EPPM 14.9

December 2012

Volume 14 | Issue 09

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Summit Systems: Materials and Parts Handling for World Beating Manufacturing – see page 16 to find out how we assisted the Stewart Group in the move to their new premises.

PLASTICS AUTOMATION

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editorial

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editor david gray david.g@rapidnews.com

in this issue

publisher mark blezard

production art samantha hamlyn production peter bartley production adrian price

advertising european sales manager tim guest

MACHINERY

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REGULARS: Latest news roundup

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SHOWCASE: FILM & SHEET EXTRUSION

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SPOTLIGHT: MATERIALS HANDLING

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IN FOCUS: Central & Eastern Europe

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THE GREEN ROOM

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CLASSIFIEDS

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Alex Collins, Director, Vannplastics Ltd.

John Ellis, Segment Manager Polycarbonate, Bayer MaterialScience

Clive Maier, Owner and Director, Econology Ltd.

Nigel Brown, Founding MD, Frontier Aerospace

Dr Martin Kay, Chief Consultant, Pira International

Jan Herring, Strategic Sourcing Leader, Nokia

Charmaine Bowers, Operations Manager, Polymer Training & Innovation Centre

Pipe Extrusion Recycling Micro Manufacturing Home Appliances

Automotives & Compounds

Mark Bonifacio, President, Bonifacio Consulting Services

Andy Bone, Sales Director, Formaplex

Andrew Smith, Head of Manufacturing, Numatic International

Wire & Cable

Aerospace Biopolymers

Andrew McArthur, Engineering Manager, IKO

Jonathon Short, MD, ECO Plastics Ltd.

Jon Herbert, Director, FS Cables

Biopolymers/Materials Science

Simon Chidgey, Director, M&H Plastics

General Industry Insight

Paul Maley, Senior Mechanical Engineer, Selex Elsag

James Goddard, Honorary Lifetime Member, Plastics Pipe Institute

Dr Terence A. Cooper, CEO, ARGO Group International

Ken Braney, 2010-2011 President, Society of Plastics Engineers

Advisor for the German & Scandinavian Speaking Countries

Film & Sheet Extrusion Recycling Mould Making

Martin Marron, MD, Biffa Polymers

Graeme Diston, Senior Injection Moulding Engineer, Bausch + Lomb

Sourcing & Manufacturing

Construction

Graham Pickwell, Technical Adviser, Polymer Training & Innovation Centre

Medical

Barry Assheton, Sales Director, CRDM

Packaging

John Bunker, Member, Worshipful Company of Horners

Medical

Rapid Prototyping

Omer Kutluoglu, CEO, 2K Manufacturing

Education in the UK & Ireland

David Gray, Editor

John Sturgess, Director, MG Stuma

Andrew Feilden, Principle Consultant, Smithers Rapra

Wood Plastic Composites

Welcome to the final issue of EPPM for 2012. As Christmas draws near, online bloggers and content managers are busy compiling lists of all things festive. Amongst the lists I’ve seen are top 10/50/100 Christmas songs, movies, top 10 moments (whatever that means), top 10 turkey recipes and, of course, top 10 toys.

Readers involved in the toy sector may well have felt a muchreported slump this festive period. Most speculators agree that this has likely been caused by A) the economy (no surprises there) and B) the marketing of ‘teenage’ or ‘adult’ goods such as laptops, phones, tablets etc into younger demographics.

So it’s no surprise that when eBay released one of these ‘festive lists’ recently, the iPad took prime position as the most searched-for item at 1.7 million searches. The second item on the list, however, was a little more traditional, and good news for the plastics sector: Lego. I loved Lego - if I had any, I’d love it still. And at 1.5 million searches, I’m clearly not alone. Earlier this year we reported that Lego had ordered no less than 1000 dosing systems from motan-colortronic for its new plant which operates 700 IMMs. It’s great to see that demand for one of the classic toys of the 20th Century is as Lego still holds up well against more strong as ever. contemporary ‘Christmas stocking And it doesn’t stop there. In third fillers’ like iPods and laptops. place, with 300,000 searches is the (not-so) humble Barbie Doll another classic, though I personally don’t have much of an affinity with this one.

Nevertheless, it’s great news for the industry.

The problem with all of this, of course, is that for one Barbie: still brilliant. reason or another, people are searching for these products on eBay, and not in shops. The demand for great plastic toys is definitely still there - but in the current climate, the price has got to be right!

The plastics industry is still fareing well globally, and next year of course we all meet in Düsseldorf for K 2013, so now is the time to start thinking about the next stages for your processes. I look forward to meeting old friends and new at K, and in the meantime, the EPPM team wishes you a merry Christmas and a prosperous new year. Thank you for your support!

Plastics for the Environment

What’s in your stockings?

Blow Moulding

Recycling

Injection Moulding

from the editor

General Industry Insight

“

Our Editorial Advisory Board is compiled of a cross-section of the plastics industry, including processors, consultants, technicians and key industry figures.

Dr Gerd Schmaucks, Independent Consultant

MACHINERY

Engel Expands Viper Robot Range Engel has expanded its viper linear robot series, with new arrivals making an appearance at Fakuma earlier this year.

The viper 120 with a nominal loadbearing capacity of 120 kg is claimed by Engel to be the largest linear robot in its competitive field.

Now available in seven sizes (from a nominal load-bearing capacity of 6 kg upwards), the linear robots in the group’s current viper generation is suitable for injection moulding processes with high clamping forces, with a mould take-off stroke of 3000 mm and a reach of 3550 mm.

Maximum stability, dynamism and ease of use combined with lightness are the characteristics shared by viper robots in all size groups. An innovative design that utilises laser-welded steel sections has kept the dead weight of the robots low, enabling the load-bearing capacity to be raised.

Smart software packages reduce the structure-borne vibration of the robots – even with longer axis dimensions – and

optimise their movement and dynamic values resulting in enhanced efficiency.

The viper robots therefore make a crucial contribution towards the reduction of cycle times and the increase of productivity for a range of applications, whilst also demonstrating their high level of energy efficiency.

Since Engel supplies both injection moulding machines and robots from a single source, full integration of the two control environments is guaranteed.

This ensures that the robots remain easy to use, even for complex applications, and also increases the availability of the manufacturing cell as the operators can independently perform many tasks for which a programmer would previously have been required.

The robots can optionally be supplied with an independent control unit and can then cooperate with injection moulding machines by any vendor via a Euromap 67 interface.

Engel viper robots can be ordered in

conjunction with Engel injection moulding machines – yet their high performance and efficiency also make them ideal for replacing old equipment and operating injection moulding machines of other brands.

Engel has significantly increased its sales and market shares in the linear robotics range since introducing the Engel viper series at Fakuma 2009. In order to continue to meet this growing demand in future, Engel introduced synchronised line assembly in its robotics factory in Dietach, Austria earlier this year.

The group says it is therefore in a position to achieve short delivery times for the viper linear robot and integrated system solutions.

Engel Tel: +43 50 620 0 Email: sales@engel.at Web: www.engel.at

INDUSTRY NEWS WEMO Celebrates 25 Years of Plastics Automation Supply WEMO Automation AB located in Värnamo, Sweden, celebrated the inauguration of its new production building and the company's 25th corporate anniversary with an open day in mid-September. During this quarter century, WEMO has supplied over 3,000 handling units. In addition to solutions for standard applications, some highly

complex and bespoke automation solutions have also been realised.

WEMO's extensive range of products includes three different construction series. At the core is the Basic 2 Series, offered in eight sizes for injection moulding machines with clamping forces ranging from 250 to 40,000 kN and with supporting force ranging from 5 to 75 kg. Depending on model, the maximum length of the X-axis is 420 to 2,000 mm, the maximum length of the Y-axis is between 1,200 and 3,000 mm, and the maximum length of the Z-axis is between 2,200 and 8,000 mm.

The product range is enhanced with the High Speed Series for packaging and thin-wall technology.

These extremely fast robots guarantee a cycle time of below 3.5 seconds.

The linear robots work in all three axes

with servo motor drives which are more accurate and faster.

Owing to the higher speed and acceleration compared with conventional systems, the parts removal times and therefore the cycle times are shorter.

The smallest class

of units are the sprue removal units, offered as pick-and-place units with servo motor drive.

At Fakuma, the company also presented its new handling control WIPS (WEMO Intuitive Programming System). This software enables the self-programming of extremely complex program steps. The actual handling programming is broken down into function blocks, shown on the monitor with icons. The intuitive operator

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interface with touch screen buttons is easy and quick to learn, according to WEMO. The new WIPS allows the simple realisation of process sequences through predefined functions via pictograms, taking the operator step by step through the robot programming.

In addition to the serial interlinking of function blocks, linking functions in parallel is also possible. Older handling programs can be updated to ensure that the same user interface is used for all handling units.

As well as the handling

units, WEMO also features a broad range of automation equipment for the plastics industry. They include a variety of different gripper systems, safety systems and standardised downstream units such as conveyor belts.

WEMO Tel: +46.370.65 85 00 Email: info@wemo.se Web: www.wemo.se

MACHINERY ROUNDUP Industry Veterans Team Up to Serve European Roto Market Four long-established companies, each led by roto industry veterans, have combined forces in order to supply innovative specialist equipment to the European rotomoulding industry.

The four companies are: Reduction Engineering Inc., based in Kent, Ohio, USA, which manufactures pulverizing equipment; Rotoline Equipment Industriais Ltda, based in Chapecó, Brazil, which manufactures rotomoulding machines; Reduction International LLC, based in Weston, Florida, USA, which currently distributes Reduction Engineering and Rotoline equipment throughout Latin America; and Rotomotive Limited, based in Northampton, UK, a research and consultancy company.

Under the new deal, Reduction International will extend its distribution arrangements with Rotoline and Reduction Engineering to cover countries in the European Community and European Free Trade Area.

Local commercial and technical support will be provided by Rotomotive, who will set up a demonstration and trial facility at its UK Technical Centre, featuring a Rotoline two-arm shuttle machine and a Reduction Engineering pulveriser. This will enable European customers to experience the features and benefits of the equipment, hands-on, before they purchase and will provide an on-going service and development capability to support existing clients.

Bob Sly, President of Reduction Engineering and Rotoline, explained the background to the new arrangements: “We have been working with our good friend and colleague Carlos Garcia of Reduction International for a number of years and his company has done a great job in promoting our equipment throughout Latin America. Recently Carlos indicated a strong interest in

taking up distribution rights for our equipment in Europe and, with our full support, we know that he will be able to extend his successful operation into this area. When he told us that he had involved another old friend, Dr Nick Henwood of Rotomotive, in his European venture, we were even more certain of a successful outcome.”

Carlos Garcia, President of Reduction International, added: “The equipment provided by our two principals has found wide acceptance throughout the world, including in the European area.

Rotoline shuttle machines represent a really competitive combination of reliable operation, superior roto technology and high production output.

Reduction Engineering pulverisers are already responsible for grinding much of the polyethylene used by the European roto industry and our new Model 85 machine has been designed specifically with the medium-sized European rotomoulder in mind.”

Dr Nick Henwood, Managing Director of Rotomotive, commented: “In my time, I have been a customer of Reduction Engineering and have bought a number of their machines.

So I know that their products are excellent. Recently I have carried out extensive trials on a Rotoline shuttle machine and I can vouch for its excellent design and easy operation.

Like many sectors, the European roto industry has suffered from the recent downturn of manufacturing, but we aim to be ready as moulders reestablish their markets and look to future expansion. Most of the rotomoulders I know have a distinctly hands-on approach and I believe that the new trial and demo facilities we will be offering at Rotomotive will be extremely welcome.

The new arrangements were formally announced at the recent Pan-European conference of ARMO, the Affiliation of Rotational Moulding Organisations, in Lyon France.

Rotomotive Limited Tel: +44 1604 497589 Email: info@rotomotive.net Web: www.rotomotive.net

Pipex px Targets 50% Production Growth with IFS Applications IFS, the global enterprise applications company, has announced that specialist UK manufacturing, engineering and construction business Pipex px has chosen IFS Applications as its new enterprise resource planning (ERP) system. The project manufacturing company believes the move will support a 50% increase in production through better visibility, improved planning and increased efficiency. The contract has been signed and the project is now under way.

Pipex px manufactures high-quality

thermoplastic and advanced composite solutions for industries including transport, oil and gas, offshore, construction and renewable energy. The company has been growing rapidly, almost doubling in size in the past five years. The implementation of IFS Applications 8 will support continued growth.

IFS won the contract with Pipex px following a competitive pitch process involving Microsoft and other ERP vendors. The first step of the project has been the deployment of IFS’s CRM

module, with finance, manufacturing, procurement, inventory, project management and HR solutions to be implemented by early 2013.

Wynn Stait, Chief Operating Officer of Pipex px, said the Plymouth-based company was keen to find a solution that could help consolidate the company’s various IT systems, thereby improving data visibility and overall business efficiency.

“We had disparate legacy systems in place and were using a lot of spread sheets, which wasn’t helping our productivity at all,” Stait added.

“When we’re manufacturing bespoke goods for our customers, whether it’s composite piping for marine applications or fibre-reinforced polymer beams for a road bridge over a canal, it’s imperative that we have visibility across the whole project.”

Pipex px chose IFS Applications because it is an integrated solution that enables the company to consolidate its business systems and processes, improve project management and increase control of inventory and other data. The system will substantially improve efficiency and reduce wastage. “We are

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confident that this will enable us to grow the business cost effectively — and ultimately improve revenue and profit,” Stait said.

Paul Massey, MD of IFS Europe West, said: “We’re delighted Pipex px has chosen IFS Applications, and look forward to helping them increase production and profit over the coming years. Their bespoke solutions mean keeping a close eye on their inventory is key, so IFS Applications is a great fit.

Good project management is also vital, and we know we can deliver what they’re looking for.

The Pipex px IFS project is part financed by the South West Competitiveness Programme, European Regional Development Fund Programme 20072013. The Department for Communities and Local Government is the managing authority for the European Regional Development Fund Programme, which is one of the funds established by the European Commission to help local areas stimulate their economic development by investing in projects which will support local businesses and create jobs.

