EPPM 17.3

April/May 2015 Volume 17 | Issue 03

Coverr Story St ry | Pa Page e8

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IN THIS ISSUE Pg 6 INDUSTRY

Pg 22 INJECTION MOULDING

Germany has overtaken Japan as the largest exporter of plastics and rubber machinery to China, while we share some of the most exciting business news to come from the European plastics arena.

Injection moulding is the plastics sector’s bread and butter, but even this mature technology continues to evolve. We explore this ongoing development with MHS Hot Runners following their successful exhibition at NPE2015.

Pg 8 COVER STORY: POLYONE GLS THERMOPLASTIC ELASTOMERS PolyOne GLS Thermoplastic Elastomers takes us on a tour through a normal day in the lives of a young, working family, pinpointing exactly where TPEs fit into the workaday routine.

Volume 17 Issue 3

head office Carlton House, Sandpiper Way, Chester Business Park, Chester, CH4 9QE. Tel. +44 (0) 1244 680222 Fax. +44 (0) 1244 671074 Web: www.eppm.com C.E.O/publisher mark blezard C.O.O duncan wood

editorial editor rose brooke rose.brooke@rapidnews.com

production art robert wood production tracey roberts

Pg 25 EVENTS

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We can hardly believe we are already covering K 2016 in EPPM, but demand for floorspace at this behemoth of plastics events is gaining momentum. Before K, we have Fakuma 2015 - which has already sold out and promises to build on the excitement of 2014.

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Pg 10 TPES

Pg 26 PLAST 2015 PREVIEW

Thermoplastic elastomers are becoming more and more sophisticated, we share news from leaders in the field Kraiburg TPE, Polymax and Perstorp.

Milan is preparing for the triennial PLAST expo and EPPM has been newsgathering all the biggest announcements from the organisers and the companies who will be on the show floor to prepare you for this gigantic European event.

Pg 12 MATERIALS HANDLING Our roundup of interesting materials handling developments touches on some announcements made at NPE2015 that could transform this market segment.

Pg 14 MEDICAL SPOTLIGHT Our six-page medical spotlight looks in some depth at the trends and challenges shaping how plastics are being developed for hospitals and homecare, including thoughts from Sabic and Styrolution.

Pg 34 EUREKA SERIES How do you future-proof our troops from deadly weaponry that may not even exist yet? The answer is by developing ultra polymers created by examining the properties of the materials at a molecular level. Gripping research from the Army Research Laboratory in the US.

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European Plastic Product Manufacturer is published by Rapid Plastics Media Ltd. Each issue is distributed in print and digital format to 17,845 buyers and specifiers in the European plastic processing industry. © May 2015.

While every attempt has been made to ensure that the information contained within European Plastic Product Manufacturer is accurate, the publisher accepts no liability for information published in error, or for views expressed.

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Optimized parts weights Short cycle times At Netstal our aim is to help you produce the perfect thin-wall packaging.

You achieve maximum output and quality in the shortest cycle times. And that’s no coincidence. Our team of experts are specialized exclusively in plastic packaging – and in machines made to perform.

Engineering Excellence

From The Editor

Ciao Italia!

I’ve said it so many times since stepping into the Editor role at EPPM, but once you see the world armed with even a little understanding of the technology and chemistry that goes into producing so many of the things we use every single day, you take nothing for granted.

This notion of plastics playing a key and enduring role in our daily lives is exemplified beautifully in our cover story from PolyOne GLS Thermoplastic Elastomers, which takes us on a journey from waking to collapsing back into bed at night, identifying where TPEs form a part of our routine hour by hour.

This theme of plastics playing a supporting role in our lives continues in our six-page Medical Spotlight, which serves to demonstrate exactly why plastics are the best choice for so many healthcare, surgical and homecare applications. From antimicrobial technology preventing the spread of disease, to materials that can withstand gamma sterilisation and harsh hospital chemicals, to surgical tools that are so lightweight they help keep weariness at bay in an eight-hour operation. The list goes on. With expert insights from Sabic and Styrolution, plus news from some of the biggest mover-shakers in medical plastics, our special feature promises to give you quite the education.

Injection moulding is the plastics processor’s bread and butter and it is only right we take a look at how this hugely important technology is advancing, with MHS Hot Runners acknowledging that injection moulding development is far from plateauing. Similarly, we report some of the biggest materials handling stories to catch our eye in recent weeks.

Finally, we are excited to be on-site at PLAST 2015 and are celebrating this massive Milanese event with a six-page preview of the five-day show, which promises to provide the global industry with an excellent snapshot of Italy’s improving marketplace and the influential role European plastics is playing on a worldwide scale.

Once you see the world armed with even a little understanding of the technology... you take nothing for granted.

I look forward to meeting as many of you in Milan as possible.

Ciao for now.

Rose Brooke, Editor

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Credit: ChinaPlas

INDUSTRY

Germany becomes top plastics machinery exporter to China VDMA results show that Germany has become the top exporter of plastics and rubber machinery to China, with the EU powerhouse gaining global market share as Chinese relations with Japan continue to falter.

Words| Rose Brooke

G

ermany has come out on top as the biggest exporter of plastics and rubber machinery to China, according to recent figures, which indicate the European economic power has gazumped former top exporter Japan.

Exports of plastics and rubber machinery may have dipped on 2013 data, the VDMA report shows, but the world's Number One economy remains a crucial customer for Germany as Chinese relations sour with former top exporter Japan.

After superseding the US as the world's largest economic power in 2014, the expansion of China's plastics industry has continued to gain momentum, not least its plastics processing machinery manufacturing sector.

rubber machinery to China, with Japanese revenue crashing by 29.6 per cent to €453.7 million in 2013 on the back of souring relations between both nations perpetuated by the ongoing territorial dispute over the Diaoyu Islands (known as Senkaku in Japan) in the East China Sea. In this instance, Germany has picked up the pieces, apparently replacing some of Japan's lost business and growing its stake in global exports in machinery to China to 34.9 per cent in 2013. And the powerful European economy holds its own for the EU in the top five, with Taiwan taking the third-largest revenue for plastics and rubber machinery exports to China, followed by the Republic of Korea and finally, Slovakia - which beats both the US and Italy into fifth place.

Nevertheless, the Asian super-nation still generates €809.3 million (£588.3 million) per annum in export revenue for Germany, according to 2014 data from the VDMA, released ahead of ChinaPlas 2015.

This figure is, however, a 5.5 per cent slide year-on-year, as the organisation reports that in 2013, exports of German plastics and rubber machinery to China generated revenue of €855.9 million, a 33.7 per cent leap year-on-year from 2012's recorded €640.4 million in revenue.

In 2013, worldwide supplies of plastics and rubber machinery to China reached a volume of almost €2.5 billion, which is stable (posting a 1.3 per cent rise) on 2012 data.

As the numbers for 2013 stand ahead of 2014's complete data coming in, Germany is the number one exporter of plastics and

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Völpker acquires montan wax business DOLCI & BIELLONI merger 'a boost' for AMUT

Völpker Spezialprodukte has announced that it will acquire the montan wax business of BASF on April 21st 2015, Völpker Managing Director Falko Preußer has announced.

This business move will allow material science giant BASF to focus on its core business of the Luwax and Poligen brands of polyethylene wax.

With 115 years of experience, Völpker is a wax producer with one of the richest traditions in Europe. WARADUR montan waxes are used in a large number of industries, primarily

INDUSTRY

in the plastics industry, particularly in engineering plastics compounds. In such instances, montan waxes act both as flow improvers and separating agents in the processing of plastics. These waxes also act as nucleating agents and dispersing additives for pigments and fillers.

Due to the versatility of WARADUR montan waxes and their long-term availability and price stability, Völpker is expanding its own international market by acquiring the montan wax business of BASF.

“Taking over DOLCI & BIELLONI company is a brilliant success for the future of AMUT GROUP,“ said Mauro Drappo, AMUT CEO. “Together we boost our leading role in the international scenario.

Synergies enhance our strengths. We constantly work to be considered by our customers as a sole partner, being able to offer the most complete range of machines for the plastics extrusion, thermoforming and recycling field,“ he stated.

DOLCI & BIELLONI now operates under the name AMUT DOLCI BIELLONI following the merger, which has established what the company calls a “solid Italian hub with a robust productive and financial organisation“.

AMUT DOLCI BIELLONI is a wellknown manufacturer of printing and slitting rewinding machines, blown and cast lines for different multilayer films (stretch, silage, barrier, technical, medical, diapers, PP and masking), coating and laminating lines.

The newly settled AMUT DOLCI BIELLONI represents the fusion between two wide backgrounds in plastic extrusion: AMUT GROUP as producer of lines delivering rigid products (foils, sheets, pipes, profiles, thermoforming items), while DOLCI BIELLONI represents mastery in cast and blown lines for flexible films. It also represents a strategic action confirming the stature of the traditional Italian high quality level, in both design and manufacturing.

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AMUT's take-over of DOLCI & BIELLONI has been branded “a brilliant success“ and “a boost“ by insiders, strengthening the major European plastics processing player's position as an international leader.

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COVER STORY

Dawn to Dark:

How thermoplastic elastomers improve our daily lives TPEs are one of those materials we are all guilty of taking for granted. From preparing a flask of coffee for the commute in the morning, to setting the alarm clock at night, TPEs are always there and PolyOne GLS reveals to EPPM exactly to what extent.

Words | Charles Page, Global Marketing Director, GLS Thermoplastic Elastomers, PolyOne Corporation

T

hermoplastic elastomers (TPEs) - those flexible, rubber-like materials that can be processed using cost-effective, highvolume moulding and extrusion - are steadily replacing conventional elastomers and finding new homes across a wide range of applications. Indeed, the global market for TPEs is forecast to reach $23.9 billion (£16.1 billion, €22.4 billion) by 2018, according to research firm MarketsandMarkets.

Factors driving the current 8.1 per cent growth rate for TPEs range from the need for greater design freedom than what thermoset rubbers can provide, to the growing consumer demand for safer and more sustainable materials.

One of the most attractive aspects of TPEs is their versatility.

These materials offer amazing variety in hardness, surface texture, colour, opacity, abrasion and chemical resistance and tear strength. They can also be overmoulded onto a broad number of plastic substrates without the need for adhesives. Some specialty TPEs deliver vibration and sound damping capabilities. Others find use in food contact packaging, or have low leachables/extractables.

To demonstrate the broad applications for TPEs and their benefits to consumers, let's consider a 'day in the life' of a young family.

Rise and shine Dad is awakened by the alarm on his smartphone, whose case is overmoulded with a durable, grippy and brightly-coloured TPE providing usability, protection and aesthetic appeal. A wail from the nursery tells him it's time for the baby's first feed.

