubber pads of the caterpillars are made with new and special compounds. Their specific anti-wear properties combined with high contact friction, allow highly effective gripping action and a surprising increase in the average life of the pads. To avoid malfunctioning on lines of such large dimensions, the new haul-off has been equipped with cutting edge management software and specific devices that constantly

Sica’s new haul-off for pipes up to pipes up to 3.5m

check the efficiency state of the machine during the pulling phase. Examples of these devices include redundant encoders for precise speed monitoring and digital pressure sensors for continuous monitoring of working pressures and caterpillar tensioning force. In addition, Sica says the independent control of each caterpillar makes this machine

Drainage innovation saves residents from temporary accommodation Polypipe Building Services, a UK manufacturer of commercial drainage systems, has saved dozens of people in West Yorkshire from being moved into temporary accommodation. The Kent-based business enabled residents at Carr House in Wakefield to remain in their homes during a major social housing retrofit project by recommending the use of its best-in-class component fabrication and live stack replacement service. Polypipe was approached by housing association Wakefield and District Housing (WDH) to manufacture a solution to replace the 11-storey building’s “aged and blocked” cast iron internal soil stacks. WDH agreed to Polypipe Building Service’s live stack replacement

Carr House in Wakef ield solution to use 22 stacks of Terrain FUZE, manufactured offsite, as it would be easy-to-install and allowed the residents of Carr House to remain in their homes during the retrofit work.

extremely versatile despite its considerable size and allowing a particularly wide range of processable diameters (from DN2000 to DN3500). Robust pipe supports with electric handling both on entry in and exit from the haul-off complete the standard equipment, making the management of the pipes simplified and safe, despite the sizes and extreme weights.

Terrain FUZE is a high performance, modern drainage system which has been used on a wide range of commercial buildings. It’s manufactured from high density polyethylene (HDPE) so has strong abrasion, chemical and temperature resistance. Polypipe Building Services worked with Barnsley-based contractor Hughie Construction to ensure there was minimal disruption for residents during the install. Despite the challenges of replacing the stack in a high-rise property, the installation took 10 days to complete. Mark Wilkinson, Business Development Manager at Polypipe Building Services, said: “The residents were thrilled to be able to remain at home during the work. Nobody wants to be forced to relocate, which would have been a certainty without our live stack replacement solution.”

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IN-MOULD LABELLING | NEWS Meech USA has installed many of its static generation products at IML IMD’s facilities, including the 994IML-20kV Generator, 994 Hydra distributors, Hydra splitters and supply cables. Meech’s IML products prove a successful solution for systems provider

IML IMD’s facilities, including the 994IML-20kV Generator, 994 Hydra distributors, Hydra splitters and supply cables. The static generation equipment works together to create a controlled static charge on a nonconductive material that will allow a temporary adhesion between surfaces with charges of opposite polarity. “Meech’s products have worked very well since the moment they were installed,” continued Ensinger. “We have used chargers from other companies in the past and none were easy to install – some had very complicated wiring.” With Meech systems being, as Ensinger puts it, “essentially ‘set it and forget it’”, there has been a very positive response from IML IMD’s customers: “Nothing is complicated, there are no constant adjustments, and once dialled in there is nothing else to do,” he adds. IML IMD says as a result of the reliability of Meech’s in-mould labelling products a long-term partnership has been fostered. Ensinger concluded: “We look forward to continuing our partnership with Meech for many more years to come.”

Meech’s range of static control products have been described as an ideal long-term solution by a producer of systems for in mould labelling. IML IMD Technology, based in Ohio, USA, specialises in the manufacturing of custom industrial robotics, end-of-arm tooling and inmould labelling systems. After choosing Meech USA as a local supplier of reliable and compact in-mould labelling systems to help produce the most visually appealing products for its customer base, the company’s President, Mike Ensinger, says the technology “ticks all the boxes.” “With our busy schedules, IML IMD needs an equipment provider who can supply high quality products that can be quickly delivered and easily installed,” explained Ensinger. “Meech, with its extensive range of in-mould labelling equipment and highly efficient service ticks all these boxes.” Meech USA has installed many of its static generation products at

IML specialist appointed regional representative for Beck UK and Ireland Beck Automation AG, a manufacturer of automated in-mould labelling (IML) solutions for injection moulding applications, has established a sales and service location for the UK and Ireland. Heading up the new subsidiary, in Oakham, Leicestershire, is Jim Ward,

Swiss IML specialist transfers technology to US sister company Swiss-based specialist in in-mould labelling (IML) systems, H. Müller, is transferring its technology and know-how to sister company, CBW Automation, in the USA. Müller’s IML systems, which are made in Conthey, Switzerland, will be manufactured in North America for the first time at CBW Automation’s Fort Collins, Colo. facility. A cross-functional team has been established between Müller and CBW to coordinate the transfer of the engineering designs, control programs, manufacturing techniques, and optimisation processes for these types of systems. The transfer of IML technology will reportedly enhance CBW’s capabilities and help meet the growing demand among processors and end users for IML systems in North America, according to Taras Konowal, CBW Automation’s North America Director of sales and marketing. “There is strong growth for inmould labelling systems in North America and our customers are hungry for domestically-produced systems that reduce shipping costs and deliver time-to-market benefits,” said Konowal. CBW Automation will initially manufacture IML systems that are designed for large 2x12 stack moulds, delivering 24 cavities per shot. These systems are for production of injection moulded thin-wall polypropylene packaging for containers and lids.

an engineer and IML specialist with over 20 years’ experience working for Beck. Beck Automation’s core business is the decoration and labelling of lids, tubs, trays and buckets for a wide range of both food and non-food applications. The company says being closer to the customer and understanding local market requirements enables it to be both flexible and innovative.