Pipex px Tel: +44 1752 581 200 Email: sales@pipexpx.com Web: www.pipexpx.com

MACHINERY ROUNDUP “World’s Smallest” Extrusion Blow Moulding Machine Made in India Indian group Smart Machinery & Moulds Pvt. Ltd. has announced the launch of what it claims is the smallest extrusion blow moulding machine in the world. Maximum utilization of floor Space was the key force driving the need to develop compact extrusion blow moulding machines.

Smart extrusion blow moulding machines are said to have the smallest footprint in the industry and are custom built to be suitable for various applications. Applications include cosmetic packaging, pharmaceuticals, medical products, pesticides, lubricants, automotive applications among others.

The machine has capacity from 5ml to 2l – even the largest capacities can run in a very small area. The fully automatic machine also helps to reduce manpower. Smart machines are compact, fast and energy efficient when compared to more complex large size machines.

The main features of the machines are: • Single or double station • Microprocessor controls • Helical gear box • Larger mould area • Superior mixing screws • a.c. drive • Fast dry cycle

• Energy efficient • User friendly If customers have concepts/drawings or samples, Smart says it can help users reduce tooling costs without compromising quality. The group’s engineers have expertise in 2D/3D modeling, mould and tool design, moulding experience, all fully supported by CAD/CAM technology, Smart Machineries and Moulds Pvt. Ltd. Tel: +91 22 28081280 Email: smartmachines1@gmail.com Web: www.smartmmpl.com

Twin-Screw Compounder Drives Innovation in Automotive Market Luxus, a recycler of innovative technical polymers, has just taken delivery of a twin screw compounding line from Coperion. The company states this latest investment will enable it to move into the next stage of the construction of its new £600k state-of-the-art Technical Centre, opening in February 2013 at its Lincolnshire-based manufacturing site.

The new research and development line comprises of a twin screw extruder from the Coperion STS Series, a Brabender loss-in-weight feeding system, a Reiter Strand Pelletiser and specific Luxus engineering designs to bring together the technologies for its needs.

Terry Burton, Technical Manager at Luxus, explained: “In our new Technical Centre the twin screw compounder will create polymer formulations for the test development stages of various materials such as PC, PC/ABS, ABS, PA in addition to standard PP and PE. The line will also be used to achieve process and product optimisation when compounding our existing products too.

“Luxus’ specialist interior automotive business in particular will benefit from the new line. Client samples will be processed on the machine and then increased to full-scale production in just a single rapid step. We’ll also formulate for higher performance polymers too. So in 2013 we fully expect our share of the global automotive market to markedly increase.

“We see the Technical Centre as an extension of our clients’ materials testing capabilities and as a service for those that simply don’t have an in-house laboratory, offering both bespoke and niche highly specified solutions on request.

“We’re also working with compounds from increasingly complex waste streams to make them into useable materials to help the UK plastics sector to meet its goal of zero landfill. The extruder system we are convinced therefore will help us satisfy demands in the processing of new materials to the highest possible extent, creating highly innovative sustainable polymers.”

Luxus claims to be the first and only UK based independent recycling company to create interior trims for the automotive market.

Luxus Ltd Tel: +44 1507 604941 Email: info@luxus.co.uk Web: www.luxus.co.uk EPPM 7

MACHINERY ROUNDUP How to Achieve Quicker Mould Changes: a Stäubli Report Minimising unproductive mould changing time is a key task for all operators of injection moulding machines. The total time taken to change moulds is determined by the sequence of the specific steps involved.

Each changeover will require the disconnection and reconnection of the mould’s cooling water and other services such as hydraulics and electrics, the mechanical handling of the moulds onto and off the injection moulding machine and the heating of the mould to operating temperature. A detailed review of each of these stages is required to ensure that mould changeover times are reduced to a minimum. The connectors division of Stäubli UK offered the following report on the process.

Quick release connectors One of the first improvements to be considered should be the method used to make connections to the mould for cooling water, hydraulics, nitrogen, electronics etc. From simple and cost effective, full flow quick disconnect couplings for water cooling applications to completely valved quick connection solutions for oil heating or temperature control circuits, the appropriate quick release coupling can be selected for any application.

Identification of sockets and plugs by coloured rings also helps, as on Stäubli’s RPL range for water and temperature control circuits; this makes circuit identification quicker and easier.

The rings can also serve to number the circuits (on the socket side) and a

strengthened locking system ensures the security of the circuits. The locked position is instantly visible by the coloured ring on the socket. The nonspill design of the Stäubli CBI range typically used on temperature control circuits, guarantees perfect sealing during connection and disconnection of circuits; no air is introduced into the circuits and there is no pollution to the work environment through leakage.

The use of quick release connectors in place of fixed connections for these applications often brings the single most significant reduction in mould change times.

Multi-couplings Further reduction in changeover times can be achieved by a move to a multiple connection plate system. Placing all the quick release couplings together on a pair of plates enables all connections to be made safely and securely in one swift, lever controlled, robust locking operation, with the additional bonus that the chance of any wrong connection is eliminated. Connection of the plate is only possible in the correct position and a foolproof keying system prevents any cross connection where several plates are being used on the same mould.

Multi-coupling plates can be designed to match the specific requirements of each application, taking into account the type of fluids used in each circuit as well as the pressure, temperature and flow rate required; couplings can be either single or double shut-off or unvalved. Electrical connections can also be included on the plates to correspond to the voltage and amperage required.

A fully automatic multi coupling system should also be considered at this stage.

This can bring additional savings in downtime and reduces the operators’ machine servicing requirements, frequently allowing a larger batch of moulding machines to be monitored, reducing manning levels.

An example of the benefits to be achieved through the use of mutlicoupling plates is at Triumph Motorcycles in Hinckley where mould change times in the injection moulding shop were reduced by 30%.

A target time of 20 minutes for the tool change was set, which with tools

weighing up to 8 tonnes, a rapid automatic multi-coupling system was needed. Stäubli RMI 212 couplings were selected for the water system, which was operating at high pressure (6 bar) and RMP 48 couplings for the hydraulics.

Both connectors were placed on a multicoupling plate and connection to the mould made via special brackets located on the tool side.

Tool change times at Triumph reduced to 22 minutes on the 420 tonne IMM and 26 minutes on the 1300 tonne machine.

The multi-coupling removed any danger of wrong connection and shaved at least 10 minutes off the tool change time.

Transfer tables The mechanical handling of moulds onto and away from the injection moulding machine can be a slow process. Datum lines on the tool holders and crane positions can save time in positioning the mould. Balance weights on the lifting straps, to avoid tilting, is also a useful idea that can save time manoeuvring the mould into place on the machine. With side loaded moulds a dedicated loading and/or insertion table may be required to ease handling of the mould. This may be a simple scissor lift roller table or a tailor made handling system fully integrated in to the control systems of the moulding machine.

Moulds need to be heated to operating temperature before moulding can take place. The installation of a specially designed pre-heat station can ensure that the next mould is brought up to temperature and ready for production just when required. This improvement alone has frequently reduced changeover times for moulds dramatically.

Finally, after each of the above improvements has been implemented, investment in a quick mould clamping system should be evaluated. There are three different technologies available – mechanical, hydraulic and magnetic, each one with their own benefits and several different design approaches in each technology. Selecting the most appropriate for each application requires detailed analysis.

Through this rigorous, step by step, evaluation process, mould changeover times can be reduced significantly. As a rule of thumb, if your mould changeover time is reduced to below 10 minutes then it is at this stage that the additional benefits of installing a quick mould clamping system should be evaluated.

Stäubli (UK) Ltd. Tel: +44 1952 671918 Email: connectors.uk@staubli.com Web: www.staubli.com

INDUSTRY NEWS Dr. Werner Wittmann Honoured with Presitigious Plastics Sector Award On Thursday, 8 November 2012, Dr. Werner Wittmann, Managing Director and Co-owner of the Wittmann group was presented with the H.F. Mark medal of the OFI Institute in the main auditorium of the Austrian National Library to honour his achievements in the Austrian plastics industry.

The H.F. Mark medal is awarded annually to distinguished personalities from scientific research into polymers and from the plastics industry for outstanding achievements. This year’s medals were granted to Dr. Werner Wittmann, and Professor Otto Glatter, Karl Franzens University, Graz.

Dr. Werner Wittmann started his career in the plastics industry following a degree course in economics and

business administration at the Viennese University of Economics and Business, gathering practical experience as a Product Designer at Krause & Co. and as Sales Manager at Mabeg/Hörbiger, before becoming Director of Sales at Engel in Schwertberg. In 1976, Dr. Werner Wittmann established his own company to produce a flow controller he had developed himself. This was followed by the production of temperature controllers a year later. In 1985, robots were added to the manufacturing program. By opening Wittmann Germany in 1983 and Wittmann USA in 1986, Dr. Wittmann laid the foundation for today’s global Wittmann group.

In his laudatory speech, Harald Bleier,

Cluster Manager of the KunststoffCluster in Lower Austria and former Battenfeld associate, honoured the achievements of Dr. Werner Wittmann and commended his commitment to his company.

Dr. Werner Wittmann took over Battenfeld Kunststoffmaschinen GmbH, which was then in insolvency, in 2008 and developed it into a successful player in the international plastics industry. The Wittmann group currently employs a total of 1,800 associates and has a leading position in the international plastics industry with 7 production plants, more than 30 sales subsidiaries and almost as many agencies worldwide.

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Wittmann Battenfeld GmbH Tel: +43 2252 4040 Email: info@wittmann-group.com Web: www.wittmann-group.com

MACHINERY ROUNDUP Multi-Million Pound Investment for Roberts Mart Roberts Mart & Co Ltd, the UK’s leading independent manufacturer of flexible packaging, has just invested a further £2.5m in new plant machinery to boost production capacity at its two facilities in Leeds.

With the company’s order books growing, this significant investment is expected to have a substantial spin off in jobs with the creation of a potential 25 new posts planned for 2013 to cope with increased production requirements, following the purchase of a state-of-theart printing press and laminator for its Aire Valley factory, as well as an extruder for its sister business, Romar Packaging, based at Newmarket Lane on the outskirts of the city.

Central to the family-run business’s investment is the new F&K 20SIX Central Impression Flexo Printing Press. Chosen

by Roberts Mart for its print quality, ease of use and versatility, the Press is the latest in printing technology for the flexible packaging industry and can be used to accommodate a wide variety of print jobs.

It already supplies specialised, high performance films to a variety of industry sectors, including food, beverages, pet food, supermarket own brand, bottled waters and textiles.

Capable of delivering the highest quality printing on any flexible packaging substrate, this addition to Roberts Mart’s equipment portfolio enables it to break into new market areas, with the company set to boost production by 30 million linear meters a year, providing a significant return on its original investment.

Meanwhile, an increase in capacity will also follow at Romar following the installation of the new three-layer coextrusion line, which will boost the subsidiary’s production of coextruded low density blown polythene film by 1600 tonnes per year.

The latest increase in capital expenditure takes Roberts Mart’s overall investment to just over £15.5m over the last eight years, bucking the general economic difficulties affecting other UK manufacturing sectors by expanding into new markets, whilst remaining at the forefront of the flexible packaging industry.

Not only is Roberts Mart family-owned, but it has attracted several generations of employees’ family members creating a resolute and loyal workforce over the years that has helped the company prosper through thick and thin times.

During the last year Roberts Mart has taken on 16 new staff and currently has a total workforce of 147 at its two Leeds sites, however, operating the new equipment will require more workers and the company will be looking to recruit again in 2013, including press and lamination operators and warehouse personnel.

Sales Director, Ben Roberts, said: “This significant new outlay we are making on capital equipment underlines our confidence in developing our existing and new markets. To meet the challenges ahead we are committed to building a team with a diverse range of skill sets. Although Roberts Mart is extremely family oriented, we always welcome new recruits selected by merit to join the company and become a part of our extended family.”

Roberts Mart was founded by William

Roberts in 1852 and from producing paper bags it now develops the latest range of specialised, high performance films to meet the growing demand from a variety of industry sectors, including food, bottled waters and textiles.

There has always been a Roberts at the helm since it was established 160 years ago, and the present joint managing directors are father and son duo, John and William Roberts.

Roberts Mart Tel: +44 113 202 6500 Email: info@roberts-mart.co.uk Web: www.roberts-mart.co.uk

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MACHINERY ROUNDUP INDUSTRY NEWS Cautious Recovery for the Rotational Moulding Industry in Europe In a new report, plastics industry consultant Applied Market Information Ltd. has documented the state of the rotational moulding industry in Europe.

The report highlights the versatility of the rotational moulding process and its ability to be a cost-effective alternative to blow moulding.

A 3% drop in the number of rotational moulders listing in AMI’s guide to the rotational moulding industry in Europe, 7th Edition highlights the effects of the global economic crisis on the European plastics industry. The remaining 336 listed production sites across Europe are estimated to have been responsible for the consumption of 211 thousand tonnes of polymer in 2011, down from the pre-recession highs of 250 thousand tonnes in 2006. Although the industry has a long way to go to regain those lost volumes, the market is expected to show some growth for 2012 after three years of declining volumes.

The weakness in the rotomoulding sector was largely a consequence of the continued economic uncertainty in Europe which resulted in the reduction of infrastructure projects and impacted on the demand for rotationally moulded

water and fuel tanks, which make up the largest end use application for this process. Other sectors however performed better and the economic downturn resulted in some applications which may have traditionally used blow moulding switching to rotational moulding because of the smaller volumes of articles required and the economic advantages of using rotational moulding for small runs. The materials handling market has been relatively unaffected by the recession and the market for IBC is still growing. This market is maintained by the requirement for most containers to be replaced a minimum of every three years. The offshore industry and fishing remains a solid and growing market especially in the Nordic Countries where over 50% of rotational moulders supply the marine and fishing markets.

The aim of AMI’s guide to the rotational moulding industry in Europe, 7th Edition is to provide accurate and up-to-date information on rotational moulding plants in Western and Central Europe.

This information has been compiled using AMI’s extensive knowledge of the industry and not only provides a

directory and listing of 336 rotational moulders within the region, but also an overview and summary of the current status of the industry.