The nipple on her bottle is injection moulded from a soft but tough, non-BPA TPE. Dad also prepares a sippy cup of juice for the toddler, who likes the soft touch and primary colours of the cup lid, which is made from a food contact grade of TPE overmoulded onto polypropylene. This resilient material also stands up to his sharp baby teeth.

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Versaflex TPE Applications: Healthcare, packaging, consumer, electronics.

Characteristics: High clarity, ultra-soft, sterilisable, overmoulds to a range of engineering plastics, suitable for extrusion, injection and blow moulding.

Meanwhile, Mum has taken the dog for a walk around the neighbourhood followed by a quick game of fetch with his favourite toy.

This colourful toy bone, moulded from TPEs that comply with FDA regulations, has moulded-in surface textures that promote dental health and provide an enjoyable mouth feel, while resisting punctures and breakage.

Afterward, Mum heads for the shower and her daily beauty routine. Her toothbrush and razor handles feature overmoulded TPE grips for ergonomics and safety and the stylish packaging of her cosmetics – such as her lipstick and perfume mister – is enhanced with soft-touch, transparent TPEs. Preparing and serving breakfast is easier with TPEs. The overmoulded grip on the instant coffee jar makes it easier to open, and the special child's bowl with a non-slip bottom ring and utensils with grippy handles encourage Junior to feed himself.

Although spills are inevitable, the mop Dad grabs to clean up the floor is easy to use, thanks to TPE grips on its handle.

Off to work Dad puts both kids in their car seats for the trip to nursery and the office. The family vehicle offers many examples of TPE applications, from door and window seals to interior trim components to buttons and knobs, and from the floor mats to the surface of the accelerator pedal. Innovative TPE film grades for automotive interior applications such as instrument panels and door panels provide superior aesthetics, including a durable, matte finish, leather-like feel, low odour and excellent colour retention.

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Another specialty TPE, configured for use with power tools having nylon grips, delivers superior resistance to chemicals, oil and abrasion. This material bonds tightly to nylon substrates to deliver a soft yet resilient grip for safety, ergonomics and comfort.

OnFlex TPE Applications: Transportation, industrial, electrical.

Characteristics: Heat resistant, approved for automotive, weatherable, good compression set, flame retardant grades and extrusion, injection and blow mouldable.

Under the hood, TPEs offering excellent resistance to oil and chemicals serve as fuel line covers and sleeves, cable jacketing and brake line covers. In many cases, TPEs have replaced traditional thermoset rubbers because of the streamlined processing and greater design freedom they offer.

Approximately 40 per cent of all TPE products consumed worldwide are used in the manufacture of vehicles.

Mum, who enjoys a more flexible schedule, cycles to the aquatic centre before work. Her bicycle handle grips are made from a soft-touch, vibrationdamping TPE for comfort, reduced impact and safety. She gets ready to swim laps in the pool by donning goggles with clear, flexible, waterproof seals made with TPEs. Afterwards, she takes her reusable commuter mug with its grip band of textured TPE (in a stylish, contrasting colour) to the coffee shop for a latte.

Dynalloy TPE Applications: Packaging, consumer, electronics.

Characteristics: Based in INFUSE olefin block copolymer licensed from The Dow Chemical Company, unique feel, colourable, superb flow characteristics and excellent processability.

At the office, TPEs find application in many types of equipment, from computer mice, laptop 'feet' and desktop CPU covers to the grips on pens and pencils. At lunchtime, the staff grab their lunch containers sealed by flexible, soft-touch TPEs from the fridge.

Dad uses ear protection while he saws, drills and sands. The lightweight hearing protector features colourful, soft-touch TPE components tightly bonded to a polycarbonate headband.

In the house, Mum interrupts the board game she is playing with Junior to change the baby. The container of baby wipes keeps things fresh with an innovative TPE lid that dispenses one wipe at a time and provides moisture retention.

These materials offer amazing variety in hardness, surface texture, colour, opacity, abrasion and chemical resistance, and tear strength.

Night shift After dinner, Mum transfers the cold leftover pasta into a plastic food storage container. Fortunately – because she has misjudged the amount of rigatoni – this distinctive container includes a stretchable lid made from a unique elastomeric TPE alloy. The material, meeting FDA food contact requirements also has great clarity and stain resistance. Plus, it is dishwasher safe.

Following baths and stories, the parents put their children to bed and settle down for some well-deserved relaxation in front of the TV. Even here, TPEs can be found in the buttons of the remote control and the easy-twist cap of the sports drink they share.

Versollan TPE Applications: Consumer, electronics, industrial.

Characteristics: Rubber-like feel with matte finish, excellent chemical and oil resistance, good adhesion with PC and ABS, good processability and flow.

Family time With everyone back at home in the evening, parents and children pursue different activities.

Dad retreats to his workshop to make progress on a wooden rocking horse for Junior. His power drill handle incorporates a special TPE to reduce vibration that can cause discomfort and even circulatory problems or muscle and joint damage. New technology allows manufacturers to overmould vibration-damping TPEs onto popular plastic substrates using two-shot injection moulding.

Versalloy TPE Applications: Healthcare, consumer, electronics, industrial.

Characteristics: Excellent surface quality, easy processing, colourable and easy processing with good flow for long, thin flow paths.

TPEs improve the tactile experience, aesthetics, safety, ergonomics and usability of a huge array of consumer products that we use every day.

Whether in electronics, housewares, sporting goods, tools, vehicle components, personal care or packaging, TPEs help make daily life more enjoyable.

In many cases, TPEs have replaced traditional thermoset rubbers because of the streamlined processing and greater design freedom they offer.

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TPEs

High-flow materials for window trim KRAIBURG TPE has risen to the challenge of developing high-flow TPS for window trim applications - an application with strict requirements and exposure to extreme conditions.

Words | Josef Neuer, Product Management EMEA, KRAIBURG TPE

T

he success of thermoplastic elastomers is based largely on the trend toward multi-injection moulding.

Thermoplastic Elastomers based on styrene block copolymers (TPS) have gained particular acceptance over recent years.

Industrial manufacturers, as well as manufacturers of consumer and medical products, are increasingly basing their applications on the TPS product group. The trend toward Thermoplastic Elastomers is also apparent in automotive applications, as KRAIBURG TPE develops and produces TPE for automobile interiors, exteriors and under-the-bonnet components.

KRAIBURG TPE implements innovative solutions to expand the market for TPS and to optimise the existing areas of application, such as for window trim applications. The material requirements for these applications are stringent. The challenge was to provide a material that features long flow distances while maintaining a homogeneous surface appearance. Another requirement of the automotive industry is excellent weather resistance. Customised precisely to these requirements, KRAIBURG TPE has developed an innovative class of compounds: high-flow materials.

The new high-flow materials, a further development of the TPS formulation by KRAIBURG TPE, fulfill all requirements for the market. The modification of the viscosity while maintaining

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the TPS-specific material properties makes it possible for manufacturers to use TPS for window trim around thinner glass or laminated glass. Applications with very long flow distances, such as rear window trim or roof trim, are also implemented with TPS now. With this innovative compound, manufacturers have lengthened the flow distances by 134 per cent. The internal mould pressure can be reduced from 1,000 to 550 bar or reduction of the mass temperature to 35 °C enables a 20 per cent shorter cycle time.

Additionally, TPS materials feature extremely good UV resistance.

A comprehensive package of additives supports the high-flow materials from KRAIBURG TPE in sun simulation tests: the materials easily pass the Florida test and Kalahari test, which simulate two to three annual cycles.

The new technical modifications of the moulds offer significant benefits to the automotive market. Component manufacturers can increase their cost effectiveness with the injection moulding process. Energy is saved: the new formulation decreases the internal pressure, mass temperature and cycle times. In addition, glass breakage is reduced as a result of less strain during processing. With its high-flow materials KRAIBURG TPE has created significant added value for OEMs and maintains its position as innovation leader.

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Polymax launches TPEs for extreme conditions

Pevalen general purpose plasticiser from Perstorp meets the needs for phthalate-free solutions in PVC Due to the fact dioctyl phthalate (DOP) is now no longer permitted under EU REACH regulations as of February 2015, PVC compounders and processors have had to seek safer alternatives.

One of Europe’s leading providers of plasticisers with upstream integration, Perstorp, is in a leading position to fill this gap with a next-gen alternative combining high performance with

ease of processing and important environmental benefits.

Pevalen is a genuinely non-phthalate PVC plasticiser derived solely from aliphatic raw materials and is suitable for a wide range of general purpose applications including textiles, coated fabrics and vinyl flooring, while in 2016 it is expected to be approved for food contact applications.

TPEs

Pevalen displays good UV stability, making it an excellent choice in applications exposed to sunlight, while it can also be used in plastisols, moulded parts, films and foils. It is as efficient as DOP, and its low volatility is similar to that of high molecular weight plasticisers such as diisodecyl phthalate (DIDP) and Perstorp’s own Emoltene 100 dipropylheptyl phthalate (DPHP).

COLD START TO DRY POLYMERS IN JUST 35 MINUTES...

Really?

Polymax Thermoplastic Elastomers, a leading manufacturer and custom compounder of thermoplastic elastomer (TPE) materials, has launched an expanded line of premium quality TPE for use in extreme conditions.

Developed using new product formulations and customengineered production machinery, the company’s extreme conditions application materials are designed to perform under very high and very low temperatures, during medical sterilisation procedures and demanding environmental conditions.

Some of the new TPEs are formulated to endure exposure to ultra-violet light, abrasion, caustic substances and flammability conditions.

“As a leader in thermoplastic elastomer material formulation and compounding, we continue to focus on the needs of our customers by expanding the range of technical performance of our products,“ said PolymaxTPE President Dr Martin Lu. “PolymaxTPE materials that can endure rigorous conditions are particularly important in the automotive, healthcare and industrial market segments.“ PolymaxTPE has a full-service facility in Waukegan, Illinois, which produces the company’s range of more than 500 grades of TPE, develops nextgeneration TPE innovations and provides custom-developed materials and technical service. All PolymaxTPE materials are produced with stateof-the-art production and testing equipment from leading American and German manufacturers to ensure premium quality, consistency and performance at optimum production speed and cost.

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MATERIALS HANDLING

DuPont Delrin acetal homopolymer could transform materials handling Delrin from DuPont could transform materials handling applications as a supertough material that can replace metal.

Delrin is a lightweight, durable, wearresistant, low friction, low noise and high performance acetal resin solution for materials handling and when compared to rival acetal copolymers, offers a higher tensile strength, stiffness and creep resistance. Indeed, the material significantly outperforms on impact resistance, allowing for thinner and lighter part design or a higher safety factor at equivalent thickness.