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Jim Ward 45


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CASE STUDY

Open Innovat! n

C CORBY-BASED INJECTION MOULDING COMPANY, AMARAY, HAS WORKED IN PARTNERSHIP WITH SUMITOMO (SHI) DEMAG, WALDORF TECHNIK AND ROTH WERKZEUGBAU TO UNVEIL A PIONEERING, FULLY AUTOMATED IN MOULD LABELLING (IML) PRODUCTION LINE THAT’S MANUFACTURING A FAMILIAR PACKAGING PRODUCT WITH NEW ENHANCEMENTS. BP&R LOOKS AT THE PROJECT IN MORE DETAIL.

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hrough a partnership with three other technology suppliers, Amaray has reinvented the traditional manufacturing process used to produce wet wipe packaging lids, driven by its underlying principle to ‘make good things better’. Extensive and ongoing market research with parents and carers to understand out how they could structurally improve upon ordinary lids has resulted in a production line at Amaray that can manufacture, stack and wrap over 7,500 easyto-open, fully decorated push-button wipe lids per hour. Rick Ormerod, Head of Technical at Amaray, explained: “Wipes are a classic on-the-go product where convenience and accessibility are paramount. During the design and trial phases, users repeatedly emphasised the dexterity challenges they face when changing or cleaning a wriggling child. Above all else, they desired a secure lid that stopped wipes from drying out to save on waste yet could be opened and closed with one finger.”

FUNCTIONAL ENGINEERING The lids, newly designed for a major bluechip personal care client, have proven to be a feat of functional engineering several years in the making. They are produced using what is claimed to be Europe’s first ever installation of a multi-cavity 12+12 stack packaging mould on a 580-tonne El-Exis SP moulding machine from Sumitomo Demag. To maximise post-consumer recycling efforts, Amaray made the intentional decision to use polypropylene. “It means that the entire component - lid and label - can be recycled after use,” added Ormerod. An integrated high speed IML Waldorf Technik robot places each label into the mould, and then removes and closes each of the 24-hinged lids as soon as they are extracted from the mould. This has to be done swiftly while the polypropylene is still malleable. Each lid is then placed on the conveyor where they are each quality checked by a camera. A robot then stacks 38 lids, passing to a binder, at which point nine stacks are fed into an automated wrapper to create a brick of 342 lids for loading onto a pallet. PROCESSING CHALLENGE In order to deliver this design, the lid needed to be moulded as a single component and decorated and assembled in a seamless process. From an injection moulding perspective, using a 12+12 stack mould, although more productive, presented a tooling and processing challenge. Sumitomo (SHI) Demag’s UK packaging expert, Kevin Heap

explained: “To create the flip-like hinge was challenging in itself, as the tooling needed to accommodate varying depths of raw material. Unlike a single face tool, the polymer is injected in the centre between the two plates and has to be evenly distributed in all 24 cavities.” Additionally, using a two-face 12+12 stack mould in conjunction with the IML system means that 24 cavities are opening at the same time, with a Waldorf Technik side-entry robot placing labels accurately within fractions of a second. “Typically, packaging moulders use a single face mould with a maximum of twelve cavities when integrating an IML system, so Amaray’s installation doubled the complexity. To insert labels on both tool faces required a much larger robotic system,” continued Heap. MULTI-TASKING ROBOT Given that the El-Exis is a fast machine, robotic speed was equally important. The Waldorf sideentry robot serves two purposes. As well as inserting the label into each cavity before the plastic is injected into the mould, it has to retract and then re-enter the moulding area to remove all 24 lids, closing them before the plastic hardens. The robot then manoeuvres around to place the lids on a conveyor where the dimensions and label are fully quality checked. The vision system, cameras and software were supplied by Mevisco. If parts fail to meet the specified criteria, they are rejected from the line by air blasts without interrupting the production flow. Concluding, Heap says the integration of injection stack moulding, IML, robotics and vision systems makes the line highly sophisticated: “There are several examples in Europe of moulders using 8+8 stack moulds for producing IML margarine lids in high volumes,” he said. “However, using a 12+12 stack mould, Amaray’s line really has pushed the packaging boundaries.”

www.britishPLASTICS.co.uk

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www.kraussmaffei.com

I

INNOVATIVE IN-MOULD LABELLING TECHNOLOGY COMBINED WITH A NEW PLASTIC CONTAINER HAS HELPED ONE FOOD MANUFACTURER TO PACKAGE ITS PRODUCTS IN A WAY THAT INCREASES SUSTAINABILITY, PRODUCT SHELF-LIFE AND AESTHETIC APPEAL. BP&R LOOKS AT THE DETAILS.