AMI Tel: +44 117 924 9442 Email: info@amiplastics.com Web: www.amiplastics.com

the first cut. In sequence, each part is detached and deposited in to a collection chute and waste material is placed onto a mini conveyor for recycling.

“Teaching the robot is child’s play, both Julian and I taught ourselves within a day,” Steve Blease continued. “The teach mode is ideal for establishing the basic approach and then it’s just a question of fine-tuning for final positioning.” Process simulation can be run in a choice of orientation and also at variable speed.

Although the positioning accuracy of the Universal Robot is ±0.1mm, the accuracy of cut is dictated by the efficiency of the fixture. Work is still continuing to make the fixture more robust to prevent the part twisting as weight and balance change. “This element of project is largely trial and error but as far as the robot is concerned, it has proved faultless,” Steve added.

Even at this early stage – and prior to dedicated training from R. A. Rodriguez – Clamcleats Ltd is deriving productivity benefits. These are mainly from the operator’s ability to multitask. Whereas the clipping process used to be a

separate activity, it can now be accomplished automatically alongside quality checking and packing.

Having reduced RSI risks by automated cutting, the company will soon turn its attention to the high volume products that are generally run in batch sizes of 10,000. Typically these are small cleats that are injection moulded in sets of 10 and ordered in huge volume by relief agencies attending the scene of a major disaster. Indeed Clamcleats Ltd is confident its Universal Robot investment will boost its ability to reduce lead times in this regard.

The robot is also mounted on a trolley in anticipation of it being moved next to the injection moulding machine, allowing Clamcleats Ltd to consider lights out production.

Julian Emery concluded: “Ultimately we plan to use the Universal Robot wherever we can in the factory. It is so easy to integrate and has potential not just in our rope cleat production but also for our trade moulding work too.”

CASE STUDY Multi-Application Robot Arm is ‘Child’s Play’ to Programme Traditional robots can substantially boost productivity but generally they are large devices that are application-specific and complex to programme. They need high production volumes to justify both capital cost and integration time. For a manufacturer new to robotics this can be off-putting and also uneconomical if products and batch sizes are many and various.

The answer for Hertfordshire-based Clamcleats Ltd was a Universal Robot – supplied, and supported by R. A. Rodriguez. This is used to automate the de-gating of injection moulded components for plastics rope cleats. It is a small, light weight industrial robot arm that has six axes of movement and above all is exceptionally quick and easy to install. A specially developed graphical user interface means no expert programming is needed. Within a couple of hours it can be ready to run. It is the ideal entry level automation device that can be set up by anyone.

The problem that drove MD, Julian Emery, to consider automating the degating process was initially focussed on the large cleats attached to comparatively thick runners. He explained: “There is an RSI risk with manually clipping these products when cold. To avoid this, our preference was to clip the runners when still warm and therefore relatively soft. But of course that put limitations on when we could run our injection moulding machines.

Automation gives us much greater production flexibility.”

Whilst a dedicated press was an option, the cost of the tooling involved for each type and size of cleat made it unviable.

So Julian Emery went in search of an alternative to do the job. “The Universal Robot stood out for me. As it didn’t need

to be traditionally guarded we could apply it to a variety of applications. That flexibility made it a safe purchase,” he continued. “For example, it could equally be used to load or unload our CNC machines automatically without the need for over-the-top guarding.”

Initially however Clamcleats Ltd is focussing its attention on developing fixtures that enable the robot to grip product variations effectively. The company manufactures a wide variety of rope cleats for camping, leisure marine and sports application with 80% of its output produced for export. It also regularly adapts its designs to suit new applications.

As RSI risk was the main reason for the robot’s purchase, it is the larger cleats in production runs of around 2,000 that are taking priority. This is the task assigned to Process Engineer, Steve Blease who has worked closely with the robot’s supplier R.A. Rodriguez to optimise production. One of their first tasks was to install a light guard, not to protect the workforce from the robot but pneumatic, fixed mounted clippers that automatically close on the gate of the runner to detach the part.

Clamcleats Ltd required any interruption of the safety light curtain to result in an operational pause rather than an emergency stop, requiring re-set. A pause function is a standard option on the Universal Robot but nonetheless R. A. Rodriguez liaised with the curtain’s manufacturer, Keyence, to ensure efficient integration.

Currently the uncut parts are manually loaded onto the fixture and located on the sprue. The Universal Robot then transfers the tree-of-parts to the clippers.

Having located on the runner, the robot sends a signal to the clippers to make

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R. A. Rodriguez Tel: +44 1462 670044 Email: info@raruk.com Web: www.rarodriguez.co.uk

MACHINERY ROUNDUP Detector Removes Metallic Contamination as Small as a Fraction of a Millimetre Designed for sensitivity and a robust construction, the new Protector Professional from the S+S Group is said to bring “new levels of protection and ease of integration” to the plastics moulding and extrusion industry. Able to detect and remove metals down to a fraction of a millimetre, a height of only 305 mm and availability of adapter plates for most machines, the new detector can be integrated with existing equipment. The detector unit is protected by a reinforced frame able to support a vertical load of up to 500 kg, allowing heavy conveyor, mixing and dosing equipment to be mounted directly onto the detector unit with complete security.

S+S exclusive “Quick Valve” selfcleaning system rejects detected contaminants with the minimum loss of good material, even with difficult to handle feedstock. The rejected material is ejected horizontally by a Venturi system, another S+S exclusive, to a container that can be located some distance away. The system is designed to process dry and wet, virgin and recycled feedstock with a grain size of less than 6 mm at up to 800˚C. The very low minimum product conveying speed of 0.005 m/sec allows even the smallest shot weights to be processed dependably.

INDUSTRY NEWS Swiss Mould Maker Turns 60

The well proven Primus digital control unit, which may be located up to 15 metres from the detector, has an autolearn function for product compensation but may also be set manually allowing the system to be fine-tuned to material currently being processed. The control unit is setup using push buttons with LED display and up to eight product settings can be stored on the built-in, non-volatile memory to simplify product resetting at product change-over.

The new Protector Professional provides the highest possible level of protection from metallic contamination damage for all types of moulding and extrusion equipment.

S+S Inspection Limited Tel: +44 1489 553740 Email: info@sesotec.co.uk Web: www.sesotec.co.uk

Schöttli AG of Switzerland is looking back on 60 successful corporate years.

At the beginning of November, the international specialist for the development and production of highperformance injection moulds for medical parts, caps, closures and thinwall packaging celebrated its anniversary with a ceremony for the company’s 160 staff members.

In 1950, the company’s founder Theodor Schöttli (90) established a small mould making facility in the village of Paradies in the Swiss canton of Thurgau and in 1952, he founded Schöttli AG. Schöttli’s first customers quickly spread the word of the precision engineer’s special skills.

It did not take long before he supplied plastics processors all over Germany and Europe. In 1973, Schöttli AG relocated to Diessenhofen and in 1986, the founder’s son Martin Schöttli (59) became Managing Director and consolidated the company’s position as a specialist supplier to the global market.

In October 2012, Thomas Anderegg took over as CEO from Martin Schöttli. In the spirit of Theodor Schöttli’s corporate philosophy and Martin Schöttli’s visionary thinking, he will continue to advance the corporate success and lead it into its seventh decade. Martin Schöttli will continue serving the company as a board member and for special tasks.

Schöttli AG aims at boosting its customers’ output rates. At present,

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Company founder Theo Schöttli (right) and his son, former CEO Martin Schöttli.

Schöttli develops high-performance moulds for medical parts, caps, closures and thin-wall packaging. Since the company’s establishment, Schöttli moulds have been renowned for their high quality and precision, reliability, compact design and short cycle times.

The international company’s core competence is engineering moulds that meet exacting requirements and offer a high number of cavities, such as stack moulds with 192+192 cavities. Schöttli uses its own hot runner systems. More than 90% of Schöttli’s products are exported. Thanks to an international network of subsidiaries and representations in all important markets, the mould specialist maintains a strong global presence.

Schöttli AG Tel: +41 52 646 2117 Email: danderegg@schoettli.com Web: www.schoettli.com

SHOW FILM & SHEET EXTRUSION Brett Martin Running battenfeld-cincinnati’s Largest Counter-rotating Extruder Since the beginning of 2012, Brett Martin Ltd., based in Newtownabbey, Northern Ireland, has been operating the largest and most powerful counterrotating twin screw extruder ever built by battenfeld-cincinnati. With this highperformance extruder for PVC sheet production with an output of up to 2,000 kg/hr, Brett Martin Ltd says it has significantly expanded its production capacity.

Brett Martin makes high-quality specialty plastic products for the building construction, manufacturing, printing, roofing and display industries.

In terms of PVC, PMMA and PC, the group offers a variety of customised products, ranging from light domes for London’s Wembley Stadium to protective shields for typhoon-resistant McDonald’s signs.

In its production plant, Brett Martin already operates several extruders from battenfeld-cincinnati and claims to be very satisfied with their performance.

“We were particularly impressed by the outstan-ding flexibility of this extruder, which enables us to produce PVC sheet with a wide range of thicknesses from

3.0 to 25 mm”, said Technical Director at Brett Martin Ltd, David Robinson. In addition to its wide processing window, this counter-rotating extruder is said to offer high output,

robust design and easy operation. With its closed-loop, self-regulating Intracool screw tempering system and its efficient air power cooling barrel cooling system, the extruder has been designed to offer constant melt temperatures and high standards in product quality. battenfeld-cincinnati Email: welcome@battenfeldcincinnati.com Web: www.battenfeld-cincinnati.com

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WCASE New Pressure Transducers Aimed at General-Purpose Applications Offering accuracy and repeatability in a value-priced package, the new Echo Series melt-pressure transducers from Dynisco are said to be ideal for generalpurpose applications in plastics extruders. The Echo transducers are based on a proven sensor design and accurate to within ±0.5% over pressure ranges from 0 – 1,500 psi to 0 – 10,000 psi.

“This new transducer is part of a family of new products developed to provide users with more flexibility in balancing price and feature-richness,” explained Matthew Carrara, Vice President, Dynisco Plastics. “Every Dynisco transducer is made to the same high

quality standards. However, when a particular application does not require all the bells and whistles that can possibly be built into a transducer, users can opt for more economical alternatives. Manufactured in Malaysia

by Dynisco, the Echo Series was created to be rugged, reliable and accurate, with features that meet the needs of general-purpose applications globally.”

The quality of the Echo Series is backed by a new comprehensive two-year warranty – double the warranty usually available on this kind of transducer. All wetted parts are stainless steel for durability and corrosion resistance, and

the diaphragm is coated with titanium aluminum nitride, a superior alternative to titanium nitride. The ECHO transducers provide the industry standard 3.33 mV/V, 4-20 mA and voltage signals designed to work with most pressure indicators. Optional thermocouple or RTD configurations are available to provide melt temperature.

The ECHO sensors feature a 1/2-20 UNF thread for installation in standard transducer mounting holes.

Additional mounting configurations are available.

Dynisco Tel: +49 7131 2970 Email: dyniscoeurope@dynisco.com Web: www.dynisco.com

Measuring Thin Film Plastics with Infrared A common application that is well suited to FLIR infrared technology is the measurement of thin film plastics. Since the process of making thin plastic film itself is highly temperature critical, it is imperative to evaluate both the temperature and the uniformity of the plastic as it exits the extruder or web process. The product is typically moving at high speeds which precludes the use of contact temperature methods.

Most plastic films have spectral characteristics similar to polyethylene which is transmissive in both the short

wave and long wave infrared regions.

Measuring thin film plastics can be challenging since without using a filter, you see through the plastic and measure the objects behind the plastic, rather than the plastic itself.

Analysis of the infrared spectral characteristics of most plastics shows that a significant absorption band exists at 3.4µm. This absorption band is a region where the plastic will appear opaque to the thermal imaging camera, allowing the camera to measure the temperature of the plastic and not the

background. The width of this absorption band will vary with the thickness of the plastic being measured.

The thicker the plastic, the deeper the absorption band will be. Utilizing a filter which allows only the energy from a region around 3.4µm is ideal for this type of plastic film.

FLIR Systems Ltd. Tel: +44 1732 220011 Email: sales@flir.uk.com Web: www.flir.com

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The thicker the plastic, the deeper the absorption band will be.

SHOWCASE FILM & SHEET EXTRUSION Through the Doors at SML: Extrusion Technology for Global Markets Extrusion specialist SML’s recent “Innovation Days 2012” turned out to be a highly successful event attracting over 250 participants from around the world.

Visitors had access to a series of presentations given by expert speakers on a variety of technological and marketrelevant subjects, as well as the chance to view three extrusion lines in full operation.

SML used the event to focus on the technologies that it will be offering its clients in the coming years. On the first of the Innovation Days, the company presented an innovative rPET sheet line with a conical twin screw extruder for thermoformable sheet and a new drying and flake treatment system using infrared radiation inside a vacuum vessel, which apart from drying and crystallization, is also capable of rapidly increasing the intrinsic viscosity of lowquality post-consumer PET bottle flakes.

On the second day, the spotlight was on a multifunctional cast film line with an integrated MDO unit for a large range of different film products such as polyolefin and polyester films with or without barrier layers, either non-oriented or

mono-oriented. The line was shown running a 20 micron MOPET film with excellent properties.

The line not only incorporates a new generation of extruders for thermo sensitive polymers such as EVOH and resins for tie, peel and seal layers, but also a brand-new cast film winder with full inline slitting capabilities, designed for large roll diameters, scrap-free roll transfers and a capability to switch between clockwise and counter-clockwise winding directions.

The Innovation Days then concluded with the unveiling of the TOPsheet line, a special cast film extrusion line producing vacuum perforated aperture film which is used as the skin-contact inside layer in adult

diapers and feminine care products. Due to the fact that this new TOPsheet line allows efficient production of vacuum perforated films, additional applications outside the hygiene film market are quickly developing.

In view of the feedback from visitors, SML’s CEO Karl Stöger is optimistic about the future: “We see clear opportunities to enter new markets with

these technologies and we are confident that in the future we will be able to maintain our innovative approach, which to date has proved so successful.”