Enhanced quality and performance coupled with uncompromised reliability and greater design freedom than metal or other plastics solutions puts Delrin at the cutting edge, which is why it is the material of choice for conveyor chains.

When used in conveyor chains, Delrin facilitates a quieter mechanism that is free of lubricant and requires minimal maintenance for long periods.

Delrin components are produced using injection moulding, which is much simpler than manufacturing steel chains.

Conveyor belts can be moulded with reduced pitch compared to their steel counterparts, which then facilitates smoother conveying. Low friction reduces the risk of product tipping, particularly on accumulation conveyors, while slashing wear on conveyor components and reducing noise. Its low density - even when reinforced with glass and other materials - can significantly reduce inertia and total assembly weight.

Moreover, Delrin combines lubricity and wear resistance with stiffness and strength for parts designed to replace metal, allowing chains to carry heavy loads maintaining high performance for longer. The material is also very resistant to cleaning agents used on conveyor lines, while several grades of Delrin have been introduced to meet stringent food contact requirements. These grades comply with regional regulations for the food industry. Two recent specialty food grade offerings are the Metal Detectable Delrin FG400MTD BLA079 and the X-Ray Detectable Delrin FG400XRD NC010.

With Delrin, there is no need for additional lubrication, as conveyor chains made with Delrin can run smoothly with reduced soap and water lubrication or even without lubrication at all. Thanks to the low friction and low wear properties of Delrin, glass container and bottling lines can run in dry condition, saving processing cost and making the process more sustainable.

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Safe hands: Conair materials handling expertise reduces chance of human error

MATERIALS HANDLING

Conair has launched three new materials handling systems to improve efficiency and dramatically reduce opportunities for human error.

Sometimes the most difficult challenges in manufacturing arise from human error. In plastics material conveying, operator error can result in the wrong resin being sent to the wrong processing destination, which in turn can lead to downtime, scrap and even product liability.

Conair material handling equipment has been developed to help avoid operator error in conveying systems include the Material Vision Proofing (MVP) system and the AutoResin Proofing system.

No wires The new Conair Invisible Line Proofing system uses a proprietary non-electrical sensing technology to confirm the proper resin source is connected to the selected destination.

Doug Brewster, Conair Conveying Product Manager, said: “The industry has used many different approaches to line proofing. There are systems that use proximity sensors, RFID chips and other approaches, but they all have one disadvantage – they involve wires that can get in the way or, worse, they can become disconnected so the system fails. Because the Invisible Line Proofing system is wireless, it is extremely fast and very dependable.“ Conair resin selection station operators simply connect the material line hose to the appropriate port on the tabletop array and Invisible Line Proofing makes this fool proof. If an incorrect connection is made, the control will not allow the vacuum pump to begin conveying material.

Seeing is believing Conair launched Material Vision Proofing (MVP) system at NPE2012. The unique system uses advanced machine-vision technology to provide automatic 100 per cent validation that the correct material is being conveyed to the right destination.

This year, Conair launched the 'next-generation MVP' with upgraded camera and shuttle mechanism and advanced controls for simple operation.

This new Conair innovation is simpler than other approaches to eliminating error and preventing contamination. A motorised camera is installed on a track behind a Conair table-top Resin Selection Station manifold. When setting up a job, an operator designates the source and destination in the standard FLX or ELS material-handling system. Then, graphics (for the benefit of workers with limited language skills) on the 4-inch colour touchscreen show where the correct connection is to be made.

Before any resin is conveyed, however, the machinevision camera traverses behind the selector table and positions itself between the appropriate rows of ports, confirming to the material handling system control that the correct connections have been made. Only then can the material be conveyed. The entire validation process takes seconds.

Because the Invisible Line Proofing system is wireless, it is extremely fast and very dependable.

Conair's AutoResin Proofing system

Simple, reliable, automatic One of the best ways to avoid operator error in material handling is to take the operator out of the picture. The new Conair AutoResin Selector is a servo-driven system that makes a hard-tubing connection between up to 20 resin sources and 20 destinations and operates with the latest materialhandling system controls. Connection ports are located on two rotating tables, one connected to material sources and the other connected to destinations. When the material handling control system calls for material, servo motors index two rotary tables until the specified source is aligned with its destination port. Then a hard-tubing connection is made between the two and conveying can begin.

Improve dosing with the MINIBLEND V After its successful week at NPE2015 in Orlando, Florida, in March, motan is keeping up the momentum by extolling the benefits of the volumetric MINIBLEND V dosing and mixing unit.

The unit offers plastics processors excellent mixing quality and consistently accurate dosing.

Mounted between the machine hopper and the feed throat of the plastics processing machine, the unit requires very little space. Disc dosing with the MINIBLEND V gives processors real volume dosing which guarantees a very high dosing accuracy - even for very small dosing quantities.

Three different disc sizes and special wear-resistant discs for hard and abrasive materials are available, in addition to dosing modules made of materials such as stainless steel or glass.

Module exchange is quick and easy, therefore enabling fast colour changes.

The MINIBLEND V is designed to dose free and normal-flowing materials and micro-batches.

The unit can be operated by motan’s volumetric controls VOLU MC or VOLUnet MC, which is equipped with an Ethernet interface.

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MEDICAL SPOTLIGHT

Enhancing Safety: using high-performance plastics in medical devices Working with its customers in the healthcare industry, SABIC’s Innovative Plastics business is helping to develop materials solutions with properties that can contribute to minimising the spread of HCAIs. Words | Cathleen Hess, Director of Healthcare Marketing for SABIC’s Innovative Plastics business

O

ne of the healthcare industry’s top priorities is to reduce the number of patients contracting infections when in the hospital or while self-medicating at home. According to the World Health Organization (WHO), healthcare-associated infections (HCAIs) cost the European economy around €7 billion (£5.07 billion) each year and add 16 million extra days annually to hospital stays.

Despite huge advances in medicine in recent years, no institution or country can claim to have fully solved the issue. In fact, the WHO estimates that at any given time seven out of 100 hospitalised patients in developed countries, and 10 out of 100 patients in developing countries, will acquire at least one HCAI. This equates to hundreds of millions of patients affected by HCAIs each year around the world. The prevalence of these infections has a concerning implication on patient safety as well as a significant economic impact. Patients can face prolonged hospital stays, as well as the possibility of long-term disability or even death.

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HCAIs are often transmitted indirectly through the use of Recently, SABIC enhanced its chemical resistance performance medical devices, such as thermometers, stethoscopes and other test data to include results from an ESC resistance study, inadequately decontaminated equipment, including electronic which shows the performance of its products when repeatedly devices encased in plastics, such exposed to aggressive healthcare as patient monitoring equipment. disinfectants used in the medical Healthcare organisations across the industry today. This includes both world have an urgent need to identify alcohol / quaternary ammonium new solutions that address this issue. compound (QAC)-based disinfectants SABIC offers a broad and and alcohol-free / QAC-based relevant portfolio of engineered Working with its customers in disinfectants, which are commonly thermoplastics which have been the healthcare industry, SABIC’s used as disinfectants to help prevent developed to help medical device Innovative Plastics business is the spread of infections. helping to develop materials manufacturers meet a wide range solutions with properties that can of challenging chemical resistance In addition to developing material contribute to minimising the spread requirements.. technologies that can contribute to of HCAIs. This collaboration has minimising the spread of infection led to several key developments, in hospitals, SABIC has played a including materials with enhanced role in improving safety in the home sterilisation performance and materials that meet a wide range medical environment. As the healthcare industry moves towards of challenging chemical resistance requirements, allowing for greater outpatient care and home administration of medication, more thorough cleaning. manufacturers of drug delivery devices, such as insulin pens, need to develop solutions that are safe, easy to use, compact The heightened emphasis on infection control in healthcare and aesthetically pleasing to patients. SABIC is helping its environments means that medical devices are regularly subjected customers adapt to this trend with its new CYCOLOY HCX1640 to intensive sterilisation cycles and harsh cleaning chemicals. resin, which can enable manufacturers to design robust, light Resin material technologies such as SABIC’s ULTEM HU1004 resin and attractive drug delivery devices that meet applicable have evolved to help answer this need for enhanced protection healthcare regulations. and can be a significant factor prolonging the life of expensive medical equipment by enabling it to better withstand intensive SABIC’s material technologies help manufacturers achieve thin sterilisation processes. walls and dimensional stability, as well as improved weld line performance and impact resistance, meaning that the devices ULTEM HU1004 resin, a thermoplastic polyetherimide (PEI) can be made safer and are less likely to break. These features also material, is a good candidate for medical and dental equipment allow manufacturers to create complex designs that are capable that will be subjected to intense sterilisation processes, including of integrating an increased number of mechanical or electronic high temperature steam autoclave (up to 134°C), gamma features. Additionally, the resin has a wide range of colour options, radiation and hydrogen peroxide helping to create an attractive design gas sterilisation (a low temperature that appeals to patients. By offering sterilisation process). In tests involving discreet, lightweight and attractive the hydrogen peroxide plasma devices, healthcare providers can sterilisation process, in particular, respond to the needs of a new ULTEM HU1004 resin outperformed SABIC’s material technologies help generation of patients who require another common material used for manufacturers achieve thin walls easy to use devices in order to safely these sterilisation applications - and dimensional stability, as well as and accurately administer their own polyphenylsulfone (PPSU) - in both improved weld line performance and medication. retention of mechanical properties, i.e. impact resistance, meaning that the tensile strength and ductility, as well As the global healthcare industry devices can me made safer and are as colour, which is critical to extending continues to improve safety in hospital less likely to break. the useful life of devices. and home settings, manufacturers can play a major role in helping The use of increasingly aggressive to create a safer environment for disinfectants to prevent the spread of patients and clinicians alike. However HCAIs is putting devices at risk for substantial wear and tear known this can only be achieved with new and innovative technologies. as environmental stress cracking (ESC). SABIC offers a broad and SABIC is committed to working with leading medical device relevant portfolio of engineered thermoplastics, including VALOX, companies to develop innovative healthcare solutions that are XENOY and ULTEM resins, which have been developed to help designed to help reduce HCAIs as well as support the growth of medical device manufacturers meet a wide range of challenging self-administration of medication. chemical resistance requirements.

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MEDICAL SPOTLIGHT

32-cavity mould for medical borne out of 4-way collaboration Eastman Chemical Company and Prestige Mold Incorporated, together with Mold-Masters and Pres-Tek Plastics have successfully collaborated to produce a multi-cavity mould for medical applications.

A

t NPE2015, EPPM had the chance to learn more about the first-of-its-kind multi-cavity mould for intricate medical devices launched

by Eastman Chemical Company and Prestige Mold Incorporated.