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TASTE the Difference

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hen Paolo Volpati-Kedra, CEO of BC Gourmet USA, the company behind the cooking sauce brand, Scarpetta, wanted to preserve the freshness and flavours of his products, he turned to a plastic packaging solution using in-mould labelling (IML) technology for optimum results. The product lines, which are non-refrigerated, posed a problem for BC Gourmet: once on shelf, any oxygen that penetrated the plastic packaging would alter the taste of the sauce and turn it bad. Aware of this, the company was initially using additives in order to prolong the life of the sauces. “We were using citric acid to maintain freshness. It took something away from the taste of the sauce though. We knew there had to be a way to bring it back,” explained Volpati-Kedra. A CONTAINER ON STEROIDS Searching for a solution, Volpati-Kedra approached Berry Global, a US-based specialist in injection moulding and outlined his requirements for a packaging solution that not only preserved the contents, but allowed product visibility and met recyclability criteria. In response, Berry produced a container known as 410 Plus+. “It’s one container that does it all—hot fill, HPP, flash freeze, reheat, high end graphic, just about anything,” explained Dave Burke, Business Development Manager at Berry Global. “It’s a simple but innovative container on steroids!”

TASTING THE DIFFERENCE One of the most important innovations of the new container is how airtight it is. “This was made possible by several factors including the Oxygen Barrier IML,” explained Thomas Coene, Regional Sales Manager for Verstraete IML in North America. “This is a unique IML label that incorporates a special ethylene vinyl alcohol layer (or EVOH layer) in the film to reduce its permeability to oxygen. As a genuine wraparound label, stretching from the brim, across the sides and around base to cover the entire exterior of the container, it dramatically reduces the Oxygen Transmission Rate. In fact, the OTR is about 100 times better than with a regular label.” This was especially important for Scarpetta sauces, according to Volpati-Kedra. “Wrapping the 410 Plus+ with this Oxygen Barrier label there is virtually no oxygen entering the package, so there is almost no need to add citric acid to act as a preservative,” he explained. “You really taste the difference.” LOOKING GOOD This was not the only benefit of the 410 Plus+ and the Oxygen Barrier IML from Verstraete. As a full wraparound label, the Oxygen Barrier IML allows printing anywhere on the container, including the base. “We were able to maximise space with the unique ‘sqround’ shape of the container – a cross between square and round,” explained Burke. “It means that when containers are placed on shelves, the branding naturally faces the right way. This means better branding and consumer awareness.”

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celebrating 180 years

For Volpati-Kedra, this was a vital part of the new packaging solution. “The entire surface of your container becomes a billboard for your brand and product,” he commented. “This is vital; as consumers we buy with our eyes. IML has allowed us to greatly improve the impact of our look. We actually adapted the images on our products to cater to our specific target group. The full wraparound packaging allows us to cover every inch of the container with our logo and images, making the perfect representation of our brand and product.” SEEING IS BELIEVING The Oxygen Barrier IML has also made it possible to include transparent windows in the packaging, allowing consumers to see the Scarpetta sauce inside. “It was so clear and transparent,” said VolpatiKedra, “that at first, everyone assumed they were looking at a picture of the product, not through a window. As such, we keep the base of the container transparent so people will realise they’re actually looking at the product itself. It’s the perfect way to show how fresh our sauces are.” ENVIRONMENTALLY FRIENDLY BC Gourmet USA and Berry Global were adamant that the solution needed to be environmentally friendly. The Oxygen Barrier IML, like all IML packaging, is made from a mono layer polypropylene. It is 100 per cent recyclable. The thin EVOH layer stays way below the five percent guideline allowing the package to be recycled as mono-material PP. “Thanks to the protection of the Oxygen Barrier IML we were able to offer BC Gourmet USA a container with 52 per cent less plastic than his previous package,” explained Burke.

We stand out. We are the only plastic package in a wall of glass. Everyone used to expect plastic packaging to be refrigerated. The 410 Plus+ and the Oxygen Barrier IML have proved them wrong.” “Previously, the incoming packaging was not nestable; containers were being packed on top of each other instead of inside each other,” explained Volpati-Kedra. “But the 410 Plus+ is nestable; we now fit four times as much packaging in a box as we used to. The impact that our freight has on the environment is a quarter of what it used to be and is a financial saving.” The 410 Plus+ also offers other effiencies, according to Burke. “You also have to think that when you ship jars full of products like sauces, 50 per cent or more of the weight is the actual package,” he explained. “The weight of the 410 Plus+ is insignificant. You’re effectively transporting only half the weight, so you burn a lot less fuel and score another point for the environment.” A SHELF-STABLE PRODUCT LINE Although Scarpetta sauces are packed in plastic, they are a shelf-stable product. The Berry Global 410 Plus+ container, combined with the Oxygen Barrier IML label, has allowed Scarpetta to infiltrate the supermarket shelves where sauces are usually only found in glass. “Because we are using the Berry Global 410 Plus+ container, you can’t avoid seeing Scarpetta sauces,” explained Volpati-Kedra. “We stand out. We are the only plastic package in a wall of glass. Everyone used to expect plastic packaging to be refrigerated. The 410 Plus+ and the Oxygen Barrier IML have proved them wrong.”