SML Tel: +43 7672 912 0 Email: sml@sml.at Web: www.sml.at

MuCell Brings 40% Weight Saving to Thin-Blown Foil Packaging MuCell Extrusion LLC has announced that its work with Nordenia Technologies GmbH (now part of the Mondi Group) to apply the MuCell process to Nordenia’s new Nor Cell thin-blown film packaging was recognised by Nordenia receiving an award from the German Packaging Institute, during a ceremony held on the eve of the FachPack Trade Fair in Nuremberg, Germany.

Mark Lindenfelzer, President of MuCell Extrusion LLC said: “Nordenia is the latest example of how we can deliver a full turnkey package of innovative technology, application expertise and complete intellectual property rights to packaging suppliers around the world to bring their newest and most inovative packaging designs to market.

“In this application, MuCell technology allowed the weight of NorCell flexible packaging to be significantly reduced without any change to the thickness and overall stiffness of the compound,” said Lindenfelzer. “NorCell 'lightweight foils'

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weigh up to 40% less than traditional foils, and that’s the kind of impact MuCell technology can bring to highly competitive and innovative markets like flexible packaging.”

According to Nordenia, the surfaces of the NorCell foils also enable unique foil haptics and can also be applicable over a wide range, from textile-like "soft touch" structures to high-quality, smooth, directly printable surfaces, NorCell foils are suitable for all areas in foodstuffs, pet foods and hygiene products.

MuCell Extrusion LLC Tel: +1 859 647 8861 Email: m.lindenfelzer@mucell.com Web: www.mucellextrusion.com

MACHINERY ROUNDUP Fast Cycling Machine Seriously Boosts Performance Sumitomo (SHI) Demag’s new El-Exis SP fast cycling injection moulding machine reportedly delivers marketleading performance benefits across the entire system. These include a 15% increase in mould movement speed, 20% improvement in injection speed and new enhanced NC5 plus control system which aids greater production reliability and a prolonged machine lifespan.

Based on proven El-Exis technology, Sumitomo (SHI) Demag made subtle design changes to create the SP model which helps high volume manufacturers of packaging products, caps and closures, and technical and medical products to achieve greater outputs with reduced cycle time and lower energy consumption. The El-Exis SP hybrid machine uses a carefully crafted blend of drive technologies including a servo driven hydraulic clamp unit to achieve precise movements, a hydraulic accumulator delivering high injection rates, and an electric screw drive for parallel plasticising, all of which shave tenths of a second off the cycle time enabling manufacturers to profit from increased margins.

areas to improve product quality, quantity and lower energy consumption. For high volume plastics manufacturers, these enhancements aid company profitability and give capacity flexibility to meet future growth demands.”

The El-Exis SP, with single or multicomponent capability, has a 150-750

tonnes clamp force range, up to 1120mm between tie bars and can accommodate up to 2.5 kg shot weight.

Those benefitting from the efficiency gains include caps manufacturer GCS Group, which reduced its cycle time by 25% using a 250 tonne El-Exis SP system whilst maintaining the same uptime and product quality performance.

Further to this, a leading European container manufacturer conducted an internal energy comparison between their new 250 tonne El-Exis SP machine and existing injection moulding equipment, to find that the new technology reduced their energy usage by 24.5% saving the company in excess of £12,000 per annum.

Sumitomo (SHI) Demag’s design team used the latest techniques to increase reliability, improving the clamp unit dynamics, creating higher speeds and smoother more linear transitions, protecting the mould from damage and guaranteeing repeatable performance.

The machine’s new NC5 plus control system also focuses on mould protection with a built-in mould safety system which monitors the status of the mould during opening and closing strokes, anticipating potential problems and quickly reacting to minimise potential mould damage. Further to this, the easy-to-use NC5 plus system allows operators to individually optimise each machine axis for maximum performance, as Technical Sales Manager Dave Raine explained: “Using simple individual machine movement slide bars via the touch screen, the machine setter can make adjustments and see in real-time how the machine reacts to each change made. This visual process helps reduce set-up time, optimising the machine to maximise speed and product quality”.

Managing Director Nigel Flowers added: “The SP model has been fine-tuned in all EPPM 15

Sumitomo (SHI) Demag Tel: +44 1296 739500 Email: salesuk@dpg.com Web: uk.sumitomo-shi-demag.eu

MACHINERY SPOTLIGHT eppm

MATERIALS HANDLING

ON THE COVER When Stewart, the UK market leader in the SUMMIT SYSTEMS manufacture and supply of technical CHOSEN FOR plastic moulded STEWART products for the RE-LOCATION gardening, home and professional catering sectors, chose to re-locate its facility from Croydon to Banbury it called in Summit Systems to handle the re-positioning of its considerable materials handling technology.

In order to facilitate the move in as seamless a manner as possible Summit loaned Stewart 17 Loaders to maintain production whilst the group decommissioned the machinery to be re-located.

At the same time Stewart removed the existing pipe-work and couplings and after cleaning, it was shipped to the new Banbury site. Liaising with cooling specialists IsoCool, in order that the new pipework was acceptable to both systems, Summit Engineers installed approximately 4 kilometres of pipes around the upper reaches of the extensive factory. Acclaimed by customers for its precision and efficiency in the installation

of large pipe-work projects, Summit has once again produced a meticulously organised system of pipes. Commenting on the project, Summit Systems Project Manager Graham Wooldridge said: “The process was staged carefully over a period of 26 weeks to match Stewart’s production requirements.”

Summit was also awarded the task of designing a state of the art product conveying system for the new premises.

Working closely with Stewart, Summit’s Technical Team designed in the region of 200 metres of bespoke conveying systems transporting moulded products from the large number of processing machines to the very busy packing department. This installation has the ability to convert between a one or two carousel system.

In addition to the re-commissioning of all the existing materials handling equipment into the new site, including three silos, Summit also provided and installed new investment machinery purchased by the growing Stewart company. This included Big Bag Frames for the support and discharge of bulk materials, additional material distribution mechanisms and blenders.

Richard Butler, CEO of Stewart, said “This move has been highly important to Stewart. It is enabling us to invest in world beating manufacturing processes and to consolidate our position as a UK manufacturer of quality products.

Choosing to work with Summit Systems on the re-location of machinery and the design and purchase of additional technology gave us the assurance that whatever the issues such a large endeavour might throw up, ultimately we would complete with the minimum of disruption. The quality of the new equipment we have installed at the Banbury site is unquestionable and definitely a long term investment which additionally offers us flexibility as our processes develop.”

He continued: “Summit Systems engineers are an efficient and resourceful team who have worked to our schedules and produced quality work. I am hopeful that we will continue to work with Summit in the future”.

Summit Systems Tel: +44 1827 265 800 Email: webinfo@summitsystems.co.uk Web: www.summitsystems.co.uk EPPM 16

MACHINERY SPOTLIGHT

The 1600X Series Granulators CUMBERLAND from Cumberland are 1600X SERIES convenient general-purpose PROVIDES granulators for injection moulding, blow moulding, FLEXIBLE BESIDEand extrusion. This line of THE-PRESS beside-the-press granulators SOLUTIONS offers a comprehensive collection of standard features, including a pivoting hopper, dropdown removable screen cradle, soundattenuated infeed systems, and HCHC knives.

With its 16.5 inch cutting circle, scooped rotor and forward offset design, the 1600X will accept a wide variety of parts. Additionally, a broad range of infeed and discharge options enable the 1600X granulators

Materials handling specialist Koch-Technik has recently KOCH-TECHNIK launched two new models of its patented gravimetric EXTENDS Graviko dosing system. The GRAVIKO GK65 and GK 200 dose RANGE plastic to the machine “with the highest reproducibility” according to the group.

Accurate and reproducible doses are key to the quality of any application.

The exact proportions of main and auxiliary components can determine the characteristics of sensitive products, making precise and reliable dosing indispensable. Koch-Technik says it has developed Graviko for the production of such applications. It is a patented gravimetric dosing and weighing system with excellent reproducibility.

The new generations dose individual components into the weighing container using a slider or by volume. Tiny quantities can be dosed with an accuracy of 0.001 seconds. Two load cells then register the actual weight of the components in the container and communicate the values to the Koch control unit, where they are compared with the calculated nominal value. Each filling is weighed hundreds of times in succession to balance out any variations. If the actual weight and nominal weight are the same, the bulk materials are emptied into the mixer underneath. A horizontal agitator mixes the dosed and weighed batch before it is processed on the machine.

Precision dosing coupled with the gravimetric weighing system produces a control circuit which ensures that dosing is carried out correctly regardless of the bulk materials used. The patented system offers an accuracy with a tolerance of +/-4 grains per 1000 grains. This value is currently unbeaten by conventional dosing systems on the market, according to Koch-Technik.

The MCm-G Touch control unit precisely calculates the values. The MCm-G Touch is an easy-to-use control unit for gravimetric dosing systems. Once the recipe has been entered on the touch display, dosing takes place (starting with the first cycle) without the need for calibration. In terms of hardware, the device features an ARM 9 microprocessor, 4 GB of nonvolatile memory and an SD slot. Ethernet and USB interfaces are available as options. Users can select from 16 different languages, manual actuation for setting up or cleaning purposes, ground material program and large recipe memory, dosing parameters with nominal and actual value display, specification of dosing volume, implemented Internet FTP server, 3 password levels and password administration, alarm management and tolerance monitoring, control of 4 conveyance components and, as an option, the export of recorded data via USB and connection to visualisation software to depict the entire production process.

to work with many different applications.

John Farney, Cumberland’s VP of Sales, explained: “Rotor diameters are critical in selecting the right granulator for an application, and the 1600X models proved the flexibility many customers need.”

The 3-knife open slant-cut

The Graviko in the Koch modular system: for rapid material changes, all device components can slide, swivel or fold away using appropriate fixtures - without tools, on the processing machine itself.

The Graviko GK 65 for machine throughputs of up to 80 kg/h, suitable for 4 dosing stations The new GK 65 and GK 200 Graviko devices are designed to either dose the batches directly on the machine or on a supplied frame. The GK 65 is designed for throughputs of up to 80 kg/h and the GK 200 for up to 250 kg/h. Depending on the throughput of the processing machine, up to four different components can be processed. Standardised in line with the Koch modular system, the new Gravikos are fully compatible with all Koch-Technik dosing and conveyance devices and accessories. All device components can be slid, swivelled or folded away on the processing machine without disassembly. Quick-fit closures and slide and swivel devices ensure rapid set-up and assembly of components without using tools.

Koch-Technik Tel: +49 7231 80090 Email: info@koch-technik.de Web: www.koch-technik.com

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rotor with scooped wings provides for both positive feeding of bulky parts and improved airflow for cooler operation. The forward offset cutting chamber design allows access to both bed knives at a comfortable working level. For added convenience, quick-release hand knobs provide easy access to the machine without the use of tools.

Cumberland Engineering Tel: +44 7825 275 214 Email: pbissell@corpemail.com Web: www.cumberland-plastics.com

MACHINERY SPOTLIGHT eppm

MATERIALS HANDLING

AEC’S BD SERIES BLENDERS ACCURATELY METER INGREDIENTS

Equipment specialist AEC offers the BD Series, a range of blenders which offers a host of sizes and blending options to suit “any processor’s needs”, according to AEC. With a 2-4 component blender, The BD 150 can process material at a rate of 0.5-68 kg/hr, and a stainless steel material supply hopper with machined access door come standard along with an integrated stainless steel mixer bowl.

The BD 500, next in the series, offers a 2-6 component blender and can process material at a rate of 5-227 kg/hr. The BD 900 and 2500 offer a 2-8 component blender; the BD 900 can process material at a rate of 5-405 kg/hr and the BD 2500 at 50-1130 kg/hr. Larger models, the BD 4000 and BD 6000 can process material at a rate between 227 -2730 kg/hr with 2-8 component blenders.

Standard with all BD blenders are a removable weigh hopper that provides quick colour changes and available features include supply hopper drain tubes with slide gate for easy cleanout.

A safety-interlocked access system shuts off air and electricity if the mixer door is opened and an adjustable slide gate stroke limiter is provided for accurate metering of minor ingredients.

A PLC-based blender controller is also standard for process control. The operator-friendly controls simplify operations by providing a menu-driven interface screen for complete control and monitoring of any batch blending operation. A user-friendly controller makes it easy to store up to 20 recipes that also provide unmatched metering accuracy for up to six ingredients, especially below 2%.

Three modes of recipe entry are available to suit any and all blending needs. The “Quick Set” mode meters colors and additives as a percentage of the virgin material for injection molding applications; the “percentage” mode meters all ingredients as a percentage of the overall batch, most common for extrusion and blow moulding applications; A “parts” mode allows for ratio recipe entry.

In addition to industry leading heating and cooling products, AEC always offers full support from start-up to training to 24-hour on-call service.

AEC Web: www.aecinternet.com

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MATERIALS

Sabic’s Valox Used in Carbon Fibre Composite Car Part A carbon composite air extractor located on the hood of the 2012 Chevrolet Camaro ZL1 sports car has been named the winner in the Performance & Customization (Aftermarket) category of the Society of Plastics Engineers’ (SPE) 42nd-annual Automotive Innovation Awards Competition.

This carbon fibre prepreg composite part pulls air through the lower grille and out through the hood, cooling the engine, increasing efficiency and reducing lift in the process. The part includes a water deflector moulded from Sabic’s Valox resin, which delivered the high mechanical and thermal performance needed in an under-thebonnet environment.

“We are pleased to have played a supporting role in helping GM garner this distinguished industry recognition,” said V. Umamaheswaran (UV), Director of Marketing, Automotive, Innovative Plastics. “Automakers today have higher demands, especially in the ever-evolving under-hood space. The award winning air extractor, with integrated water deflector, allowed GM to achieve high performance and high temperature resistance, all with the desired styling, which is not possible with a one-piece carbon fibre solution due to design limitations. Sabic’s contribution to this part speaks to its ability to respond with the unique thermoplastic solutions that the industry needs. We look forward to continued collaboration with our customers to help them meet the increasingly complex application challenges that lie ahead.”

Sabic, working with GM and system supplier TransGlobal LLC, helped develop the water deflector by providing material selection assistance, predictive engineering work, as well as tool build design and validation support.

The Camaro ZL1 air extractor is engineered from carbon-fibre composites to achieve the highest stiffness and strength achievable with the lowest mass.