The two businesses joined forces to create the 32-cavity multi-cavity, hot runner mould specifically for Eastman Tritan copolyester to address future customer needs for durable medical device parts free of bisphenols A and S. Donna Pursell, CEO of Prestige Mold, explained that one of the main challenges the companies faced included creating a product that could withstand regular exposure to harsh cleaning chemicals and ensure as low a contamination rate as possible.

Vice-President and General Manager of Specialty Plastics at Eastman Burt Capel added: “Medical parts have to withstand the wear and tear that comes with ongoing exposure to aggressive disinfectants

and harsh oncology drugs. We wanted to proactively address these concerns for manufacturers. To do so, we employed Prestige Mold’s expertise.“ “It was a great collaboration and a success,“ he added.

The idea for the mould was prompted by customer needs for small medical device parts produced in a multi-cavity hot runner mould.

Eastman Tritan copolyester is well-suited for the medical device market because it improves upon typical copolyesters that traditionally have good chemical resistance. It is especially strong against aggressive disinfectants used to prevent hospitalacquired infections, has a low contamination rate and excels in secondary processing. To feature these qualities, a mould was made specifically to work well with Tritan.

The companies worked with Mold-Masters, the world’s leading supplier of hot runner technology

3D-printed moulds for medical prototyping slash costs by 88%

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he medical sector is a mainstay of Minneapolis-based Diversified Plastics' customer base and the company has found 3D printing technology has slotted itself well into its operations for this demanding sector.

The company has invested in an Objet260 Connex 3D printer by Stratasys, allowing it to take its rapid prototyping capabilities to new levels to better fulfil its customers' needs.

Diversified's long-time customer Coloplast - an OEM specialising in urology applications commissioned the development of a new product that required testing before the investment was made in a production tool. Prior to owning the Objet260, Diversified would have to make a mould from aluminium or soft steel - a six-week process - but with the 3D printer, this timeframe was slashed to just five days.

Diversified made savings of 80 per cent in time and a staggering 88 per cent saving in cost, as a metal mould would have cost the company $13,000 (£8,800, €12,100) compared to the $1,500 investment in the 3D-printed mould.

Vice-President of Diversified Plastics Annette Lund commented: “By making the Objet260 Connex part of our equipment line up, we now have the ability to help our customers bring products to market very quickly and cost effectively.“

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and systems, and Pres-Tek Plastics, a medical moulding and technology centre, to develop the mould. Mold-Masters built the machinery, while Pres-Tek honed the moulding process and validated the mould. The demonstration mould was used as an example for running a universal female luer. The luer was designed to meet the upcoming ISO Standard 80369 for small bore connectors, proactively addressing customer concerns.

“Our first run of the mould was impeccable, without any process or ejection issues. The success we've had with this mould speaks to our belief in the importance of early and ongoing collaboration,“ said Pursell. “Four companies were able to work together to push each of our capabilities and use each other’s expertise. Now, the companies involved are better able to help customers from product concept all the way through the final production.“

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3/19/2015 4:58:08 PM

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Solvay boosts PEEK production

MEDICAL SPOTLIGHT

Disposing of the disposable?

Fresh data from Frost & Sullivan’s Western and Eastern European Custom Procedure Trays and Packs (CPTP) Market report indicates that more hospitals and hospital trusts could be switching from a disposables-dominated culture to utilising more reusable apparatus. The expanding aging population has put pressure on inventories and the CPTP market report indicates single-use trays and packs may fall from favour in hospitals as green culture promotes reusing and reprocessing kit, putting those manufacturers with reprocessing and serialisation services in a good position for the future.

Fluoropolymer coatings specialist establishes medical arm Manufacturer of fluoropolymer coatings, Whitford Corporation, has established a new medical coatings group. The use of fluoropolymer coatings in medical apparatus is renowned as dependable and offers numerous benefits. Whitford’s new medical coatings arm is expected to be fully operational in the second half of 2015 and is setting its new venture up as something of a flagship for the medical coatings industry.

Whitford will implement an ISO 13485 compliant quality system to service all tiers of the medical supply chain.

Solvay is building a new resin unit for the development of specialty polymers in the US, significantly expanding its production capacity of PEEK. The new unit in Augusta, Georgia, is expected to come on-stream in mid-2016 and combined with the on-going expansion at its site in Panoli, India, Solvay’s total PEEK neat resin production capacity will soar to more than 2,500 tonnes worldwide. This investment confirms Solvay’s long-term commitment to keep apace with growing demand for PEEK in the medical and healthcare sectors, while the material is also becoming a rising star in automotive, electronics and oil and gas.

Chinese plastics industry spearheads wearables Wearables are already part of daily life for many Europeans and it appears the Chinese plastics market is ready to spearhead this zeitgeist for itself. ChinaPlas 2015 organisers announced that the world’s secondlargest plastics event would provide investors with a window into the future of wearables, where a range of materials including halogen-free nylon and new thermal resins will indicate how the next generation of wearables will look, allowing the technology to be more functional, more space-efficient and more comfortable for the wearer.

3D printing gives breast prostheses perkier price tag

Global PEEK market to surpass $1bn by 2020

A German swimwear, bodice and breast prostheses manufacturer has slashed its costs by half by using a basic additive manufacturing device to produce its moulds.

Anita’s X400 3D printer technology, provided by RepRap, has replaced the wooden template once used to create fibreglass prototypes. The team at Anita only 3D prints with PLA. The PLA model is then casted with sand and a foundry turns the resulting mould into its aluminium tool, cutting out the milling process.

Credit: German RepRap

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The worldwide PEEK market is anticipated to growth at a CAGR of up to 10 per cent between 2014 and 2020, surpassing the $1 billion (€900 million, £670 million) mark. This is according to Future Market Insights analysis, which puts Western Europe as the region with the highest demand for the medical-grade material, followed by the US and Japan. China and Western Europe are anticipated to record the highest growth rate over this period. It is used as a biomaterial in medical implants such as spinal fusion devices and reinforcing rods and is chemical-resistant, stable and durable.

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MEDICAL SPOTLIGHT

Doctors are only as good as their tools

Doctors are only as good as their tools, which is why OEMs all over the world are using Styrolution's expertise in polymers for medical applications to ensure their products are of the highest possible quality.

Words | Rose Brooke

W

ith the rise and rise of homecare and the on-going battle against hospital-borne super bugs, there has never been a more critical time for plastics in the medical world.

Global styrenics specialist Styrolution is at the front line of developing materials that can stand up to the rigours of the medical world and New Business Development Manager for Healthcare and Diagnostics Bernd Elbert shared with EPPM some of the trends that are driving the latest innovations in medical field.

But what happens if these connections fail? Elbert revealed too many IV sets fail because of leakages due to cracking in the drip chamber, which is where the importance of high quality products comes into play, and where the cheapest materials prove to be a false economy.

“You need really good materials that bond well to each other to prevent failure on the market later.“

Quality and mechanics “One of the key trends I observe is really that customers and OEMs are looking for high quality products. In the past, many things have been driven by pricing issues but that has changed a little bit,“ Elbert began.

“If we talk about a typical IV infusion set, IV sets consist normally of an IV bag for the drug and a medical drip chamber. The upper

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part of the drip chamber is very stiff because it has to be injected into the IV bag, while the lower part will be squeezed to fill the drip chamber with the fluid. So from a mechanical point of view, there are a lot of requirements in such a small application.“

Styrolution maintains a good relationship with OEMs to ascertain what the market needs and to understand the application fully, so not just the material requirements but understanding everything from the assembly process, to the drugs being delivered, to how the equipment will be stored and who will use it.

“This is very important. For example, with drip chambers, they can be bonded with different chemicals, but they also need to be mechanically fitted. That means in terms of material properties there are totally different requirements. For mechanical fittings you need stiffness, while for bonding you need a little bit more flexibility. For Styrolution, this means we have to look really deeply into the application,“ Elbert stated.

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If you do not understand the requirements, Exploring clear you can propose everything and the materials customer will be frustrated in the long Styrolution's work in the term because they are left with trial medical field is well established, and error. but its medical packaging unit

Champions in their field Within Styrolution's healthcare operation, there are specialist segments for the various applications such as IV and fluid delivery, ligature and mobile health, respiratory drug delivery and so on. Within each of these segments, there is a global champion who is totally dedicated to understanding their own niche in terms of the market, the materials, competition and the customers. Styrolution's global footprint and strong strategy, which takes the business firmly into 2020, qualifies the company as a leader thanks to its ability to reach all four corners of the map, with consistent service and knowledge across the board.

“Coming back to the drip chamber story, learning about those assembly processes,“ said Elbert, “that is something a polymer producer needs to understand to make the correct materials call for the customer. If you do not understand the requirements, you can propose everything and the customer will be frustrated in the long term because they are left with trial and error.“ “Styrolution wants to be different in that way,“ he continued. “We have these global segment champions to provide tailor-made proposals to the customer.“ Styrolution steps in at the very early stage of the design phase by talking to design engineers at the beginning of the development cycle - something Elbert states keeps costs down by limiting the wastage of time and resources. Elbert and his colleagues take pride in offering their customers more than a data sheet, offering expert knowledge on matters such as when a polymer returns to normal after gamma or heat sterilisation, which turns the material yellow for a period of time. This additional knowledge of the chemistry offers added value to OEMs and gives them a more attractive product in the end - in all respects.

Elbert used a dialyser housing as an example. The material used in dialyser housings will stay yellow for up to 95 days after sterilisation and when red blood runs through a yellow housing, it looks brown in colour, which is an aesthetic problem.

Because of this, OEMs sometimes have to store radiated housings for weeks to allow the material to change colour, wasting time and money. Styrolution's expertise comes into play at times like these, when the company can offer materials that do not change colour and knowledge on how the properties perform in the three months after gamma radiation.

- which explores housings for inhalors and other such external jackets and boxes - is new, while the company is also exploring transparent materials in the medical world. Interestingly, demand for transparency is a case for mechanical common sense as opposed to aesthetics.

“We have an intubater and the handle grip has a lot of mechanics inside. Engineers at each stage of the process would like to see from the outside how the inside is working, we are using transparent materials with the right chemical resistance so they can see the snap fit is going in the right direction and the mechanics are working.

Eventually these transparent materials will be coloured in company colours,“ Elbert explained.

Being immersed in the world of medicalgrade materials has given Elbert an interesting perspective on his own healthcare. He revealed that when in hospital a few years ago, he was asked if he had any fears by the surgeon.