IML has allowed us to greatly improve the impact of our look. We actually adapted the images on our products to cater to our specific target group. The full wraparound packaging allows us to cover every inch of the container with our logo and images, making the perfect representation of our brand and product.” www.britishPLASTICS.co.uk

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Two great names under one roof

Small footprint 1 and 2-zone Hot Runner Controllers The All New HRCM512 2-zone controller • Small footprint fully featured 2-zone controller • 2 independent control zones • Includes all the features you need • Includes 2 connector plugs

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RECLAMATION AND RECYCLING | NEWS New guidance published to improve the UK’s plastic packaging recycling rates WRAP, which manages The UK Plastics Pact, has published guidance that sets out which plastics used in household packaging are currently classed as ‘recyclable’. It aims to provide direction to packaging designers and specifiers, setting out a ‘best in class’ vision for design, including targets for recycled content and is part of plans to significantly improve the UK recycling rate of plastic packaging. Through consultation with industry, WRAP has identified what types of plastic packaging are actually recycled, at scale and in practice, and are therefore defined as ‘recyclable’. The On-Pack Labelling Scheme (OPRL) is anticipated to adopt what is classed as ‘recyclable’ under The UK Plastics Pact when it updates its guidance later in 2019. Often used for drinks bottles and trays, the document highlights a preference for clear PET, on the basis that the end market for this

Fibrax invests in Shini rubber granulator to reduce outgoing waste Rubber and plastics injection moulder, Fibrax Limited, has invested in the installation of a Shini SG-50

Jonathan Coupe, Material Technologist at Fibrax

material is significantly higher and by using ‘clear’, there is the greatest potential for it to be used back, ideally into plastic packaging. In terms of colour, only those that can be sorted in the recycling processes using near-infra red technology will be deemed recyclable. WRAP plans to publish further guidance on this in the coming months, specifically in relation to new near-infra-red (NIR) detectable black plastics. Peter Maddox, Director of WRAP UK, said: “If plastic is recyclable, and clearly labelled as such, we stand a far greater chance of keeping that plastic in the economy and out of the natural environment. We also know from recent research that citizens want to see packaging

that is 100 per cent recyclable, which they can recycle at home. By rationalising the number of polymers used in packaging, we can develop a more efficient recycling system, and reduce confusion for citizens.” “Through The UK Plastics Pact we are working at pace with our members to respond to this, and ensure that all plastic packaging is re-usable, recyclable or compostable by 2025. This new guidance is a significant milestone in our journey towards reaching that target.” While the scope of the guidance is currently rigid plastic packaging it will be updated in the future to include films and flexibles.

soundproof granulator that will process rubber waste generated at its manufacturing facility in Wrexham. This £20,000 investment in a granulation system for thermoset elastomers is part of a wider programme that seeks to divert waste from landfill and third-party recyclers to alternative value-added streams. The new granulating equipment will be used to produce high-quality fine rubber granulate that is free from contaminants and suitable for use in the sports and leisure industries. Jonathan Coupe, Material Technologist at Fibrax, said: “By installing the Shini SG-50 granulation system, we are able to process EPDM rubber waste effectively and create a quality material for manufacturers of safety play surfaces, 3G sports pitches, and equestrian arenas.

“This investment will reduce our waste management costs and create products that will go directly back into the supply chain.” “As well as granulating our waste, we also manufacture products using raw materials made up of post-consumer waste. By combining these processes into our recycling strategy, we hope to significantly reduce our outgoing waste via third parties.” Sylwia Gorska, Environment Health and Safety Practitioner at Fibrax, said: “We are delighted this investment into our waste management strategy enables us to reduce our impact on landfill and demonstrate our ability to meet the requirements of ISO 14001.” “Our aim is to implement a similar waste management scheme with silicone scrap so we can close the loop on the recycling of waste here at Fibrax.”

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AS SCOTLAND GETS SET TO BECOME THE FIRST UK COUNTRY TO IMPLEMENT A NATIONWIDE DEPOSIT RETURN SYSTEM (DRS), TOM WALKER SPOKE TO ZERO WASTE SCOTLAND’S DAVID BARNES, THE PROGRAMME MANAGER FOR DRS, WHO IS AT THE FOREFRONT OF THE SCHEME’S INTRODUCTION.

WORDS | TOM WALKER

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he DRS has seen numerous trials throughout the UK, be it at the Welsh Assembly in Cardiff or a collaboration between Veolia and restaurant chain LEON at London King’s Cross, but Zero Waste Scotland is looking to introduce an unprecedented national scheme. Interest and coverage of DRS has been building over the last 12 months, but as Barnes explained, Zero Waste Scotland has been mooting one for a number of years. He said: “We started looking at this around 2014. Just before that, there was a report commissioned seeing how the schemes operated in Scandinavia and wondering how the idea could be transposed into Scotland. “We then continued to research that through stakeholder engagement and further calls for evidence. The DRS was mentioned again in the Scottish Government’s Circular Economy Strategy, and we ran the call for evidence the year following that, in 2017.” LOGISTICAL CHALLENGE As of yet there is no official deadline for the opening of the scheme, primarily thanks to the huge logistical challenge that comes with making the scheme all set for a launch across the country, but Barnes is still confident that Scots will not be waiting too long. He said: “The Scottish Government is looking to begin the process in the summer of this year, after the regulations have been adopted, and there’s an implementation period of at least 12 months before the scheme is operational.” Despite the lack of a firm date, the major details of the scheme are all but concrete, with Zero Waste Scotland opting for a return to retail model, meaning a business that sells a drinks container will be responsible for taking it back, with an estimated 17,000 businesses across Scotland expected to be involved.