The air extractor makes extensive use of adhesive bonding to join two

components to the one-piece design.

Those two components are a polyamide vent screen and the water deflector moulded from Sabic’s high-performance Valox resin, a thermoplastic polyester.

The adhesive bonding also isolates the carbon composite panel from the rest of the aluminum hood, preventing galvanic corrosion.

Valox resin delivers the high heat performance required to ensure the long-term durability of the air extractor’s water deflector. This component, designed to deflect water from entering the engine compartment, must be able to withstand high temperatures coming from the engine. This is particularly critical given the deflector’s location on the under-side of the hood and close proximity to the engine. The Valox resin grade selected for this application meets the requirement, delivering up to 216°C in heat resistance, while also offering an excellent balance of chemical resistance, dimensional stability and impact performance.

Another key benefit of Valox resin for this application is the material’s high quality feel and surface appearance, giving the deflector part a premium look and aesthetic attractiveness that consumers demand in a high-performance sports

car. The part is also moulded-in colour, offering improved aesthetics while reducing costs and emissions associated with the painting process.

The Valox resin family is based on polybutylene terephthalate (PBT) and/or polyethylene terephthalate (PET) polymers and is available worldwide.

Since 2009, nine automotive plastic innovations moulded from Sabic

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materials have been selected as SPE Automotive Innovation Award winners.

An additional 11 applications with Sabic materials have been honored as finalists over this same time period.

Sabic Tel: +1 248 926 4219 Email: david.cameron@sabic-ip.com Web: www.sabic-ip.com

MATERIALS ROUNDUP Advanced Functional & Industrial Printing Conference Returns for 2013 ESMA has announced that the Advanced Functional & Industrial Printing event will return to Düsseldorf on 6-7 March 2013.

Expert speakers will offer printers, OEMs and Tier 1 suppliers a series of presentations covering the best practices, as well as offering an invaluable insight into the latest technologies available. Applications to be covered include automotive, film insert moulding, nameplate, fascia, printed electronics, circuit, label and solar cell technologies.

Confirmed keynote presentations to complement the technical programme include Professor Gunter Hübner of Hochschule der Medien addressing

Printers enjoyed networking opportunities in the tabletop exhibition at the 2011 event

‘Functional printing with screen or digital’ and ‘Volume printing of multilayer products’ by Swansea University’s Professor Timothy Claypole. Full conference programme can be found at www.AFIP2013.org Advanced Functional & Industrial Printing 2013 will take place at the easily accessible Radisson Blu Scandinavia hotel in Düsseldorf. The conference programme will be presented in dual English and German, and will be supported by regular intervals dedicated to an accompanying tabletop exhibition of leading manufacturers of machinery and consumables.

Discounted Online Registration Open Online registration is also open now at www.AFIP2013.org and for a limited time only, attendees can take advantage of a reduced ‘early bird’ delegate fee of only €495. Registration includes access to all presentations, exhibition displays, refreshments, lunch and dinner. Further discounts are available for multiple delegate bookings and ESMA members.

Track Record Advanced Functional & Industrial Printing 2013 follows on from the 2011 event which incorporated the Membrane Switch Symposium and was deemed an outstanding success by an international audience of over 140 attendees from 19 different countries. 100% of attendees stated that the conference programme was good or very good, and 98% said the 20 presentations would be useful to their business.

The 2011 event attracted 140 attendees from 19 different countries.

Technical presentations were made by representatives of Agfa, Algra, Bayer, ColorGATE, Conductive Compounds, Folex, GC Limited, KIWO, MacDermid Autotype, Marabu, Natgraph, Pröll, Sefar, SignTronic and Xennia. Keynote speakers included Ed van de Kieboom of the Plastic Electronics Foundation, Gunter Hübner from HDM Stuttgart, Lumoza’s Wouter Moons and Peter Kiddell of PDS Consulting.

Organisers Advanced Functional & Industrial Printing 2013 will be staged by ESMA, a European association for specialist printing manufacturers of screen, digital and flexo technology. Members are

manufacturers of machinery, equipment, software or consumables. The event is supported by Chameleon Business Media and both partners have proven track records of staging highly successful educational conferences and exhibitions, including Advanced Functional Printing, Membrane Switch Symposium, GlassPrint and CTS & Digital Work Flow.

Advanced Functional & Industrial Printing Conference Tel: + 32 16 894 353 Email: info@esma.com Web: www.afip2013.org

FEEDBACK FROM THE 2011 EVENT A selection of comments from attendees at the 2011 event include: “It was a very good and interesting conference with a lot a high level speakers. Not being a screen printer, it made me realise what an incredible number of technical applications are covered by screen printing. In these specialty markets we have to analyse what digital printing can bring.”

“We were able to meet with several current and potential customers at the symposium, and to make contact with many other suppliers and industry participants who we were not aware of. The content of most presentations was both timely and relevant to the rapidly growing market for printed electronics applications and technology worldwide.”

Emmanuel Swolfs, EFI (Belgium)

Douglas Banfield, Conductive Compounds (USA) “The workshop was perfectly balanced between practical, hands-on information and on the other hand a solid scientific content and exciting new developments.”

Bart van Duffel, Sirris (Belgium)

“Our compliments for the excellent event ESMA have held in Düsseldorf. An event full of survivors that believe in our screen printing common future and had the opportunity to “digest” top quality, informative and professional presentations that clearly show a future vision for many new “Opportunity” applications on “thin” and “thick” screen printing industrial perspectives…if we want!”

David Forrester Zamith, Ruy de Lacerda & Ca. Lda (Portugal)

EVENTS New Event for the Plastics and Composites Sectors The Forum de la Plasturgie et des Composites is a new event which will take place on the 30th and 31st of May at Disneyland Paris’s Congress Centre. This event, which aims to bring together members of the entire plastics and composite material industry is a new type of event for the industry. It aims to promote the latest technology and research, highlight the strengths of the French plastics industry, and facilitate networking.

The event will include plenary conferences, technical workshops, and an exhibition area bringing together companies from across the industry.

During these two days, the Forum de la Plasturgie et des Composites will focus on showing off the strengths of the French plastics industry at a time of new industry challenges.

The plenary conference programme aims to decrypt and illustrate the strategies of stakeholders upstream and downstream of the industry and it will provide real prospects. The workshops and exhibition area will present cutting edge solutions and services.

The technical workshop programme will attract a large number of professionals directly involved in the event (general management, purchasing, research,

technical, HR) who will be able to build their own "tailor-made" programme from the various subjects proposed.

The exhibition area and many highlights will punctuate these two days focused on facilitating exchanges and networking between all the participants.

The common thread of this first conference on plastics and composite materials invites you to think and act differently to promote the industry's strengths.

Three plenary conferences will be available to decode industrial change and make the most of it. They will bring together personalities from the worlds of economics, politics, and industry. For your information, you will find a list of the subjects selected so far in the annexe.

A call for proposals was issued to industry manufacturers to collect and present around 30 communications among the most relevant for the industry on subjects such as techniques, industrial performance, innovation, human resources, and organisation during the 2-day event.

Forum de la Plasturgie et des Composites Web: www.forum-plasturgie-composites.com

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MATERIALS ROUNDUP

A New Member for EPPM’s Advisory Board In our first issue of 2013, the editorial advisory board for this magazine will welcome a new member to specialise in matters relating to global chemical legislation in the packaging sector. Victoria Sayer, Regulatory Manager at ColorMatrix Group, has kindly agreed to offer input on this critical subject whenever we look in-depth at packaging materials. As this is our packaging feature issue for 2012, we introduce her here.

In the following report, Victoria explains why chemical legislation is a complex business and how regulatory teams play an important part in getting a new technology to market….

The plastics packaging industry is evolving rapidly with R&D teams continually discovering new additive technologies and improved formulations.

Based on a vast array of chemicals, these innovative new products are designed to deliver benefits in areas such as product protection, processing efficiencies, aesthetic quality and increased sustainability – all crucial to manufacturers and brand owners competing in an industry where there is more pressure than ever to reduce operational costs, enhance shelf impact and minimise environmental impact.

The regulatory considerations involved when introducing a new additive to a plastic are multifaceted and materials will not be allowed near a production line – or into a specific country for that matter – unless they meet the extensive requirements governing such products.

Everything from chemical legislation imposing requirements on the manufacture, marketing, and use of the initial raw materials all the way to compositional and good manufacturing practice requirements for the finished materials need to be considered.

Violations of the relevant provisions are punishable in accordance with the sanctions in place under the applicable country or member state law. More importantly, violations of legislation, particularly with regard to food safety, can lead to irreparable damage to the brand name of the finished article manufacturers, especially if the violations lead to product recalls.

With so many factors and procedures to consider, the regulatory teams at materials suppliers play an important role in ensuring that their products meet the necessary guidelines and legislation requirements. Regulatory functions also provide documentation and support to reassure global customers of the applicable regulatory compliance for their application and region.

Chemical Inventories Chemical inventories are one of the first hurdles to negotiate and are essentially lists of the chemicals permitted to be manufactured in, or marketed in a particular country. Any chemical not appearing on the inventory is considered a ‘new chemical’. Usually before it can be marketed, manufactured or imported

into a country, substantive data must be submitted to the authorities to have it included on the inventory. Chemicals are often assigned unique numbers which act as chemical identifiers and help determine which materials are listed on which inventories.

In Europe, REACH (Registration, Evaluation, Authorisation and restriction of Chemicals), requires the registration with the European Chemicals Agency of all chemicals manufactured or imported in quantities exceeding 1000kg per year per legal entity in the European Union.

This is being phased in over a period of time from 2010 to 2018 and to take advantage of these transitional phase-in periods, materials must already be on the ‘existing inventory’ (EINECS). If a material is not already on the ‘existing inventory’, it is regarded as a new chemical requiring a dossier to be submitted prior to being marketed.

Countries like China, Canada, USA, Korea and Australia all have their own individual chemical inventories. A common feature of such chemical inventories may include restrictions on the amounts of specific chemicals imported or produced, as well as the applications. Any deviations to this, such as a significant increase in production volumes, or a change in intended use, may require submission of new information to the authorities. Most inventories are continually updated as new chemicals are introduced.

Food contact legislation Consumer safety is paramount and legislation governing chemical usage in food packaging is understandably rigorous. Food contact legislation usually stipulates which chemicals are permitted to be used in plastic articles that will come into contact with food and may set restrictions on permitted use levels, or maximum levels of chemicals that may migrate into the food stuffs.

If you were looking to introduce a new chemical for a food packaging application, there would be a number of key considerations such as food contact time, temperature of use and food type.

Building a hazard profile of the new additive is also essential to establish the potential risks involved in its use. This is where regulatory teams must be able to provide information on the chemical

structure, which can help to identify any potentially hazardous properties.

Regulators typically assess not only the hazard of a material, but the risk based on the use level, its migration behaviour and ultimately how much the consumer will be exposed to. Any regulatory approvals granted will take all these factors into consideration and a material will only be approved if consumer exposure is many magnitudes lower than any dose level of concern.

Food contact regulatory restrictions also vary from region to region. As an example, Europe and the United States, have different requirements that must be met to comply with food contact legislation in those regions. Risk assessment, a major influencing factor in whether a chemical gains approval or not, is generally based on the level at which a material migrates. This is then used to calculate the amount of the chemical that a consumer may be exposed to, which is dependent on the application (I,e how widespread/frequent the use is). The safe exposure level will clearly differ for different chemicals.

Europe then tends to regulate by setting a ‘migration limit’ for the chemical, whereas the US FDA tends to describe explicitly the use level, polymer type and applications that are permitted.

Generally speaking, the EU and US lead the way in determining regulations in

other territories but China and Mercosur, which governs food contact in Latin America, are major players in the global packaging industry and they have adopted different elements of both systems as well as some of their own.

On top of chemical inventories and food contact legislation, there are additional factors that fall under the remit of regulatory teams such as chemical classification and labelling, material safety data sheets, heavy metal usage, shipping requirements and antimicrobial criteria. Suppliers are constantly looking for that game-changing technology, but using chemicals that don’t adhere to global legislation, or failure to follow the correct procedures in terms of testing or data collection, can seriously hamper or prevent the commercialisation of a new additive material.

Victoria Sayer, Regulatory Manager at ColorMatrix Group joins the editorial advisory board.

Borealis Acquires DEXPlastomers Borealis, a global provider of chemical and innovative plastics solutions, has announced that it has reached an agreement to acquire the shares of DSM Plastomers B.V. and Exxon Chemical Holland Ventures B.V., each holding a 50% interest in DEXPlastomers V.O.F. in Geleen, The Netherlands, from DSM Nederland B.V. and ExxonMobil Benelux Holdings B.V. DEXPlastomers is a 50/50 Joint Venture ultimately owned by Royal DSM and ExxonMobil Chemical Company.

Following this agreement, the relevant employee representatives are being informed and consulted on the proposed sale to Borealis. The transaction is

subject to customary approvals and notifications.

The products of DEXPlastomers are specialties complementary to Borealis’ current innovative plastic solutions.

Borealis Tel: +43 1 22 400 302 Email: kerstin.meckler@borealisgroup.com Web: www.borealisgroup.com

EPPM 21

MATERIALS ROUNDUP Styrolution Consolidates Styrenics Portfolio Styrolution, a global specialist in styrenics has announced measures to consolidate its product portfolio. The company’s current portfolio is comprised of key styrenic assets inherited from its heritage companies, BASF SE and INEOS Industries. In order to offer customers a clearer choice in product solutions, Styrolution has made a strategic decision to reclassify and ‘harmonise’ product ranges into a unified product portfolio.

Styrolution has developed two business models to address its customers’ distinctive requirements, grouping its portfolio offering into two categories: Styrolution Specialty and Styrolution Standard products. The Styrolution Specialty product range consists of clear and opaque copolymers and specialty acrylonitrile butadiene styrene (ABS) grades. Styrolution Specialty products feature properties developed for specific market applications, such as highperformance, pre-coloured solutions.

Styrolution Standard products are commodities like styrene monomer, polystyrene and standard ABS. These are typically robust and highly versatile workhorse grades for which customers “expect competitive pricing and consistent quality with the reliability and supply efficiency of a global and regional supplier”, according to the group.