“I said no, I know you are an expert, but if I look around to the equipment, my biggest fear is to get an infection from equipment that fails or has not been approved. [Doing this means] I don't take anything for granted.“ Indeed, Elbert acknowledged that materials science is partly an unsung hero of the medical world.

“On one side you have the experts, but they can only work as well as their devices.“ He explained that in the case of a surgeon performing an eight-hour procedure, the surgeon and his or her team would have to work for eight hours with their kit of instruments. At the end of those eight hours, the weight of a metal instrument will be taking its toll, opening doors for lightweight plastic alternatives.

Similarly, lightweight alternatives are growing in popularity in the homecare arena, where patients need to carry equipment around with them all day in their coat pocket or bag. In the end, however, it always returns to the fact that OEMs have to select the correct material for the job.

“There are plenty of materials on the market, but you have to select the right one. This is the biggest feedback we have had from customers and designers,“ Elbert remarked.

“We can offer material properties, work with them and take the time to learn about the challenges with these applications.

Every year there is a new challenge.“

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INJECTION MOULDING

Development into wireless injection moulding tech receives EU boost A consortium of eight partners has secured €3.3 million (£2.4 million) in European funding to develop cutting-edge wireless technological solutions for injection moulding setup and process optimisation using recommended machine parameters to minimise manufacturing downtime.

on historical data, which in turn are sent to the operator and displayed on a mobile device. This industrial wireless connection enables the reduction of visible components and simplification of the installation, providing greater efficiency, comfort and interoperability.

PREVIEW (PREdictive System to Recommend Injection Mould setup), a three-year project, commenced at the beginning of the year and aims to provide the injection moulding industry with a process control system that will lead to reductions in mould setup time and scrap and energy consumption, and an increase in productivity and flexibility.

The consortium includes: Fundacio Privada Ascamm (ASCAMM) and Plastiasite SA (PLASTIA) from Spain, IRIS Advanced Engineering Limited (IRIS) from Ireland, Humboldt-Universitaet zu Berlin (UBER) from Germany, Smithers Rapra and Smithers Pira Ltd (SRSP) from the UK, Promolding BV (Promolding) from the Netherlands, Proform Ipari es Kereskedelmi Kft (Proform Kft) from Hungary and MPT Plastica SRL (MPT PLASTICA SRL) from Italy.

The PREVIEW concept is to develop a data acquisition system where real time data is collected from the mould and the injection moulding machine and wirelessly transmitted to an advanced predictive system. This calculates a set of recommended parameters and process statistics based

The project has received funding from the European Unions Horizon 2020 research and innovation programme.

As easy as using a smartphone KraussMaffei has announced that with the MC6 Multitouch control system, it is the first and only provider on the market to offer an easyto-use control system for injection moulding machines in a capacitive 24inch Multitouch screen design.

The Multitouch allows processors to control even highly complex production systems through gestures, just like a smartphone, while guideways embedded in the screen allow operators to control all axes on the machine without looking at the screen.

Günther Grimm, Head of Software and Control Technology at KraussMaffei, explained: “With the new MC6 Multitouch, there is no need for injection moulding machine operators to apply physical pressure with their fingers.

Displays can be controlled through gestures with two or more fingers.

These include swiping movements and spreading your fingers to zoom.“ The increase in the size of the screen from 19 inches to 24 inches has created an additional area with a height of approximately 150 mm and improved the layout and user-friendliness. “Operators can define their favorite screen pages in this area as they wish,“ said Grimm. Options include pages from the injection moulding machines or robots, or the page can display the coolant flow or the live picture from a camera. Each operator can individually configure the preferred screen display and when operators sign in on the machine with their RFID badge, the system presents them with an individualised screen, thus enabling the operators to have personalised control of the system.

As many customers requested a screen that would allow them to complete the operation without concentrating on the screen, KraussMaffei and its partners developed the SlideX guideway. This enables mould setters to control all axes by feeling grooves. The command finger is led in the guideway and cannot slip out. The further the operator moves the finger to the right or left, the faster the movement is. A robot can also be integrated to move the axes using the SlideX.

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The new, MC6 Multitouch can be used for all five machine series from KraussMaffei: AX, CX, EX, GX and MX.

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The key to automated injection moulding

INJECTION MOULDING

MHS Mold Hotrunner Solutions believes that cooling-free valve gate hot runner systems are a key technology for highly automated injection moulding. EPPM spoke to MHS President Harald Schmidt and Director of Business Development Jörg Schmidt about the company’s new products and the future of injection moulding.

Words | Rose Brooke

T

he auspices of the biggest plastics show in North America, NPE, provided the perfect platform for MHS to launch the new Black Box: the world's most reliable valve gate actuator.

The Black Box's development is borne out of MHS' approach of looking at injection moulding as a whole and addressing the most important challenge facing valve gate hot runner technology: continuous performance in high temperature conditions without cooling or maintenance issues. The result of this is the pneumatic Black Box actuator.

Asking the right questions Harald Schmidt, MHS President, and Director of Business Development Jörg Schmidt, explained that advancements such as the Black Box can only be made when looking at the bigger picture and asking the right questions.

“Consider, if you run a five-second cycle, these valve gates have to make six million cycles over the course of a year. They are moving in a very severe environment in high heats of up to 350°C and they have to operate at extreme melt pressures of up to 2,500 bar.

This is only achievable with very wear-resistant and heat-resistant components and therefore the development of the actuator that controls these valve pins has to be geared towards extreme reliability because they are integrated into the mould and have to function 24/7 in thatproduction environment,“ Harald said.

Valve gate hot runner system featuring cooling-free Rheo-Pro Black Box actuators.

“We've found over the years that downtime is often caused by the breakdown of seals and lubricant. That can be due to regular wear on the O-rings or grease, or poor maintenance, or because of cooling issues like inadequate water quality. So, we developed the Black Box cylinder to do away with these weaknesses.

We made the actuator bulletproof.“

The Achilles heel of pneumatic valve gates Rheo-Pro valve gate hot runner nozzles.

“Injection moulding is ideally a fully-automated process and that process goes hand-in-hand with direct valve gated hot runner systems,“ Harald explained. “Because melt distribution from the machine into the mould is a process that has to tie into other disciplines like flow analysis and the rheological process - pressure, time and volume - these key parameters have to be managed as part of the melt distribution system.“ The prevalence of complex plastic parts and the growing number of advanced mould designs and functions dictates that the hot runner system performs more duties than simply distributing the melt to the cavity, it must be able to control the melt flow inside specific locations throughout the mould. Valve gates deliver a fully predictable mechanical solution. Since the process relies on moving parts, the challenge is to make the actuation as simple and robust as possible.

“You have single cavity and high cavity moulds, you have moulds with cascades with sequential fills where you control a lot of the final part properties with the valve gate hot runner, like venting and valve lines and hold pressure. You have multi-material injection, overmoulding and barrier moulding. The hot runner has overtaken a key function in process control. Valve gates have become an essential element in the automated process,“ Harald stated.

The Black Box was designed for all valve gate applications. It is also ideal for high-temperature materials such as PSU, PPS and PEEK, which are becoming increasingly popular within the automotive and medical sectors. Historically, high-temperature jobs wreak havoc on machinery, resulting in increased downtime for maintenance. The Black Box's secret weapon is that it simply has no seals that can cause abrasion, or lubricants that break down resulting in contamination. This also makes the product perfect for cleanroom injection moulding.

The Black Box Seals and lubricants, according to Harald, are the Achilles heel of pneumatic valve gate systems. Seals are traditionally made of a high-temperature elastomer and have a limited lifecycle. They can only operate in environments of up to 200°C and not for a very long period, so in order for the plastics processor to slash their maintenance times, they require a high-temperature-resistant actuator. Processors also have the option to use a hydraulic and electric-driven actuator, but the latter is not resistant to temperature (having to be kept below 100°C), while hydraulic actuators require hoses, connectors and a special system for the circulation of oil, which is not practical or economical - particularly in cleanroom environments.

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INJECTION MOULDING

“From this point of view, we decided to create a very reliable airactuated valve gate cylinder that can operate in high temperature injection moulds that run a mould temperature of up to 200°C, and processing temperatures of up to 450°C. This is what the others cannot do,“ Harald said.

Valuable real estate MHS recently launched its second generation of iVG nozzels, the world's first and only internal valve gate hot runners. Like the Black Box, these units also operate without seals, lubricants or cylinder cooling, however the piston is located directly inside the nozzle body. iVG nozzles are available in a number of sizes for a full range of applications and can operate maintenance-free in temperatures of up to 400°C.

“Mould up time is a very important measure in a production environment, especially for moulds that run around the clock for years,“ Harald noted. “So moving away from the actuators for a moment, we can look at the controllers that steer them.

Cascade and sequence controllers go hand-in-hand with valve gate hot runners and you have to be able to control these actuators with complete precision and a lot of transparency. It's a process that's so advanced you can do pretty much anything, like oversee production on a global scale.“ He explained that this realtime understanding of the process, offering processors transparency and ease-of-use, is an important part of ensuring injection moulding continues its evolution.

“We're trying to build as much intelligence into the product we can,“ said Jörg. “Some basic controllers out there haven't changed in decades. Controllers have to have a level of sophistication in a simple-to-use package in order to accurately control the processes while being smart enough to have alarms and built-in safety features.

Rheo-Pro iVG internal valve gate hot runner nozzles in a compact back-to-back stack mould configuration.

Jörg explained: “[With the iVG] we're not placing any of the actuation inside the manifold plate or on the other side of the manifold plate like in traditional valve gate mould designs. Having everything related to your valve gate actuation placed on the nozzle side of the hot runner manifold is revolutionary. You're taking away that extra space inside the injection mould for actuators, saving the mouldmakers a lot of space and material cost.

Real estate inside the mould is extremely valuable, so everything has to be as small and as compact as possible, Also, the iVG is fully front-accessible, which is extremely important throughout the life of a mould.“ “I think most people understand the Black Box right away because the actuator is a stand-alone unit that looks more like a traditional valve gate and we designed it to easily retrofit into existing systems. The iVG by comparison is something completely new to the world of injection moulding. Once people wrap their head around it, it's amazing what they end up doing with it,“ he added.

The iVG is something completely new to the world of injection moulding. Once people wrap their head around it, it’s amazing what they end up doing with it.

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Hot runner system featuring Rheo-Pro iVG valve gate nozzles (back-to-back stack mould).

“Basically we're trying to make everything as hard to break as possible. When a machine is running, that's when it's happiest - it's like a car. When it has to stop, that's when the most damage happens.“

Looking to the next 30 Understanding the entire injection moulding cycle is critical, even when - like Harald Schmidt - you have specialised in hot runners for three decades. But this broader understanding of the technology and of the marketplace is the key to MHS' success and it seems fitting that with 30 years behind him, Harald and Jörg both look to the next 30.