The more material we capture, and the higher quality material we capture, the bigger the benefits are for the country, and we need to build awareness of all the benefits of the scheme, not just the recycling side.”

Barnes said: “Essentially all of the stores of the big-name supermarkets would require a machine of some description, whereas the medium-size retailers will be dependent on a range of factors. “The really small retailers and shops will be taking back so few containers per day that it makes more sense not to take up room in their shops with a machine, and instead facilitate that manually.”

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the bigger the benefits are for the country, and we need to build awareness of all the benefits of the scheme, not just the recycling side. “The Scottish Parliament agreed that we’re in the middle of a climate crisis, and it sees the DRS not just from the context of drinks containers, but also from the ability to engage the public and get the public to think about these things.”

SCALING UP As mentioned earlier, small-scale trials taking place throughout the UK is nothing new, but Barnes noted that the results of these are almost inconsequential when it comes to scaling up a DRS for the whole country. He said: “In 2014 we ran a number of trials to see what the impact would be at a very local level, and some of the smaller retailers could establish how easy their customers found the machines to use, and what staff would need training in order to use and maintain the machine. “But in terms of that behaviour change in the public, where regardless of what drinks container you buy, you have to pay a deposit and that influences you to then take that back, I don’t think you can trial the effect of that. “I think you’ll only see that full benefits of the DRS once it has been rolled out at a national level, and that’s the reason the Cabinet Secretary in Scotland has set an ambitious timescale on us, because she wants to start seeing these benefits as quickly as possible.” MULTIPLE BENEFITS Speaking of benefits, Barnes made it clear that Zero Waste Scotland is attempting to increase the public knowledge of the benefits of a DRS, and not just from the specific recycling point of view. He said: “We’ll be capturing a lot of material, and because of that it generates around four million tonnes of CO2 savings over 25 year. “The more material we capture, and the higher quality material we capture,

‘ON-THE-GO’ VERSUS ‘ALL-IN’ There has been some opposition towards a DRS scheme being implemented in England, mainly due to the model used. The ‘on-the-go’ model proposed by the UK Government drew criticism from a number of environmental groups, due to the fact it restricts the type of containers that the machine can take, and the fact that an ‘all-in’ system could see economic benefits to the tune of £2 billion over ten years. However, Barnes made it clear that Zero Waste Scotland will be pursuing the all-in model, favoured by countries such as Norway, which has seen recycling rates rocket to 97 per cent. Barnes said: “We looked at an on-the-go scheme and the reason it was ruled out at an early stage was that we felt it was difficult to define and might confuse some of the public. “The second reason was that if you look at the figures associated with our scheme, we’re currently capturing just over half of these containers for recycling. We’re aiming for 90 per cent through the new scheme, and we’re confident this would all be food-grade, high-quality materials that can be used in closed-loop recycling.” PASSION AND PRIDE And for Barnes, being at the head of such a potentially revolutionary scheme is something that he finds incredibly rewarding. “I’m obviously very passionate about using our resources better, but when you’re talking about leading the design of a world-class system and helping the Scottish Government realise its ambition to not just be leaders in the circular economy, but also deal with the climate crisis, it fills me with a lot of professional pride. “I know that everyone involved in the programme is enthused by the ambition and are now at the next stage of supporting that implementation process.”

Revolution www.britishPLASTICS.co.uk

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BP&R SOFTWARE GUIDE MONITORING Tel: +44 (0)1793 827666 Email: sales@transxl.co.uk Web: www.transxl.co.uk Sheet Equipment

SHEET LINES

1600mm wide Omipa 3 roll polishing stack

890mm Welex sheet line PIPE/PROFILE

Thermoforming

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400 x 400mm Blackfriars Model 40/40 Granulator

750mm wide Battenfeld/Gabler in line lid forming machine PELLETISING

Extruders

Pelletising

PlantMaster BMS Vision Ltd T: 01254 662244, E: sales.bla@visionbms.com Website: www.visionbms.com/ plastics. Affordable and flexible MES system for the plastics/rubber industry. Easy to use systems from a €600m company with over 30 years experience.

intouch T: 01604 537100 E: enquiries@ intouchmonitoring. com Website: www.intouchmonitoring.com Real-time production monitoring systems. Designed to be easy to use and providing affordable solutions to all sizes of businesses. Production monitoring, scheduling, reporting, data import/export, databases for parts, tools and operators, integration with other software packages.