The following changes to brand names

will become effective January 1, 2013: • All polystyrene products will be marketed under the new brand name Styrolution PS, replacing the former Polystyrol and Empera brands • All Standard ABS products will be marketed under the brand name Terluran • All Specialty ABS products will be marketed under the brand name Novodur, replacing the former Terluran and Lustran specialty brands • All SAN products, will be marketed under the brand name Luran, replacing the former Lustran SAN brands

• The ABS and polyamide-based thermoplastic polymer blends, Terblend N and Triax, will be consolidated and marketed under the brand name Terblend N. Branding for the remaining specialty copolymers and blends will remain unchanged. Furthermore there will be no changes to the product grade nomenclature, with the exception of polystyrene in the Europe, Middle East and Africa and Mexico.

“Optimising our portfolio by harmonising branding along the lines of our standard and specialty business models allows

Styrolution to clearly communicate both function and value to customers,” said Alexander Glück, Senior Vice President Global Strategy, R&D and procurement at Styrolution. “With the breadth of our combined technology and industry knowhow, we are confident we will continue to offer the quality, reliability and innovation Styrolution’s customers have come to expect.”

Styrolution Tel: +49 69 5095501200 Email: globalinfo@styrolution.com Web: www.styrolution.com

Second SPE Eurotec Conference Heads to France

3M and DSM Fuse Materials for Lighter Automotive Parts

The Society of Plastics Engineers (SPE) has selected Lyon, France as the site of Eurotec 2013, a wide-ranging plastics technical conference with more than 200 original, peerreviewed presentations on such topics as automotive, composites, extrusion, injection molding, and thermoforming.

Eurotec 2013 will take place July 4-5, 2013 at Lyon’s Cité Congress Exhibition Centre.

In addition to the technical presentations, there will be an exhibition with displays by companies representing the entire plastics industry supply chain, including processors, machinery manufacturers, and raw material suppliers.

“After the success of Eurotec 2011 in Barcelona, SPE continues to extend its outreach to the European plastics community,” said Wim De Vos, CEO of SPE. “In years to come, the continued development of exciting new products and applications in the European marketplace will be reflected in the growth of our Eurotec conference.”

Lyon is a center for plastics innovation and is the home of a number of plastics training centers, noted Olivier Crave, Chair of Eurotec 2013. “France’s wellknown ‘Plastics Valley’ is located

The combination of Stanyl polyamide 46 from DSM and 3M Dyneon Fluoroelastomers has created a component material to support the rising trend for lightweight automotive construction.

Lightweight vehicle components are manufactured using an economical twocomponent injection moulding process followed by vulcanisation. Components made this way demonstrate high mechanical strength, are able to withstand high temperatures for extended periods and are resistant to the chemical impact of oil and fuels. This makes the light construction material ideal for use in the entire powertrain. It also eliminates the use of cleaning products, phosphate compounds and bonding agents needed for traditional metal processing.

Stanyl Polyamide 46 from materials producer DSM N.V. and fluoroelastomers from Dyneon, a subsidiary of the diverse technology company 3M, are highperformance materials that, when combined, form an excellent characteristic profile for use in engines.

Stanyl polyamide retains its stable mechanical properties even at temperatures up to 200°C. With 80% less density than steel, it also substantially reduces the weight of construction components.

The wide range of Dyneon Fluoroelastomers offers very high chemical resistance against oils, fuels and numerous other chemicals at temperatures up to 230°C. Stanyl polyamides and Dyneon Fluoroelastomers are already used for many seals, gaskets and components in automotive powertrains.

The two-stage manufacturing process

northeast of the city and has the highest concentration of plastics converting companies in Europe,” Mr. Crave said.

“Visitors to Eurotec will also enjoy the beauty of the South of France at the most magnificent time of year.”

A leisure program will be available for spouses and guests not attending the conference events.

SPE Eurotec Tel: +32 2 761 1647 Email: spe@kelleneurope.com Web: www.4spe.org

EPPM 22

provides economic and environmental advantages. Suppliers currently process metal components using planning processes, followed by chemical cleaning and surface treatment. This requires cooling lubricants, cleaning agents, phosphate compounds and transportation between the different production stages.

Unlike time-consuming and labour intensive metal processing, it is possible to manufacture the new material combination using a two-component injection moulding process followed by vulcanisation. During this process the Stanyl polyamide amino end groups enter into a chemically stable bond with the Dyneon Fluoroelastomers. This eliminates the cost of auxiliary materials as well as their disposal, and the simplified process provides quality consistency. During continuous production, the cycle time for the twocomponent process — as verified by the German Institute for Rubber Technology — is reduced to a mere three minutes per component. Including the vulcanisation process, the components are ready for installation after just two hours.

This makes the new material combination ideal for components such as crankcases, seals and gaskets, both dynamic and static. In addition, this innovation provides more freedom for new construction designs and assembly techniques as well as the integration of functions.

3M Web: solutions.3m.com DSM Web: www.dsm.com

MATERIALS SPOTLIGHT eppm

PACKAGING

OPINION BOB THOMAS, TECHNICAL DIRECTOR, COLLOIDS, OPENS UP ON PACKAGING

Bob Thomas, Technical Director, Colloids Ltd – a leading supplier of masterbatch – offers his thoughts on plastic packaging, a subject which hits the headlines year after year during the festive period…

Maybe the run-up to Christmas is the right time to be thinking about packaging. Not just the quantities generated: many will no doubt be fuming that the kids prefer playing with the

packaging than the presents inside.

Just like most of us, I am all for reducing the volumes, as well as minimising environmental impact - and these are key challenges in the plastics industry - but there’s one sure way to raise my heckles.

It’s when people say: “It’s only packaging”. It’s that “only” that gets my goat. It just doesn’t stand up, not when we spend so much time: • making sure items get delivered safe and intact, whether it’s your precious new tablet or that perfectly ripe avocado • helping products to look their best, including consistent repeatable brand building through precision colouring and special effects, no matter where you are in the world • delivering impact strength, reduced weight, clarity/opacity, antistatic control, antibacterial and a whole host of other properties - on demand, to support clients’ goals.

Take some real world examples of how the right masterbatch adds value - to “packaging” and beyond: • leading the way on bio–plastics and degrade–able initiatives: plastics are not going away so we need to minimise and mitigate their long term impact • managing anti-static and conductive/shielding properties whether to repel dust particles on the shop shelf and improve appearance plus sales, or to ensure

Rising inks, adhesives and energy costs being passed on to customers through higher selling prices was the main factor in European flexible packaging production growing by 5.1% in value terms in 2011.

This is one of the conclusions from PCI’s latest annual report on the €11.6 billion European converted flexible packaging market. Paul Gaster, the report’s author, also noted, “Even in these uncertain times, volume growth in European consumption was almost 2% last year, confirming that flexible packaging continues to suffer less than other industries in a downturn.”

This overall growth figure does, however, cover up some significant regional differences in demand trends – the larger volume markets of Western Europe grew at around 4 – 6%, while demand in the Spanish and Portuguese markets was broadly static and in Greece flexible packaging values declined again in 2011. Key East European markets, Russia and Poland, continue to exhibit growth at twice the average for Europe as a whole.

Further industry consolidation was another significant factor which has changed the European supplier base and is noted in PCI’s report. Following Amcor’s acquisition of Alcan’s European flexible packaging operations in 2010 has been the recent acquisition by Mondi of Nordenia International which sees Mondi emerging as Europe’s third largest player after Amcor and Constantia. Also a number of venture capital groups, notably Sun Capital, have been active in reshaping the structure of the industry via a series of acquisitions. This has resulted in Britton Group and Kobusch Packaging appearing in PCI’s European top

that electronic chips arrive in pristine condition • improving segregation of PET waste for recycling by deploying novel black grades (non carbon black) for sheet extrusion, which do not interfere with infra red detection systems.

So remember, “Packaging” is not the only “P” - it stands for “Passion” too: that’s what you need to get the results customers deserve from masterbatch.

And if you don’t believe me, just ask my wife where to find me in the supermarket. I’ll typically be in the detergent aisle. I am always looking for things “I” have made. Or buying unknown products so I can take them into the lab to de-formulate them so we can look to offer an enhanced version should the opportunity arise.

But I don’t have a collection of plastic bottles at Bob Thomas, Technical Director, home. Not any Colloids - the Makers of Masterbatch more.

PRICES DRIVE EUROPEAN FLEXIBLE PACKAGING GROWTH

EPPM 24

20 table of flexible packaging converters for the first time. The table also shows for the first time a converter from Eastern Europe appearing in the list, namely the fast growing Ukrainian company Ukrplastic.

Now in its 12th edition, PCI Films Consulting’s “The European Flexible Packaging Market to 2016” has become an invaluable tool in driving business planning, investment and future product developments.

Based on original field research, it is the most recent and comprehensive report available on the European market, providing over 400 pages of historical data and comprehensive market analysis and statistics for 2011, estimates for 2012 and forecasts through to 2016.

PCI Films Ltd Tel: +44 1604 74900 Email: info@pcifilms.com Web: www.pcifilms.com

MATERIALS SPOTLIGHT

Producers and end users of plastics caps and closures can were able to find out more about SABIC’s latest developments in polyethylenes and polypropylenes at the 2012 Plastics Caps and Closures Europe Conference and Exhibition which was held in Brussels on November 20 and 21.

Customer demands in terms of organoleptics are very tough in the still water sector, and can be met by SABIC HDPE CC860V, specifically developed for this application. Meanwhile, producers of custom closures for products such as sports drinks will be particularly interested in another recent SABIC development, SABIC PP Qrystal QR674K random polypropylene, which is a step up in terms of processability from previous generations of PP. Caps and closure designers and manufacturers are constantly on the look-out for new ways to improve the use of resources — materials and energy in particular — while delivering products that perform well, and which are easy and safe to use. At this year’s event, SABIC demonstrated how it is

POLYOLEFIN INNOVATION DRIVES CLOSURE TECHNOLOGY

continuing to work on developments that meet these needs.

“Good organoleptic properties, which manifest themselves in very low alteration of taste in the packaged water, and which are achieved by strict control of manufacturing conditions, help consumers feel reassured of the high purity of water,” said Philippe Rasquin, Technical Marketing Engineer HDPE Europe at SABIC. “Organoleptic requirements in the NF V09013 triangular test are met by SABIC HDPE CC860V, and it also has a very low level of Volatile Organic Compounds (VOCs) according to the relevant EPA protocols.

In addition to that, it processes easily and has good thermal stability.”

“Consumers want packaging they don’t have to think about,” said Rasquin. “That translates into lightweight products that are easy to use and re-use, and which maintain the original properties of the contents as much as possible, for as long as possible.

“Our Caps & Closures portfolio is tailored to smart packaging, secure sealing and easy dispensing. It’s designed for optimised cap design and processing in term of energy consumption and faster cycle time, and it’s optimized for life-time as well as endof-life.”

“By using our SABIC PP Qrystal QR674K

random polypropylene, processors – particularly producers of custom closures for products such as sports drinks — can lower their machine temperatures when they use this new grade without compromising part quality,” said Timo Latvakangas, Technical Marketing Engineer PP at SABIC. “We have customers already achieving processing cost savings of close to 15%. As the processing

EPPM 25

temperature is lower, there is also less heat that needs to be removed during the cooling stage, providing the possibility to reduce cycle times significantly.”

SABIC Tel: +31 46 722 2168 Email: solange.schlosser@sabiceurope.com Web: www.sabic-europe.com

MATERIALS SPOTLIGHT eppm

PACKAGING

UPDATE: THE 21ST CENTURY PLASTIC MILK BOTTLE

Milk bottles are one of the most commonlyused plastic packaging formats. It makes sense therefore that reducing the carbon footprint of this type of bottle would be key on the agenda for manufacturers. We

The evolution of the milk bottle has reached a pivotal point and it’s crunch time. The plastic milk bottle is the most used item of packaging in the UK – with approximately four billion purchased every year. In November 2012, it reached an important milestone, with the 30th anniversary of the four pint bottle, the last time a major change in the design of milk packaging took place.

Prior to this point, the way in which milk is contained and delivered has been an ever changing phenomenon over the last two hundred years. From the milk pail to the glass bottle in the 1800s, to the invention of the plastic milk bottle in 1964 in response to society’s new preference for disposability. After that, changes in consumer and environmental trends led to the introduction of the cardboard milk carton, and the one-, two- and four-pint plastic bottle in 1982.

Since then, however, there has been very little development in milk packaging, but that’s all about to change.

Increasing pressure on retailers to cut waste, through initiatives such as the Courtauld Commitment, and on the whole milk supply chain to reduce its carbon footprint through the Dairy Roadmap, mean that a new plastic bottle — right for the 21st century — is required. As the leading manufacturer of plastic milk bottles in the UK, it’s a challenge that Nampak has relished.

We’ve been on a four-year journey and have come up with Infini: a plastic bottle that is lighter and more environmentally friendly, but doesn’t compromise on its strength. Put simply, it’s a paradigm shift for the industry.

In the past, lightweighting has been achieved by simply using less material, but there is a limit to how thin the walls can be and for the bottle to still be fit-forpurpose. Extensive research and testing was conducted, and innovative design

received the following report on the successful development of the next generation lightweight plastic milk bottle by Ashwin Moorthy, Head of Engineering & Innovation at Nampak Plastics, a UK group which has invested £10 million in developing its new “Infini Bottle”. changes were made with a particular focus on minimising stretching by bringing corners closer together.

The result is a bottle that contains up to 25% less plastic than the standard design and uses up to 15% recycled material. Crucially, if Infini was widely adopted and replaced the current standard bottle, we would have a material reduction of approximately 16,000 tonnes per year and an impressive carbon saving of up to 34,000 tonnes per year.

Another essential part of the development strategy was to improve the overall customer experience. To achieve this, we decided to move the handle to the corner of the bottle, rather than keeping it at the side, giving easier access when removing from the fridge.

The results of independent consumer research shows that 75% of people questioned preferred Infini to the current standard bottle, particularly when made aware of its carbon saving potential. In

EPPM 26

essence, it does the job it’s designed to do, and does it fantastically well.