“We always try to look at larger trends,“ stated Jörg. “We spend a lot of time thinking about the future of injection moulding and what it will look like in 30 years' time. Themes like improved automation, lightweighting, material savings and new material development, these things make production more sustainable and ensure that injection moulding remains a growth industry. Plastics will continue to play a very important role in our everyday lives.“ “I started to develop hot runners in 1985,“ said Harald. “I started in plastics engineering in Germany in 1979 before I came to North America, so my experience goes way back. You would think that during that time period the technology would mature, that we would hit the limits of what is possible, but there's still so much room for innovation. Plastic material development, injection moulding development and a higher and higher degree of automation - in the tailwind of these trends, hot runners will grow and evolve.“

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EVENTS

Fakuma 2015 sells out Fakuma is six months away but the international plastics processing showcase has been booked out since February.

S

ix months ahead of the week-long international plastics processing trade show, Fakuma 2015 has sold out.

Fakuma Project Manager Annemarie Lipp has confirmed that every hall at the Friedrichshafen Messe - in addition to all ancillary floor space - has been booked since February.

High levels of steady business and optimistic prospects for growth this year, along with an internationally receptive marketplace, have paved the way for the key event in the plastics processing calendar. Indeed, the GKV (general association for the plastics processing industry), has not only broken last year's record turnover amounting to just under €60 billion (£43 billion), but business has also grown at above average rates in nearly all sectors.

Therefore, hopes are high for months to come, particularly due to the fact manufacturers and distributors have conducted thorough research into all the challenges facing plastics in Europe and further afield.

Equipped with expertise and know-how for both standalone and complete solutions in all areas of injection moulding, extrusion and thermoforming technology, the entire plastics processing industry is displaying great confidence, claims Fakuma organisers.

This industry-wide shift in confidence is reflected in Fakuma's record-breaking participation.

Lipps stated: "Due to the fact that Fakuma is held twice every three years and will thus not take place in 2016, many manufacturers and distributors wanted to take advantage of the opportunity of participating in the continuing boom for plastic products, or of profiting from substitution options through the use of new plastics and composites."

Be seen in EPPM's Fakuma preview EPPM will once again be present at Fakuma as a media associate. Ensure your news is included in one of our two printed previews by emailing announcements and images to rose.brooke@ rapidnews.com.

Demand ‘lively’ for K 2016 K Show looms large on the horizon for the plastics industry and with 18 months until the massive Düsseldorf event, demand is already flourishing.

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ith just weeks to go before registration for K 2016 widely perceived as the most hotly-anticipated event in the plastics processing calendar - demand for space on the show floor is rampant.

Messe Düsseldorf has recorded an avalanche of enquiries from companies across the industry both in Europe and abroad, ensuring that next year’s incarnation of the triennial expo will once again provide a complete overview of the world’s plastics and rubber industry.

Around 3,000 exhibitors will be attending the show from October 19th26th with all 19 of the Messe’s halls

set to be fully booked and stacked to the rafters with exciting exhibitions.

Companies from all continents have already registered to present their innovations under the categories of raw materials, auxiliaries, semifinished products, technical parts and reinforced plastics, machines and equipment for the plastics and rubber industry.

Werner M. Dornscheidt, President and CEO of Messe Düsseldorf, stated: “Thanks to its unparalleled breadth of offering and the unmatched internationality of exhibitors and visitors, the fair is in a class of its own worldwide. It is the place where key decisions for products and processes

and problem-solving are taken, and it points the way forward for the whole industry for the coming years. We are delighted that demand for exhibition space is again extremely buoyant.

“Companies from the world of plastics and rubber know that they can look forward to an excellent springboard for their business success every three years in Düsseldorf. Registration for K 2016 is still possible until 31 May 2015.”

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A special show illustrating the potential of plastics and rubber for forwardlooking applications will complement exhibiting companies’ presentations at K 2016. This showcase is being organised by the German plastics industry under the auspices of PlasticsEurope Deutschland e.V. and Messe Düsseldorf and will demonstrate the extent to which plastic innovation shapes everyday life.

25

PLAST 2015 PREVIEW

Cream of Italian plastics processing on world stage The best of the Italian plastics processing scene will be given a global platform at PLAST 2015, showcasing the strength and sophistication of the innovations to come from the heart of Europe.

In February 2015, the number of exhibitors reached 1,200 - a 3.9 per cent rise on the same period ahead of PLAST 2012 - and now organiser Promaplast anticipates nearer 1,500 exhibitors from across the entire plastics processing supply chain.

Growing export market The fact the Italian plastics market has been doing so well in recent months will provide fertile ground for the five-day event. Analysis

by Assocomaplast - the Italian trade association and member of Confindustria, a group that unites some 170 companies - of official foreign trade data revealed that between January and September 2014, sales of Italian plastics machinery to foreign countries reached €1.89 billion (£1.41 billion). This is a year-on-year rise of four per cent.

Managing Director of Promaplast Mario Maggiani said in February: “Beyond the numbers it is important to note how foreign exhibitors continue to believe in PLAST, reclaiming, if not expanding, the same spaces reserved in 2012.

“PLAST is not only holding its ground, but gaining more, as confirmed by the increase in new exhibitors, both Italian and foreign, who have made the decision, for the first time, to exhibit at the fair.“

“We feel it is our duty to find a way to facilitate young entrepreneurs and the companies that represent our future. The decision was thus taken, together with the technology incubator Comonext, to select up to a maximum of 50 startups working in the field of plastics,“ said Maggiani.

Keep up to date on all things PLAST 2015 with EPPM. Follow our reporters on the ground on Twitter @EPPM_Magazine and at www.EPPM.com.

International representation Promaplast has credited the continued economic rally across the Atlantic in the US, along with recent moves by the European Central Bank, as key optimism drivers for the triennial show, playing a key role in bringing more international visitors and exhibitors through the doors of the Fiera Milano exhibition centre.

The global market share for importing plastics and rubber machinery into Italy is still dominated by Germany, which claims 40 per cent of the pie (or pizza?). This is followed by France (11 per cent), Switzerland (8.4 per cent) and China (6.9 per cent), according to the latest figures from VDMA: the plastics and rubber machinery association in Germany. Indeed, Italy imported €454 million in plastics and rubber equipment into the country between January and September 2014, according to Assocomaplast a year-on-year leap of seven percentage points.

In addition to the global plastics market being represented at PLAST 2015, organisers have ensured the spotlight reaches the various specialisms and sectors of the industry. To this end, PLAST 2015 will feature its own RUBBER 2015 section, while additive manufacturing will be represented at 3D PLAST and startups will have their time in the sun with START PLAST.

26

FAST PLAST FACTS • Host city Milan is Italy’s second largest with a population of 5.2 million • Floor plan for PLAST 2015 covers 60,000 m sq across six halls • More than 1,500 exhibitors expected this year • 58 countries represented at PLAST 2012 • 50,593 visitors attended in 2012 • Over three-quarters of floor plan devoted to machinery • Nearly two-thirds of exhibitors are Italian • More than 20 side events at PLAST 2015 • Host city Milan is the industrial and financial heart of Italy • Milan is twinned with Germany's financial hub, Frankfurt and Birmingham, UK.

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An exhibitor's eye view: EREMA at PLAST 2015 EREMA will be securing its share in the Italian market at PLAST 2015 with live demonstrations of its cutting-edge recycling systems and the official introduction of PURE LOOP into the European Market.

Head of Marketing and Business Development Gerold Breuer shared some of EREMA's plans for PLAST with EPPM. Words | Rose Brooke

The European plastics market is enjoying some buoyancy after the slowdown at the end of the noughties and the Italian corner of this thriving marketplace is proving particularly active in the global arena.

It is, therefore, apt that so much excitement surrounds PLAST 2015 in Milan this May, where plastics processors from around the globe will be gathering at the Lombardian industrial hub to ensure they nab their share in the Italian market.

EREMA, global leader in the production of plastics recycling systems and components, will be bringing its cuttingedge technology to Milan, where it will also be officially introducing its new business PURE LOOP to the European Market. Gerold Breuer, Head of Marketing and Business Development at EREMA, was kind enough to give EPPM a preview of what visitors can expect from EREMA at PLAST 2015 and how the on-site team has been getting ready for this exciting event.

“PLAST, as the biggest plastic show in Europe beside the K show, is one of the most important trade fairs for us,“ Breuer explained. “Furthermore it is located in Italy, which is one of the big marketplaces for plastic recycling technologies in Europe.“

EREMA's main focus at PLAST 2015, he revealed, will be its top-selling INTAREMA systems, which feature the core technology Counter Current. On-site, visitors will be able to see a live demonstration of the INTAREMA 1007 TVEplus system with EREMA melt filter SW/RTF 4/134, which has been designed especially for the recycling of heavily-printed and metallised production waste, in addition to a showcase featuring the fully automatic edge trim system INTAREMA 605 K with enhanced development for the in-house recycling sector.

“EREMA has been adapting its technologies continuously to the requirements of the wide variety of recycling applications for more than 30 years,“ said Breuer. “And, as we have also noted a rapidly growing demand for efficient solutions for the processing of thick-walled plastic materials at the current time, we have designed our latest product, the RegrindPro system, to meet the exact requirements in this field of application.“ Demand for processing regrind materials for high-quality recycled plastic pellets, he explained, is on the rise, particularly in the thick-walled packaging, electronics (WEEE) and automotive sectors.

Visitors will be able to learn all about the RegrindPro system at PLAST from EREMA's on-site team.

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The official introduction of PURE LOOP to the European market will be another significant highlight for EREMA at PLAST 2015. PURE LOOP was founded on New Years Day 2015 and specialises in the recycling of clean production waste using shredder-extruder technology. Operating as a sister company to EREMA, PURE LOOP pursues a clear position in the market of shredder-extruder technology for repelletising production waste in a wide variety of forms such as film, tapes, fibres, nonwovens, fabric, hollow bodies and solid parts. PURE LOOP's corner of the exhibition will feature its Integrated Shredder Extruder Combination plant system.

With so much to offer the Italian market - which is gradually building its strength on the European and global plastics stages, Breuer admitted the cohort bound to represent EREMA at PLAST 2015 is impatient for the event and to show off everything EREMA has to offer.

“The whole team is very exited and can't wait to present EREMA's latest technology developments to customers, prospective customers and partners of the company.“

PLAST 2015 visitors can find EREMA in

Hall 15 Stand B121

27

PLAST 2015 PREVIEW

AMUT

Battenfeld-Cincinnati

AMUT GROUP will officially introduce the new AMUT DOLCI BIELLONI into the European market at PLAST, where the company will display the latest developments in extrusion, recycling and thermoforming.