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PROCESS OPTIMISATION SOFTWARE RJG Technologies Ltd Moulding Technology T: +44 (0)1733 232211 E info@rjginc.co.uk Zero Defect Moulding – What’s your target?

• Cycle time reduction • Reduced scrap rates • Improved process capability • Higher yield and OEE PRO-OP™ software provides a stepby-step procedure for optimising the injection moulding process to deliver optimum quality products at the most favourable cycle time. PRO-OP™ is a server based application which, by setting an optimum moulding process, highlights weaknesses and problems in relation to part design, mould design, mould construction, moulding equipment efficiency, moulding equipment specification and material selection. The moulding process is documented with explanations for each key process parameter setting demonstrating the processing conditions and equipment contributions to the final result. PRO-OP™ is aimed at companies whose focus is quality and consistent part manufacture. PRO-OP™ supports companies by providing a documented and structured validation protocol which is recognised in the in the pharmaceutical and medical sectors.


BP&R BUYER’S GUIDE MATERIALS MASTERBATCH

ASSEMBLY

Eclipse Buyers Guide_Layout 1 07

hot plate welding

Branson Ultrasonics

colour masterbatch

Units 3E + 3F, Hillam Road Industrial Estate, Bradford, West Yorkshire, BD2 1QN T: 01274 731552 F: 01274 738118 E: sales@eclipsecolours.com W: www.eclipsecolours.com

When it comes to matching colour, no one gets closer.

ultrasonic welding

InControl Ultrasonics Ltd (FFR Ultrasonics Ltd)

50mm high and 35mm

PO Box 10380, Sileby, LE12 7ZX T: 01509 621992 E: enquiries@ffr-ultrasonics. co.uk W: www.ffr-ultrasonics.co.uk W: www.incontrolultrasonics.co.uk

• We want to bring your colour inspiration to life.

www.abbeymb.com Tel: +44 (0)161 308 2550 Email: aml@abbeymb.com

Polymer Specific and Universal Colour and Additive Masterbatches. Fastmatch colour matching service. 1 mm Easysperse MicroPellets to 4 mm MaxiPellets. Standards second to none.

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• We develop amazing new colours and special effects for some of the worlds leading brands. • Performance is built-in, and cost designed out. • Any colour, Anywhere, Anytime.

Telsonic UK Ltd

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

www.pmb.co.uk

cleaning materials

Unit 3 Vitrage Technical Park 27 Witney Road , Nuffield Industrial Estate, Poole, Dorset BH17 0GL T: 01202 697340 F: 01202 693674 W: www.telsonic.com Blog: telsoniccuk.wordpress.com

vibration welding

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

MATERIALS

158 Edinburgh Avenue, Slough, Berkshire SL1 4UE T: 01753 756675 F: 01753 551270 E: bucuk.sales@emerson.com W: www.bransoneurope.eu

COMPOUNDS

Purging Compounds Release Agents Mould Maintenance

QUALITY PVC PELLETS FOR EXTRUSION

www.ChemTrend.com www.UltraPurge.com

vekacompounds.com +44(0)1933 427 750

Motan Colortronic Ltd

Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

MACHINERY & EQUIPMENT

MOULD RELEASE

ASSEMBLY

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UK Manufacturers est. over 60 years

Shredders Plastic separation Conveyors | Bailers Full recycling systems

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   

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CONTROL SYSTEMS AND EQUIPMENT quality monitoring control Kistler Instruments Ltd

T: 01256 741550 F: 01256 741551 E: sales.uk@kistler.com W: www.kistler.com Pressure transducers and associated monitoring/control equipment for new and existing injection moulding applications.

DRYERS

Motan Colortronic Ltd

Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

DEHUMIDIFIERS Motan Colortronic Ltd Cavity pressure measurement systems and sensors for control of the injection moulding process and automatic hot-runner balancing, provides zero-defect production with 100% quality control. T: F: E: W:

Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

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01256 741550 01256 741551 sales.uk@kistler.com www.kistler.com

TO ADVERTISE IN THis SPACE CONTACT MANDY O’BRIEN: 01244 952519 www.britishPLASTICS.co.uk

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BP&R BUYER’S GUIDE HEATING EQUIPMENT

MACHINERY & EQUIPMENT DRYERS

HEATING EQUIPMENT

induction heating for platens and tools

HOT RUNNER SYSTEMS

MF Induction Heating

hot runner controllers

Unit 5, Martindale, Hawks Green, Cannock, Staffs, WS11 7XN Replacement Coils New platens T: 01543 570642 E: sales@mfinduction.com W: www.mfinduction.com

MATERIALS HANDLING AND STORAGE gravimetric/ volumetric blending

Motan Colortronic Ltd

INJECTION MOULDING

MATERIALS HANDLING hopper loaders

METAL DETECTION

and dosing

MIXING, FEEDING AND DOSING

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Motan Colortronic Ltd

Servicing & Maintenance Commission/Decommission Robotics Projects Planning Servo Kit Installations Component Supply Training - Any Level Beston Sales

Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

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SCREWS & BARRELS

HOPPER LOADERS Engineers to the Plastics & Rubber industries, specialising in the following:

www.magog.co.uk Design, Manufacture, and Refurbishment of Screws & Barrels for the Plastics and Rubber Industries. • Screw design • New manufactured Screws, Barrels, Feed Sections & Liners • Proven wear resistant specifications for screws • Nitrided and Bimetallic barrels • Refurbishment and repairs • Condition monitoring and wear checks

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POLYMERS

Screw & Barrel Manufacture Screw & Barrel Refurbishment Tie Bar Repair & Manufacture Screw Tip Assemblies Feed Liners, Plain & Grooved 100 Tonne Screw & Barrel Press Bimetallic Barrel Blanks up to 50 mm In Stock Please e-mail or phone Karl for more info. E. info@tws-mail.co.uk T. 01706 655402 W. www.tws-ltd.com Technical Welding Services (Rochdale) Ltd

FILTRATION ALUMINIUM MATERIAL STORAGE BINS Off the shelf or made to order with very competitive pricing! Standard sizes available: 80l, 200l, 420l, 830l. Contact us today on 01827 265800 or visit www.summitsystems.co.uk Prices start from £428 10% reduction with offer code:

BPR18 TO ADVERTISE IN THis SPACE CONTACT MANDY O’BRIEN: 01244 952519 56

METAL DETECTION AND SEPARATION EQUIPMENT Motan Colortronic Ltd

TO ADVERTISE HERE CONTACT MANDY O’BRIEN ON 01244 952519 MOULD CHANGE

Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

www.britishPLASTICS.co.uk

Motan Colortronic Ltd

Matilda House, Carrwood Road, Chesterfield Trading Estate, Chesterfield S41 9QB T: 01246 260222 F: 01246 455420 E: sales@motan-colortronic.co.uk W: www.motan-colortronic.co.uk

SECONDHAND AND RECONDITIONED Cooper Plastics Machinery

8 Lyall Court, Flitwick, Bedfordshire MK45 1UX T: 01525 719850 E: Cooperplastics@gmail.com W: www.cooperplastics.co.uk Extruders, water baths, haul-offs, fly knife cutters, conveyors/tip tables, in-line punches, coilers etc. New and used. Repairs, servicing or rebuilds. UK agent for Lyons Electronics.

DTL Machinery UK

- We buy / sell all makes / age / sizes of Plastic Injection Moulding Machinery & Ancillaries equipment. - We also buy redundant, nonrunners & faulty machinery. - Machinery repair and maintenance services available. T: 01925 596170 M: 07838138342 E: info@dtlmachinery.co.uk E: douglastrading@gmail.com


BP&R BUYER’S GUIDE SECONDHAND AND RECONDITIONED

MACHINERY & EQUIPMENT SECOND HAND & RE-CONDITIONED

BUSINESS FOR SALE

Designer/ manufacturer injection moulding tools Ref: KP/642

Southern England Good reputation, solid customer base, low debt Excellent opportunity to bring service in house or as a bolt-on Contact Paul Holohan in complete confidence on 07798 530684 or info@kingswood.co.uk

kingswoodbusinesssales.com

For Sale Rubber and Plastic Moulding Company Established for over 20 years Existing Customer Base Turnover of £3.5 million 30 Experienced Employees Further Financials on request For further information email us on rubbermouldings1@gmail.com • Rubber • Plastic • Silicone Mouldings • Injection Mouldings

Refurbished machines with fault and leak free guarantee. We buy & sell all manner of plasscs equipment. Visit our workshop in Wellingborough, Northants. 01933 272747

sales@stvmachinery.co.uk www.stvmachinery.co.uk

Single Machines to whole plants purchased Tel: David 07540 633552 info@plasticinvestments.co.uk www.plasticinvestments.co.uk

Ultrasonic Plastic Welders New & Used

For Sale &

Plastics Processing Machinery Bought & Sold, Thornhill, South Marston, Wiltshire SN3 4TA T: 01793 827666 F: 01793 823826 E: sales@transxl.co.uk W: www.transxl.co.uk

‘USED INJECTION MOULDING MACHINERY DEALERS’

THERMOCOUPLES

FOR SALE

TransXL International Ltd

Wanted

Branson - Mecasonic - Telsonic Sonotrodes (Horns) all Frequencies Fixtures, Repairs, Service, Parts Sub-Contract Welding, Hire & Consultancy

TESTING EQUIPMENT Gammadot Rheology Testing & Consultancy Services

Unit 5C, Leaton Industrial Estate, Bomere Heath, Shrewsbury, Shropshire, SY4 3AP T: 01939 291677 E: enquiries@gammadot.com W: www.gammadot.com Providing independant testing solutions to all your quality control, failure analysis & flow simulation data needs

hardness - IRHD and shore

MAPRA Technik Co — BAREISS For Bareiss of Germany IRHD & SHORE hardness testers, Abrasion & Rebound testers. T: 020 8508 4207 F: 020 8502 5107 E: info@mapra.co.uk W: www.mapra.co.uk

Tel; 01258 459257 Tel; 07730 413197

als.ultrasonics@gmail.com www.als-ultrasonics.co.uk

SERVICES TRAINING

TESTING/CONSULTANCY

inspection & measurement

MAPRA Technik Co – DOSS MARCEL AUBERT – KAFER

For DOSS visual solution of Italy – Inspection & sorting machines for O’rings, Seals, Gaskets. T: 020 8508 4207 F: 020 8502 5107 E: info@mapra.co.uk W: www.mapra.co.uk