At present, over one million Infini fourpint bottles are being supplied each week into all Marks & Spencer stores in England and Wales, as well as Sainbury’s and Morrisons outlets in the South East.

Nampak Tel: +44 1908 611554 Web: www.eu.nampak.com

In Focus: Central & Eastern Europe Russian Plastic Sector Key for Exporters Capacities in Russia’s packaging sector are being extended and plants modernised, and, in particular the food and drink industry is seeing processed and packaged foods and convenience products becoming increasingly popular.

Packaging plays an important role in the entire consumer goods sector in Russia, both in terms of transportation protection, and also, of course, in the marketing and presentation of products.

The development of key consumer industries is also leading to growing demand in the plastics and rubber industry. The packaging sector is of great significance and the construction industry has also been revitalised, primarily as a result of extensive nationwide renovation and modernisation measures for which, for

example, insulation material, piping, window frame products etcetera are all needed.

Many small and medium-sized companies have sprung up in the last few years, investing in the expansion of existing capacity and the creation of new factories, not least due to state support.

These positive future prospects will be of great benefit to the exhibitors at interplastica 2013, the most important platform for plastics and rubber technology in Russia, and UPAKOVKA/UPAK ITALIA, Russia's leading trade fair for the packaging industry.

Exhibitors from around the world will attend both events, which will take place from 29 January to 1 February in Moscow's trade fair centre, Expocentre

in Krasnaya Presnya, to showcase their products and services to the promising Russian market.

There is already an active demand for exhibition space. The synergy of the two trade fairs has proved itself over many years; they perfectly complement each other in terms of what they offer and their target visitor group. Well over 800 exhibitors are expected and the two events will occupy a net exhibition space of more than 16,000 square metres.

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About 20,000 visitors from across Russia and many CIS countries came to the previous events in 2012; the exhibitors reported interesting and promising discussions, a positive number of new customers and on-the-spot deals.

Interplastica Tel: +49 211 45 60 7768 Email: koschkes@messeduesseldorf.de Web: www.interplastica.de

IN FOCUS CENTRAL&EASTERNEUROPE Kraussmaffei Group Doubles Production Capacity in Slovakia The KraussMaffei Group has officially commissioned the second assembly hall at its plant in Sucany, Slovakia.

Production therefore started earlier than planned. This means that the production capacity is being doubled just two years after the opening of the Sucany plant.

During an official opening ceremony in the presence of guests and employees, the KraussMaffei Group today commissioned the second assembly hall at the plant in Sucany (Slovakia).

Production in the second assembly hall is therefore commencing well before the originally planned starting date in the first quarter of 2013. I would like to thank all participating companies and our

employees for their great commitment and dedication, said Jan Siebert, Chairman of the Board of Management.

With this step, the KraussMaffei Group is doubling the production area to around 13,000 m2 (previously: 6,600 m2) exactly two years after the opening of the plant in October 2010. Doubling of the production capacities is an important move for the KraussMaffei Group so that it can cope even better with the increasing demand for electric injection moulding machines and reaction process machinery and systems on our core markets and on growth markets such as Eastern Europe and Asia, stated Siebert.

In future, this plant will also produce for the KraussMaffei brand injection moulding machines in the EX series, linear robots, reaction process machines and systems, and component trimming machines (for example punching machines which cut gates or produce openings). To date, KraussMaffei injection moulding machines in the AX series, as well as switching cabinets and moulds have been manufactured in Sucany.

During the extension of the plant, a large number of improvements were also made in production processes and

quality management. In addition, competencies were strengthened in the areas of development and design of electric injection moulding machines.

Around 200 people now work at the plant in Sucany.

Kraussmaffei Tel: +49 89 8899 4712 Email: markus.betsche@kraussmaffei.com Web: www.kraussmaffei.com

EPLA Event to Enjoy Strong Growth for 2013 The EPLA Plastics and Rubber Trade Fair will take place in Poland at the MTP from 5–7 March 2013, and already, the organisers are claiming, promises to be an extremely interesting event for the plastics and rubber industry.

EPLA is an event which aims to get back to the basics of a good trade fair – the facilitating of a place to actually do business, on the spot. The organiser says that key to its current growth is the atmosphere generated during previous events, which has provided an excellent trading environment.

The event is host to a variety of exhibitors, not only from the supplier sector but also those representing the plastic processing industry. This leads to some very interesting marketing synergies.

The structure of the fair is divided into: • Raw materials showroom • Rubbers showroom • Thermoforming showroom • Injection showroom Additionally, making their debut at the fair will be: • Composites showroom • Machines showroom Conferences and lectures are set to include: • Rubber Congress • Central & East European Thermoforming Conference • Plastics Technology Club Convention EPLA Tel: +48 61 869 2000 Email: info@mtp.pl Web: www.mtp.pl EPPM 28

THE GREEN ROOM

Closing the Loop: Purac Promotes Recyclability of Biobased PLA Purac – a leading company in lactic acid based bioplastics – has sponsored the Perpetual Plastic Project to highlight how easily polylactic acid (PLA) bioplastic can be recycled. PLA drinking cups were provided by Purac; intended for use at events where people can immediately recycle them into new products after use. The project is designed to educate people on the recyclability of bioplastic, in order to close the loop and promote a circular, biobased economy for future generations.

The Perpetual Plastic Project has successfully created a ‘do-it-yourself’, interactive ‘Machine’, which provides users with a small-scale demonstration of how easily PLA can be recycled: following the steps of cleaning, drying, shredding, melting and extrusion, before finally being remade into a new article. In this case, a 3D printer was used to create jewelry and small toys from the used PLA cups. The Machine is currently touring the Netherlands at numerous events, including the Dutch Design Week in Eindhoven, the Science Center NEMO in Amsterdam and the National Sustainability Congress in Nieuwegein.

The Perpetual Plastic Project is an initiative created by former TU Delft students. Purac, together with GroenBeker, provided the PLA bioplastic drinking cups which accompanied the

Machine. François de Bie, Marketing Director Purac Bioplastics, is pleased with the project: “This initiative demonstrates in a tangible, understandable way just how easily PLA can be recycled. Although PLA is still a relatively new material to the plastics industry, it promises to become widely implemented throughout a broad range of applications. It is therefore vital that we already start to think about how best to recycle these valuable materials.

Thanks to the Perpetual Plastics Project, we can show people at events and festivals what can ultimately be achieved on a much larger scale’.

Purac has created a short video to highlight the project and the recyclability of PLA - visit purac.com/recycle to view the film.

Purac Web: www.purac.com

Protection Developed for Cutters, Shredders and Choppers Whenever plastics are being recycled, whether end of use material, reject mouldings or sprue, there is an ever present risk that the input stream may contain metallic contaminants with the potential to damage downstream equipment.

The Plasticon metal detection system from S+S has been designed specifically to detect and remove metal fragments before cutting mills, chippers and shredders can be damaged.

Although designed for the plastics industry, the Plasticon is equally suitable for demanding applications in other industries where a combination of robust construction and sensitive metal detection is needed.

The conveyor system is built on a heavy-duty, welded steel frame to withstand the real world conditions in recycling facilities and may be fitted with a choice of tunnel or plate metal detector heads to precisely match the material size and scanning sensitivity EPPM 29

demanded by the application. The conveyor belt uses the latest materials developed to ensure that the scanning sensitivity is not compromised and lateral guides, fitted with brush seals, prevent even the smallest pieces from getting under the belt. A wide range of options are available including steerable wheels on the conveyor base for ease of relocation, feed hopper and discharge chute. The height of the conveyor belt is adjustable at both infeed and discharge to facilitate integration with existing conveyor installations.

When metal contamination is detected, the belt can be stopped or reversed automatically and a visual or audible warning may be specified as an option.

For applications where the highest detection sensitivity is essential, the well proven S+S Sensity control unit may be fitted.

S+S Inspection Limited Tel: +44 1489 553740 Email: info@sesotec.co.uk Web: www.sesotec.co.uk

GREEN ROOM ROUNDUP Erema Combines Multiple Processing Stages with New System “Corema” is a brand new product concept from Austrian group Erema.

The development is based on the idea of processing inexpensive recycling raw material to make customised plastic compounds in a single step without intermediate cooling. This combined recycling and compounding system means “forward integration for the recycler in the direction of material production and reverse integration for the compounder towards material procurement”, according to the group.

The new system was presented publicly for the first time at the end of June during the course of the Erema Discovery Days at the company’s headquarters in Ansfelden and was received with great enthusiasm by around 400 customers and industry experts.

The compounding technology comes from Coperion GmbH, the global market leader in this segment. Inexpensive recycling raw material (e.g. PP nonwoven, PE edge trim, PA fibres etc.) is turned into filtered melt using Erema’s technology. In the patented Erema cutter/compactor the material is cut, homogenised, heated, dried and buffered. The preheated material is plastified in the tangentially connected single-screw extruder and cleaned in the fully-automatic, self-cleaning filter. The prepared melt then goes directly to the co-rotating twin-screw extruder from Coperion. With its excellent mixing and gas removal properties, this part of the system can handle all compounding

tasks. Besides the dosing of a wide variety of additives, high amounts of fillers and reinforcing agents can be mixed (e.g. 80% CaCO3, 70% talcum or 50% glass fibres).

“We made a conscious decision in favour of Coperion as a partner. This company has a wealth of experience in the production of compounds and the twin-screw extruders are made in such a modular way that they can be adapted for any individual job. And the same applies to our recycling system, said Manfred Hackl, one of Erema’s two CEOs. The result is customised plastic compounds for high-quality applications. Hackl continued: “Together we are convinced that with this combined technology customers can take another step in the value added chain and turn waste into new products in an economic way.”

When it comes to materials and quantities Corema systems are available for both smaller amounts of 300 kg/h and large amounts of up to 4 t/h. The same applies to the raw materials to be processed — Corema is suitable for an extremely broad spectrum of material. The large, patented Erema cutter/compactor can be used for a wide variety of recycling jobs and applications according to the design. Hackl said: “We are of the opinion that Corema is the ideal system not only to process inexpensive mixed fractions such as PET/PE with additives, but also to produce a compound with 20% talcum out of PP

nonwoven waste, for example.” As well as being used in the electrical and construction industry, PP/talcum compounds are used mainly for white household goods and in the automotive industry. The amounts of PP recyclate used in these applications are still relatively small, yet the potential is big, says Erema.

A pilot Corema system with an output of 400 kg/h is already in use at a customer’s plant near to the company’s headquarters and Erema operates a system of its own at the headquarters with 600 kg/h output.

Dutch company Rodepa Plastics B.V has also reportedly got a serious interest in the Corema system. This company has been operating two Erema recycling systems for a number of years and has noted increasing customer demand for filled recyclates

EPPM 30

over a longer period. Mark Langenhof of Rodepa explained: “This is why we looked very closely into compounding and had a look at what machines were available on the market. When we heard that Erema covers this topic with their own product line we contacted them straight away.” Rodepa is now moving into the compounding business with Corema.

At the moment Rodepa mainly uses production PP for injection moulding applications – also in the automotive sector – and LDPE for film applications.

In the future, however, the company intends to process more post-consumer material.

Erema Tel: +43 732 3190 00 Email: erema@erema.at Web: www.erema.at

GREEN ROOM SPOTLIGHT eppm

ADDITIVES FOR RECYCLING

Additives Play a Crucial Role in Recycling Bjoern Klaas, Director of New Product and Technology Development at ColorMatrix, discusses some of the additive technologies on the market that improve PET recyclability.

Sustainability remains a key consideration in today’s plastics industry and right at the top of the agenda sits recycling. While there is significant room for improvement globally when it comes to collecting, sorting and processing used plastic, brands and converters must strive to incorporate more materials that improve the recycling potential of the polymers they use.

Historically, the use of colorants and additives in plastics was a major barrier to their recyclability and the long-term environmental feasibility of plastics. The world of additives and colorants for plastics has evolved significantly. Processors use cuttingedge additive technologies to reduce their energy use, improve quality and reduce cost. At the same time, they are seeking out additives that have a positive impact on the recycling stream, or at the very least, have no negative impact.

Maintaining long-term clarity is critical to improving the recyclability of PET containers.

Firstly, let’s take a look at the problem.

The quality of a polymer degrades every time it is re-heated during processing.

Along with discoloration, physical properties can be affected over one or more recycling processes that may render the polymer unsuitable for certain reuse applications. If we look at PET in particular, the most common polymer used to manufacture plastic bottles and food containers, it is an organic polymer that is prone to yellowing when exposed to high temperatures, which significantly reduces the reuse potential of the material. Increasing the number of times that PET recyclate can be used is key to improving its sustainability.

So, the biggest hurdle is maintaining clarity. There are a number of additive solutions in the market that help achieve this, or indeed carry out multiple functions to positively impact the recycling stream. Joule RHB, a unique liquid dispersion reheat agent developed by ColorMatrix, is an excellent example of an advanced technology that delivers qualitative and environmental benefits throughout polymer processing and recycling. The reheat agent has been engineered to initially improve the absorption of infrared energy by the polymer during the secondary blowing process for container preforms. Along with primary energy and cost efficiency gains, Joule RHB is able to offer benefits in the recycling stream in two ways.

Firstly, with the incorporation of Joule RHB the polymer is able to retain its reheat capability over repeated processing, resulting in energy efficiency gains through multi-trip recycling. In fact, when polymer containing Joule RHB is added to inferior PET grades, it can greatly improve bottle blowing rates, thus

boosting the recyclability even of blended resins.

Secondly, and most importantly in PET recycling terms, Joule RHB is able to enhance the clarity of the polymer. The additive is based on inorganic material, which means it can naturally withstand higher temperatures and is less likely to yellow. It also has natural blue toning properties that help to further reduce the appearance of b* yellowing. This optimises visual clarity even after long-term recycling and in many cases eliminates the requirement for Joule RHB reheat agents improve the absorption of infra-red additional toners, energy by the polymer. saving on material costs and usage. in the US, both of which endorse the With so many performance product as having no negative impact requirements demanded of plastics, it is on current recycling processes. imperative not only to use materials and Plastics are an established part of additives that improve the recycling modern life and if anything the stream, but where possible, make sure potential for their use is increasing, that they do not have any negative which makes it more important than impact. ColorMatrix’s Ultimate UV light ever that we find ways to recycle as barrier technology, for instance, can much as possible. Specialist additive significantly reduce light transmission companies have given brands and through a PET container wall to protect converters the access to a variety of and increase the shelf life of UV sensitive products - a major requirement technologies that help improve the recyclability of their products or in the world of food and beverage. The key to this product is that it delivers high packaging. These technologies, together with ever-improving systems levels of protection without affecting the for dealing with and processing clarity of the container. This is backed plastic recyclate, will contribute up by the both the European PET Bottle significantly to the long-term Platform (EPBP) and the Association of sustainability of the plastics industry.