At PLAST, battenfeld-cincinnati will present a wide range of solutions for pipe extrusion – from PVC foam core pipe to PE-Xa pipes and the FDC system for automatic dimension change. In addition, the company’s equipment for WPC/NFC extrusion, pelletising and thermoforming sheet production will be showcased.

AMUT will be demonstrating the AMP850W-GP thermoforming machine on-site. Equipped with a 50-cavity mould, it produces 240 ml cups efficiently in terms of energy and wastage. AMUT will also be showcasing the counter-rotating twin-screw extruder, model BA92, a peculiar extruder developed for the EasyWood manufacturing system, while the AMUT’s compact series for foil production will be on show, fitting every model of thermoforming machine. The EA130 extruder permits to produce a 1000 mm-width foil, a thickness up to 2 mm and to achieve a capacity of 800-1200 kg/h.

Finally, a shuttle bus service will connect the fairground to the AMUT DOLCI BIELLONI premises where an open house will be held to present two cast lines for stretch film, one producing hand and automatic rolls and the other producing jumbos. The 2000 mm stretch film line is extremely innovative, with six extruders to guarantee a flexible production and a unique design capable of producing thinner, stronger film.

Hall 13 B71/C72

As an extrusion equipment specialist, battenfeld-cincinnati offers a portfolio of extruders with high performance, excellent homogenisation and high energy efficiency.

For pipe extrusion, the twinEX series of parallel twin screw and the solEX series of single screw extruders are available, with output rates of up to 2,500 kg/h and 2,200 kg/h respectively. The bestselling ‘plug & play’ alpha single screw extruder is the perfect solution for standard applications, small pipes and technical profiles. battenfeld-cincinnati also offers tailor-made, complete systems for WPC/NFC extrusion that are rounded off by wearoptimised metallurgical solutions. Recently, the cost-efficient fiberEX 9334D extruder for medium outputs (up to 400 kg/h) was introduced. It is able to process a great variety of different formulations with just one plasticising unit.

Hall 13 A01

Arburg

BMB

Arburg will exhibit a broad range of efficient plastic part production applications at PLAST, where the Freeformer will be given its Italian debut. The Freeformer shows how one-off parts and small batches can be produced from standard granulate without a mould using additive manufacturing. An on-site demonstration will showcase how the Freeformer can combine standard ABS material with a special support material to produce a key fob with a ball joint.

At PLAST 2015, BMB will showcase its fully electric eKW 38Pi/2200 injection machine producing a 300 gm, 10-litre plastic bucket. There will also be a completely electric eKW 16Pi/700 on show. The eKW 16Pi/700 is small but achieves a high rate of production and will demonstrate its capabilities by producing an espresso wafer using a 16-cavity mould on a 2.5-second cycle. The third machine featured at the BMB stand will be an eKW 85Pi/8500 Hybrid with electrical clamping and plasticisation and hydraulic injection using hydraulic accumulators. This machine achieves high performance in high weight packaging and at the fair it will produce 1 kg on a 20-second cycle.

Arburg will present a broad range of industrial applications and processes in the area of injection moulding including multi-component injection moulding and liquid silicone rubber (LSR) processing, as well as highperformance machines for the medical technology sector and the packaging industry. An electric Allrounder 520 A with a clamping force of 1,500 kN and a size 400 injection unit will demonstrate a thin-walled application, while an electric Allrounder 470 E with a clamping force of 1,000 kN and size 290 injection unit will be configured for processing liquid silicone (LSR).

Finally, Arburg will be showcasing the advantages of its Multilift Select, which has servo-electric drive axes and is fully integrated in the Selogica machine controller.

For the operator, this means only one data set, a familiar approach during programming and perfect synchronisation of robotic system and machine.

Packaging represents BMB’s core business. Among BMB’s most recently developed packaging machines is a 700 t with a 4500 injection unit for well known Danish company that can mould thin-walled containers with a multi-cavity mould and very short cycle time. Technology like this makes BMB a serious competitor with its top European counterparts.

At this point, 80 per cent of BMB machines are sold outside of Italy.

Hall 22 A101/B102

Hall 22 C81/D82

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ENGEL

HERBOLD

Injection moulding machine manufacturer and system supplier ENGEL will demonstrate how highly integrated and automated system solutions from a single source can innovate five applications at PLAST.

HERBOLD will present new solutions for washing, separating and drying plastic waste featuring low operating costs and higher efficiency at PLAST 2015.

The trend of process integration as a path to greater efficiency, safety and quality is well established. Now it is necessary to adopt a more diversified stance. The object is no longer simply to integrate process steps upstream or downstream of injection moulding, but also to combine different process technologies with one another. To produce centre console components in PC-ABS at its stand, ENGEL will use the ENGEL duo 2550/550 with integrated ENGEL viper 20 robot to combine two technologies: ENGEL foammelt, the MuCell foam injection moulding process developed by Trexel, and ENGEL variomelt, a variothermal injection moulding process. The double technology integration enables the production of thin-walled parts with very high quality surfaces and excellent fine structure reproduction at the same time in a single step.

During the show a tie-bar-less ENGEL victory 330/80 will feature the ENGEL ecodrive servo-hydraulic system. With ecodrive, the energy consumption of hydraulic drives is reduced by up to 70 per cent, depending on machine type and application.

Hall 24 B81/C82

Under the spotlight will be the HERBOLD wet shredder HGM. 25 years ago, Herbold made wet granulation marketable and with it, created new industry benchmarks. This technique is well suited for highly contaminated material such as agricultural film. It is also suitable for post-consumer film from households and wet granulation has significantly increased the life between knife changes enabling a more economic operation. Wear protection cuts out the needs for timeconsuming machine protection, as Herbold’s product range includes granulator housings equipped with exchangeable wear plates. This shortens the downtime and increases the life of the granulator.

The HERBOLD plastcompactor is a solution for turning film, fibres and foams with low bulk densities into an agglomerate with high bulk density and excellent flow properties. The plastcompactor at the end of the wash line offers two benefits: higher bulk density and free-flowing properties, and acts as a very efficient drying step. With this material it is possible to homogenise large loads of 20 tonnes in order to produce the required product properties.

Hall 15 D31

EREMA

KIEFEL

EREMA will be giving its newly-founded sister company PURE LOOP its official European premiere at PLAST 2015. PURE LOOP pursues the further development of EREMA’s shredder-extruder technology. This is used for the repelletising of production waste in a wide variety of forms such as film, tapes, fibres, nonwovens, fabric, hollow bodies, solid plastic parts and much more. PURE LOOP will present its ‘ISEC’ (Integrated Shredder Extruder Combination) plant systems in its own presentation area using 3D models, among other things.

German film extrusion specialist KIEFEL will be celebrating its most successful year to date at PLAST 2015.

EREMA’s other focus at PLAST 2015 will be on its top-selling hit, the new INTAREMA generation of systems featuring the core technology Counter Current. The global market leader in plastics recycling system engineering has already been able to sell more than 210 new systems worldwide after only 18 months since sales began in 2013 and the trend is set to continue. Visitors will see live in action: an INTAREMA 1007 TVEplus system with EREMA melt filter SW/RTF 4/134, designed especially for the recycling of heavily printed and metallised production waste, plus the fully automatic edge trim system INTAREMA 605 K with enhanced development for the in-house recycling sector.

Hall 15 B121

Last year was the best business year in the history of the company.

Turnover - including that of its subsidiary companies - has increased by approximately 20 per cent at well over €100 million - a record level for Kiefel, as is the increased level of orders at over €120 million. This has surpassed the previous record year in 2013 and has formed an excellent foundation for the future.

New developments in the key technologies of joining and forming films for the four key business areas of automotive, packaging, refrigerator industries and medical technology are responsible for this positive business development. Examples for this are: high-speed forming plants for the production of drinking cups and yoghurt pots, thermoforming machines for the economic production of self-service packaging for meat, fruit and vegetables, and welding systems for medical items or for manufacturing high-quality parts for automotive interiors.

KIEFEL’s automotive business is galvanised by the recent takeover of the Czech company SWA - a specialist in punching and pressing technology.

Hall 13 Stand B125

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29

PLAST 2015 PREVIEW

KRAIBURG TPE

MEUSBURGER

KRAIBURG TPE will present its innovative material solutions for wide-ranging applications at PLAST 2015.

Meusburger, the leading manufacturer of high-precision standard parts for tool and mould making, will be bringing its expanded size range of assembly table and new steel, brass and aluminium electrode holders to PLAST 2015.

With over 50 years of experience in working with steel, the company stands for high-quality products and outstanding service. The aircushioned assembly table has been developed by Meusburger to facilitate operations in repair and assembly work on injection moulding, die casting and punching tools. To meet growing demand, the H 4062 is available in the sizes 496 x 1156 mm and 796 x 1496 mm and now 996 x 1846 mm.

KRAIBURG TPE offers its customers a comprehensive customer- and market-oriented portfolio of products and services. The TPE specialist also supports its customers with technological knowhow, from the product idea through material selection and tool design all the way to series production. KRAIBURG TPE has acquired this expertise through many years of experience in the manufacture and processing of TPEs. Since numerous OEMs and suppliers of the Italian automotive industry will be represented at PLAST, the TPE specialist will reinforce its close customer relations with the focus on Thermoplastic Elastomers for the automotive sector. With its highly temperature-resistant products HIPEX and THERMOLAST V, KRAIBURG TPE offers TPEs for use under the hood. For interior and exterior applications, KRAIBURG TPE has likewise developed a custom engineered portfolio to meet the special technical requirements for materials and surface quality.

Another focus at the KRAIBURG TPE exhibit will be on compounds for applications with drinking water contact. These compounds fulfil the most important European drinking water certifications.

Meusburger has also expanded its product range with high-quality electrode holders in three different material grades. The electrode holders are available in steel, brass or aluminium and in various versions.

They are especially adapted for Meusburger’s large range of electrodes and are compatible with the ITS50 clamping system. The electrode holders can be ordered as individual components or in a set and are available from stock.

Hall 22 A161

Hall 9 32

KraussMaffei

Netstal

At PLAST 2015, KraussMaffei will demonstrate just why it holds its leading market position for premium quality injection moulding machines for logistics products.

Netstal will present the production of insulin pen piston guides at PLAST 2015 manufactured on an ELION 1750-510 with a fast cycle time of approximately 8.5 seconds.