PRINTERS

3D Printing

printers of plastic mouldings

in Plastic & Rubber

Total Print Ltd

Specialist Pad Printers Station Road, Gedney Hill, Lincolnshire PE12 0NP T: 01406 330122 F: 01406 330123 E: info@totalprintltd.com W: www.totalprintltd.com Sub-Contract Pad Printers to the Plastics Industry

COMPONENT PRINTERS

Tel: 01420 88645 www.cdg.uk.com

TAMPO.SCREEN.FOIL

MOULDFLOW ANALYSIS SOFTWARE

Mould Tool Design CAD CAM software

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

Contour Marking Co Ltd Albert house, Gledrid Industrial Park, Chirk ,Wrexham, LL14 5DG T: 01691 770093 F: 01691 770023 Sub Contract Tampo, Screen & Foil Printing to the plastic moulding industry E: sales@contourmarking.com W: www.contourmarking.com

TO ADVERTISE IN THIS SPACE CONTACT MANDY O’BRIEN 01244 952519 Tel: 01420 88645 www.cdg.uk.com

TO ADVERTISE IN THis SPACE CONTACT MANDY O’BRIEN: 01244 952519 www.britishPLASTICS.co.uk

57


IN HIS COLUMN THIS MONTH, OUR RESIDENT MATERIALS EXPERT, MIKE BOSWELL, LOOKS AT THE INFLUENCING FACTORS ON POLYMER PRICES AND OUTLINES WHAT CONVERTERS SHOULD BE MINDFUL OF HEADING INTO THE LATTER HALF OF THE YEAR.

What is the outlook for polymer prices in the second half of 2019? Whilst, styrene-based polymers including GPPS, HIPS, ABS and SAN continue to demonstrate relatively high levels of volatility due to strong swings in benzene and, consequently, styrene monomer pricing, the price action on polyolefins has been quite sedate over the past 12 months.

the end of this year, supply of PP still looks quite adequate at this stage. The volatility of benzene and its impact on styrene monomer and the subsequent effect on styrene-based polymers remains difficult to predict and here there is always the opportunity for some surprises. In the arena of engineering polymers, the overall price trend continues to be one of decline and reduced demand in the automotive sector is a cause for concern.

The relative weakening of PE versus PP is largely a result of increased imports of LDPE, LLDPE and HDPE product from the US, where the economics of shale gas feedstocks, combined with a rapid increase in polyethylene output, has led to a significant increase in competitively priced product arriving in Western Europe; this is clearly illustrated in the table of import tonnage below.

Despite a continuing move towards gas rather than crude oil-derived feedstocks, the price of crude oil continues to be a key determinant in terms of both energy and feedstock costs and here the tendency appears to be towards stability, even in spite of increasing geo-political tensions in the Middle East with Iran. Furthermore, concerns about the stability of global economy will also have an influence on oil prices, not least of all in the US, where presidential elections started to come to attention and there will be a strong desire to avoid higher oil prices with the likely consequence of economic slowdown.

In the case of PP, there was an expectation that numerous planned maintenance shutdowns would make supply in the European market quite tight with the likely consequence that prices would increase. However, due to a slowdown in demand the market remained well supplied and hence the lack of any significant price action.

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

The issue of Brexit will continue to be a major influence for UK plastic converters and the significant decline in the value of Sterling against both the USD and Euro is largely being offset in many cases by a reduction in polymer prices. The graph below shows that the financial markets are already taking a pessimistic view on the likely consequences of the UK leaving the EU at the end of November.

Of course, in Western Europe, the second half of the year starts with the holiday season and demand tends to be rather low, particularly as the countries in the South take quite lengthy shutdowns and it is not normally until late August or early September that normal buying activity resumes. At this stage, it is difficult to envisage the second half of this year looking significantly different to the same period last year with the prevalence of US-origin PE only set to increase, and, although producers have further maintenance scheduled before

Of course, this ‘fair’ outlook must be combined with the usual warning to beware of the unexpected.

Tonnage Material

2017

Jan-18

Feb-18

Mar-18

Apr-18

May-18

Jun-18

Jul-18

Aug-18

Sep-18

Oct-18

Nov-18

Dec-18

2018

% Increase

HDPE

87,192

4,813

10,272

8,293

9,157

9,420

11,973

13,190

13,098

24,295

28,452

25,275

35,194

280,624

222%

LDPE

21,105

1,085

1,549

2,156

1,871

1,725

2,763

3,772

4,032

2,861

1,884

2,138

3,915

50,856

141%

LLDPE

21,130

2,284

3,660

15,062

14,429

6,081

14,280

6,012

4,730

4,129

6,454

8,510

6,136

91,767

334%

Total

129,427

8,182

15,481

25,511

25,457

17,226

29,016

22,974 21,860

31,285

36,790

35,923

45,245 423,247

227%


SUMMIT SYSTEMS

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BP&R July/Aug 2019  

BP&R July/Aug 2019