KraussMaffei is bringing its GX 650-8100 to Italy in order to demonstrate the efficient production of transport crates, thereby emphasising the efficiency of the GX Series for high-speed applications. The trade fair exhibit is equipped with the new high-speed SP 8100 injection moulding unit. With a diameter of 105 mm and an injection speed of up to 400 mm/s, it is especially suitable for high-speed, thin-wall applications such as transport packaging. The GX 650-8100 will produce a stackable polypropylene transport crate with integrated handles and a shot weight of 500 g in a cycle time of approximately eight seconds at the show. The machine contains - as a standard feature - a chute which is also suitable for wide conveyors. The finished components can therefore be demoulded either with or without an automation solution.

The height of the machine was increased by 150 mm so that large free-falling parts can also be transported. The machine on-site will be equipped with KraussMaffei’s new APC (adaptive process control) function, which can be used to immediately compensate for fluctuations in the manufacturing process during injection moulding, resulting in consistently high component quality.

Hall 24 Booth B62

The Swiss machine supplier will demonstrate its medical expertise by producing polyoxymethylene (POM) insulin pen piston guides on a 16 cavity mould from Kebo (CH). The extremely complex processes of the mould and core traction movements during mould removal require a very flexible and configurable control. The aXos control supports the process very efficiently in this case. Due to the sophisticated nature of the thermal and geometric properties of the moulded part, the very small core diameters must be cooled skilfully in order for the process time to be as short as possible. The requirements placed on manufacturers of medical technology in terms of cleanliness, precision, short cycle times and low material costs are very high and Netstal can address all of these confidently.

The Swiss machine supplier will also present a production system for the manufacture of a polystyrene cup with a cycle time of approximately two seconds on an ELION 1200-530 with a 2 cavity mould.

Hall 24 Stand B62

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ST SOFFIAGGIO TECNICA

WITTMANN BATTENFELD

ST SOFFIAGGIO TECNICA SRL will present its ISIT 400 blow moulding machine at PLAST.

Austrian manufacturer WITTMANN BATTENFELD will be providing an injection of confidence into the Italian market at PLAST 2015, where it will be showcasing its cutting-edge plastics processing equipment.

Part of the latest range of machines to join the ASPI and TA series, ISIT embodies efficiency and Italian simplicity, guaranteeing high productivity with highenergy savings at a competitive market price.

Specially developed for the production of blown articles for the technical, automotive and industrial packaging fields, the blow moulding machine ISIT 400 at PLAST will be made up of a HEX 60 extruder and an 8 l accumulator head. The clamping unit features two diagonal guiding columns support and makes the mould platens sliding. In this way, the gripping and extraction pliers of the blown product can move freely. The blowing unit has a structure connected to the main frame a roller rail system.

This solution allows movement under half of the mould during the mould change process.

In addition to the model ISIT 400 on display, the range of ISIT blow moulding machines includes the models 500-800-1300-1600.

This continuous evolution is testament to ST SOFFIAGGIO TECNICA’s dedication to meet the needs of its customers in a constantly evolving market.

WITTMANN BATTENFELD trusts that the Italian economy is in recovery, and therefore PLAST 2015 provides the perfect showground for its five PowerSeries injection moulding machines, robots and peripheral equipment. Featured in the PowerSeries is the SmartPower, which was premiered at Fakuma in 2014 and features Servo hydraulics and all the advantages of an all-electric machine combined with those of a hydraulic machine: energy efficiency, precision, speed, precision and cleanliness.

Two small hydraulic SmartPower presses will be on display at the company’s stand: the first (a 60/120 featuring a clamping force of 60 tonnes) will produce PA items with a mould supplied by Austrian Greiner Packaging, the second machine (a 120/525 with a clamping force of 120 tonnes) will mould the front board of a coffee machine with a singlecavity mould supplied by Wittner.

Hall 22 B121/C122

Hall 22 Stand B122

Starlinger

WM Wrapping Machinery

Starlinger viscotec will showcase the deCON 20 decontamination dryer at PLAST 2015. The dryer processes flakes and recycled pellets from PET and HDPE for use in food grade packaging.

WM Wrapping Machinery will be showcasing the latest incarnation of the Speedmaster Plus pressure forming machine model FC 780 E IM2 at PLAST 2015.

Unique to the deCON 20 is its ability to process input material in different forms – e.g. pellets, flakes and skeleton waste – simultaneously. The process is compliant with the relevant FDA and EFSA standards, so the material can be used directly for the production of food grade packaging.

Also on display will be the new recycling line recoSTAR dynamic, which was launched by Starlinger in March 2015. The machine is characterised by a very energy-efficient production process as well as a high grade of automation. This ensures reliable and constant production, higher output, and great flexibility with input materials. The comprehensive, energy-efficient design of the new machine concept is highlighted with the ‘rECO’ stamp. By using motors with the best efficiency ratings, energy recovery systems in various process steps, as well as infrared heating, energy consumption and CO2 emissions are reduced significantly. The recoSTAR dynamic recycling line processes industrial and post-consumer plastic scrap and produces high-quality regranulate.

Hall 15 C6

The new Speedmaster Plus is the next generation of vacuum and pressure forming machine, assuring the highest level of automation and top performance with any materials. The Speedmaster Plus includes integrated power regeneration offering valuable energy savings thanks to its ability to convert the kinetic energy generated during braking movements into electrical energy that is regenerated into the power system. The machines are fitted with two infrared ceramic heaters and various partitions are available to optimise processing performance.

The Speedmaster Plus also features an optical reader in order to have an automatic closed loop control of temperature. The entire oven structure is insulated to keep heat dispersion at a minimum, increasing the yield, providing further energy saving. All Speedmaster Plus thermoforming machines are equipped with the latest generation software providing perfect management of all cycle parameters and machine functions.

Remote service assistance is assured with new access hardware support.

The machine on the stand will be displayed with a mould for a clamp shield container made of APET material.

Hall 13 C31/D32

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EPPM Classifieds EPPM_210x143_04-15.pdf

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22/04/2015

16:21

45 Years inNew & Used Machinery to thePlastics Industry Worldwide.

sales@rawmec.com 01992 www.rawmec.com 471796

Download our full stock lists online

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Rawmec EEC Ltd, Rawmec Industrial Estate, Plumpton Rd, Hoddesdon, Herts. EN11 0EE See our machines in action More info, machines & photos visit: www.rawmec.com or email: info@rawmec.com on our YouTube account EPPM_210x143_04-15.indd 1

21/04/2015 14:12

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1350mm Union/Welex coextrusion Sheet line; 100mm union extruder. Gearpump, mixer, 1270mm Die, 1350mm Stack. Haul off.

Plasmec 1000 litre batch gravimetric blender 2 off Process Controls Gravimetic Feeder blenders

1650mm Wide Casplast Horizontal 3 Roll Stack . 500mm Dia Rolls Independently Driven Via 5.5kw Ac Motors. 2 roll haul off. 2005.

1000mm wide Omv coextrusion sheet line.

120mm and 70mm extruders, melt pump, .

1000 x 500mm polishing stack, pump group, haul off, winder.

1000mm Wide Esde FL 1000 3 Roll Sheet Downstream. 350mm dia rolls. Pneumatic top nip. Individual driven rolls. 1998.

50ltr Motan Luxor 50 Dryer With Twin Desiccant Beds dehumidifing dryer.

Hopper loader and material blower.

100mm Union single screw extruder. 35D vented with fan cooled barrel. Vacuum vent.

110kw dc motor and drive. Temperature panel. 1987.

250mm Speedex vacuum unit 125mm Speedex vacuum unit 125mm Speedex Saw unit

1000mm wide Bulldog model F-40HB skeletal waste granulator with dancer arm, sound proofing, blower and cyclone. 2006.

125mm diameter Speedex pipe downstream comprising 1 x 6m vacuum tank and 2 x 6m spray tank with 3 belt haul off and upstroking travelling saw. 1995.

1100mm wide SML coextrusion sheet line for 150micron to 800micron PP. model SMLSC90,45/1100/. 90mm extruder 45mm coex, calender, haul off winder.

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EUREKA SERIES

Future proofing soldiers Future-proofi with super polymers How do you develop materials for soldiers to help protect them against deadly weapons that might not even have been developed yet? The scientists at the US Army Research Laboratory believe they can future-proof the infantry with sophisticated polymers.

Words | Rose Brooke

P

olymer fibres such as Kevlar and Nomex are well known for their use in defence applications, namely in the production of protective clothing for soldiers in conflict zones, but scientists have to continue developing polymer fibres to ensure they can protect the infantry from the weaponry of the future, which are certain to be much more sophisticated and deadly.

The Army Research Laboratory (ARL) in the US has been tasked with designing new polymers for superior protection capabilities and it is starting by unravelling the complex relationship between polymer chemistry, microstructure and energy absorption.

ARL is currently working on polymer fibres - the next-generation of polyamides such as Kevlar or polyethylenes like Spectra - that can withstand extremely ballistic environments. The research team is investigating polymers at a molecular level under high rate loading conditions at the ARL-established Enterprise for Multiscale Research of Materials, which is currently making breakthroughs that are allowing the team to model polymers at high strain rates, pressures and temperatures. This work will ultimately allow the team to design ultra high molecular weight polyethylene - the core constituent for Dyneema and Spectra.

ARL researchers Dr Jan Andzelm and Dr Tanya Chantawansri together with Professor Mark Robbins of Johns Hopkins University are leading the research to clarify mechanisms associated with polyethylene using atomistic simulations and coarse-graining methods. The key to modelling this system is the development of reactive potentials to be used in the atomistic modelling of Ultra-High Molecular Weight Polyethylene.

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The team has successfully achieved this by using accurate quantum mechanical data to find atomistic potential.

Prof Robbins explained: “This potential is unique and its development was made possible by combining the expertise in state of the art electronic calculations at ARL with the complementary experience at JHU on classical models of polymers.“ Dr Andzelm added: “These potentials are general enough to be applied to many materials and will help in the advancement of other materials too, such as graphene and other novel 2D polymers.“ Valid computational models are pivotal to the team’s work. The data the researchers generate provides valuable input to the computational models, but when it comes to complex systems such as ballistic fibres, the production of appropriate model systems can prove a challenge. ARL’s new in-house Center for Advanced Polymer Processing is a state-of-the-art facility with extremely controlled processing conditions that can provide these model systems as well as complex fibres with advanced performance based on computationally predicted relationships between chemistry, microstructure and performance.

Once researchers understand the processes of how these materials respond to ballistic simulations, ARL believes “the parents of soldiers in 30 years’ time can be rest assured that ARL has provided the scientific foundation to protect them to the fullest extent“.

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Blown Film Technology: It’s Time to Share!

The most innovative European Extrusion Centre is at the forefront of BLOWN FILM TECHNOLOGY, always looking to the future, and BANDERA now wants to share it

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