Postconsumer Plastic Recyclers (APR)

Evonik Gets Symbolic Evonik's High Performance Polymers Business has planted 31 trees in the vicinity of Sendenhorst in North-Rhine Westphalia, Germany. Every single tree is dedicated to one of the many partners who make the broad-scale spectrum of resource-friendly plastics applications a reality in cooperation with Evonik.

“For us, every one of the trees has a double meaning,” said Markus Hartmann, Senior Business Manager of the Energy Supply department. “On the one hand, it stands for the sustainability and efficiency we’ve already achieved with our products, and which we aim to achieve further. And on the other hand, the trees symbolize the excellent relationship with our customers and partners.”

Thomas Grosse-Puppendahl, Vice President of the Resource Efficiency

growth line, added: “Relationships with our partners will continue to grow and form ever stronger roots just like these trees. Of course, we hope many more trees will sprout up, too.”

Among others, Evonik's highperformance polymers include the VESTAMID NRG and VESTAMID Terra brands. Designed especially for the oil and gas market, VESTAMID NRG makes the transportation and extraction of fossil energy fuels efficient and secure.

In contrast, VESTAMID Terra is based on renewable raw materials. With a bio content of up to 100%, it is deployable in a wide variety of technologically challenging applications —and in the process, it enhances the CO2 balance during production.

Evonik High Performance Polymers www.evonik.com EPPM 31

GREEN ROOM SPOTLIGHT eppm

RECYCLING SERVICES

WHITE PAPER CITES ‘ENORMOUS PLASTICS RECYCLING POTENTIAL’

The recycling firm VinyLoop has released a white paper aimed at raising awareness among manufacturers, retailers, policy-makers and the public that recycling can dramatically shrink PVC’s environmental footprint and boost sustainability.

The White Paper says VinyLoop’s recycled PVC cuts primary energy demand by nearly half, by 46%, compared to producing virgin PVC compound. R-PVC also slashes global warming potential by 39% and water consumption by 72%.

“We as a material producer take our responsibility to inform the whole value chain about the environmental footprint,” said Paolo Groppi, General Manager of VinyLoop. “This White Paper aims to create more demand pull for recycling.”

“This White Paper demonstrates how recycling supports the growing demand for a more sustainable way of life.” said Christian Thamm, Marketing and Development Manager of VinyLoop.

Further quality recycling adds economic value to marketing of manufacturers. “The final customer already knows it’s a cool thing to do”.

The White Paper shows how VinyLoop’s “Life Cycle” approach considers the environmental impact from all stages of a product’s lifetime. “We have also

FURTHER £1 MILLION INVESTMENT OPTIMISES AXION POLYMERS’ ELV PLANT

Plastics recycler Axion Polymers has invested a further £1 million this year to optimise materials recovery from end-of-life vehicles at its purpose-built plant at Trafford Park, Manchester – one of the most advanced of its type in Europe.

Axion’s in-house engineering team designed, built and now operates the highly-specialised, multi-million pound Shredder Waste Advanced Processing Plant (SWAPP) jointly with S Norton & Co, one of the UK’s leading ferrous and non-ferrous metal recyclers.

calculated an LCA for a final product containing recycled materials to showcase the influence of recycling” said Thamm. As an example, a garden hose made with 50% of VinyLoop, saves almost 20% of Global Warming Potential.

PVC is on example of how to cut resource use through recycling, according Ghent University Chemistry Professor Jo Dewulf: “Everyone is claiming sustainability. But sooner or later you need backup information to prove it. In this context, this study makes sense.”

VinyLoop notes the green marketing potential for its recycled PVC, or R-PVC, to produce garden and air hoses, and waterproofing membranes. “The VinyLoop process produces a high-quality secondary PVC compound (R-PVC) to replace conventionally produced PVC Compound,” said Paolo Groppi, VinyLoop General Manager.

The White Paper is part of a call to action, in the framework of the industry’s VinylPlus campaign, to recycle 800,000 tonnes of PVC per year in 2020.

Recycling can assist the EU’s Growth Strategy Europe 2020, which aims to cut greenhouse gas emissions 20% and increase energy efficiency 20%.

VinyLoop Tel: +39 0532 789 411 Email: vinyloop@solvay.com Web: www.vinyloop.com

Opened in January 2011, the plant is already capable of delivering over 95% recycling and recovery of materials from end-of-life vehicles (ELVs), ahead of the 2015 EU ELV recycling and recovery target.

Director, Roger Morton said: “This latest cash injection is part of on-going efficiency optimisation at the facility, which has an annual 200,000 tonnes capacity. It enables Axion to separate the non-metallic fractions from the equivalent of about 800,000 cars a year.

“Although the operation is still developing, we are already delivering the 95% recycling and recovery target through a combination of plastics recycling, producing materials for the construction industry and fuel to substitute coal,” explained Roger.

Plastic concentrate is taken to Axion Polymers’ Salford plant for further processing into a range of plastic products, such as the Axpoly PP51 extruded pellets that go to a wide range of customers, including some in the automotive sector, thereby ‘closing the recycling loop’.

Axion says that the polypropylene recovered from automotive post-consumer waste presents a great opportunity for manufacturers to tap into a stream of truly sustainable materials. Creating new manufactured products using materials resources that are ‘mined’ from closed-loop recycling routes provides a complete ‘cradle-to-grave’ approach for vehicle producers that is both sustainable in the long term and also lower cost.

As well as automotive applications, Axpoly PP51 has potential uses in the utility, construction and wider manufacturing industries.

“Axpoly PP51 is an example of the new recovery technologies and refining techniques we have developed to satisfy the higher 95% target levels. We are seeing increasing interest from other ELV recyclers in using spare capacity when available on the SWAPP facility as the 2015 deadline for the 95% recycling

EPPM 32

VinyLoop is used in the internal layer of garden hoses and saves 20% CO2 emissions.

target draws closer,” continued Roger.

Axion works in partnership with Cartakeback.co.uk and has hosted site visits by senior personnel from major European car manufacturers; demonstrating how the SWAPP facility is fulfilling a critical element of producer responsibility while contributing to automotive closed loop recycling.

The European End of Life Vehicles (ELV) Directive aims to reduce the amount of waste produced from vehicles when they are scrapped. Since 2006, the UK and all other EU member states have been expected to reach a national recycling and recovery target of 85%, rising to 95% in 2015.

Axion Polymers is part of the Axion Group that develops and operates innovative resource recovery and processing solutions for recycling waste materials.

The Group works with a wide range of clients within the recycling and process industries on the practical development of new processing and collection methods.

Axion Polymers Tel: +44 161 426 7731 Email: sales@axionpolymers.com Web: www.axionpolymers.com

GREEN ROOM SPOTLIGHT

BÜHLER’S TURNKEY SOLUTION FOR DECEUNINCK RIGID PVC RECYCLING

Plant and equipment technology specialist Bühler has co-ordinated and installed a turnkey optical sorting system for Deceuninck, a Belgian sustainable building products manufacturer. The system forms part of its new plastics recycling line which opened in October in Diksmuide, Belgium taking its annual recycling capacity to 20,000 tonnes.

With sales in more than 75 countries, as one of the top three European compounders and producers of PVC window systems and building products, Deceuninck recently acquired a PVC recycling line as part of its global strategic vision Building a sustainable home. The recycling line, which will process both postindustrial and postconsumer rigid

GRANULATION CAPACITY INCREASED AT REGAIN RECYCLING & PLASTICS

PVC waste, was installed adjacent to Deceuninck’s existing state of the art compounding factory. For Deceuninck recycling is simply another source of raw materials.

In order to meet its efficiency requirements, Deceuninck contacted Bühler in January 2012 to source the most appropriate sorting technology for the job. After initial consultation, Bühler’s optical sorting experts were able to supply and install the complete sorting solution including all equipment surrounding its SORTEX technology.

Bühler’s expert team worked with Deceuninck to undertake in-house trials and demonstrations to iden-tify the most appropriate solution to meet the company’s needs. Bühler’s engineers then oversaw the installation including the commissioning of its SORTEX Z+ bichromatic colour sorting machine and the auxiliary equipment required.

Bühler’s optical sorting technology will sort 2t/h (tonnes per hour) of mixed PVC 50% white and 50% colour into groups. The sorted product will be reused and transformed into new window systems and building products.

Alexander Proemer, business development manager at Bühler said: “Bühler’s optical sorting customers can now enjoy many benefits as a result of this turnkey offering. Our complete design, equipment, ma-terials handling, installation and aftersales customer care of plastics sorting solutions offers the ultimate in efficiency, competitiveness and accountability. The fewer the suppliers in a project; the easier the control of the project. Since we installed the Deceuninck

Following the commissioning of a Zerma 800 heavy-duty granulator at Regain Recycling and Plastics at Rainham in Essex, the company states capacity has been increased by up to 5,000 tonnes per annum.

With a nameplate capacity of circa 1,800 kg per hour and complete with air classification for dust removal, the new granulator provides increased opportunity for Regain Recycling and Plastics to access and recycle rigid plastic scrap arising in London and the South East.

Historically, scrap materials arising in this locality would have required transport to the Regain Polymers site at Castleford, West Yorkshire, something that the company states often proved uneconomical.

Installation of granulation capacity at Regain’s Rainham site will therefore facilitate delivery of

additional feedstock to its compounding business in Yorkshire.

Commenting on the increased granulation capacity, Mark Roberts, Technical Sales Director at Regain Polymers, said: “2012 continues to be a milestone year for Regain as investment in our businesses, as well as that in the industry generally, continues to gather momentum.

“The commissioning of this granulator at the Rainham site was the next step in our investment programme, as we seek to reduce cost and deliver process efficiencies across our plants. In addition to an overall capacity increase, this new installation allows us to size reduce cleaner feedstock more competitively at Rainham without the need to put such materials through the existing wash process.”

Due to changing market forces, the Association for Organics Recycling (AfOR) has recently merged with the Renewable Energy Association (REA) and is now known as the Organics Recycling Group, part of the REA. This merger will create an organisation of around 1,100 members. In addition to representing several hundred members directly involved in the bio-waste industry, (AfOR) has promoted and managed the certification of compostable packaging in the UK for several years.

All staff will remain in place and will be supported by a much larger office staff based at REA London Offices. Whilst the merger will directly benefit those

members involved in the bio-waste industry, it is also hoped it will bring benefits to the association’s compostable packaging clients.

REA Chairman, Martin Wright, commented: “I am absolutely delighted with this move, which will strengthen the REA’s position as the leading trade association representing the UK’s renewables industry.

“In particular, the scientific and technical expertise of the AfOR staff will greatly enhance REA’s advocacy on behalf of the organic waste-to-energy sector. It also makes strategic sense to house all organics certification activity under one roof.”

AfOR have cooperated with European certification bodies European Bioplastics, DIN Certco and Vincotte to manage promote and police the use of compostable packaging. AfOR now has a compostable packaging client base spanning several countries. AfOR was instrumental in helping deliver the

UK ASSOCIATIONS MERGE TO FORM NEW RECYCLING GROUP

plant we have already received enquiries from two prospects who have heard about the project - and who want us to replicate its success.”

Philippe Somers, Managing Director of Deceuninck Compound said: “Our investment in the Deceuninck plant will further enable us to offer a closed-loop solution; At the end their > 50 years of useful life our products are recycled into new sustainable window systems and building products. This investment also guarantees another source of raw materials. We are grateful to Bühler for its rapid response and development of an efficient, cost effective solution – which will increase the plant’s yield and operating profit.”

Buhler Sortex Ltd Tel: +44 20 7055 7777 Web: www.buhlersortex.com

Regain Tel: +44 1708 524100 Email: info@regainrecycling.com Web: www.regainrecycling.com

EPPM 33

waste recycling targets for the London Olympics. As an add value benefit, all compostable packaging clients are eligible to join a contact group set up with AfOR. This contact group disseminates relevant information received at the AfOR office to members.

In order to be certified as compostable and therefore able to display the coveted Seedling Logo products need to demonstrate compliance with the following criteria: biodegradability, disintegration, eco-toxicity and chemical analysis. To promote the production of high quality compost, AfOR developed the PAS100 specification for composted materials and the Compost Quality Protocol (CQP). All sites certified under PAS100 & CQP must only accept packaging materials labelled as compostable.

Organics Recycling Group Web: www.organics-recycling.org.uk

ADVERTISERS’ INDEX

EPPM CLASSIFIEDS PROCESSING EQUIPMENT

Company

Page

Abbey Masterbatch

12, 35

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RE-PROCESSING EQUIPMENT Cont’d

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34

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27

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24

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34

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23

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9

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16

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30

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ANCILLARIES, AUTOMATION & TESTING EQUIPMENT

For further information: T: +44 (0) 1789 206600 F: +44 (0) 1789 206651 E: sales@enquires.co.uk

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1, 18, 34

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EPPM 34

To advertise here please contact Tim Guest: Tel: +44 (0) 7581 398 723 Email: tim.guest@rapidnews.com USED MACHINERY

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Maschinenhandel Borowski Used plastic processing machines Injection moulding, blow moulding and accessories Tel. 0049-2173-8950790 Fax 8950799 www.mhborowski.de info@mhborowski.de

Over 35 Years of Service

1650mm Kaufman super-2 Sheet Line. 1983.

120mm cascade extruder. 1650mm wide Edi die. 1650mm kaufman 3 roll stack. Pump group Haul off and guillotine.

1300mm Battenfeld coextrusion sheet line; 2 x 90mm single screw extruders. 1300mm x 600mm 3 roll polishing stack+ haul, 2 station winder, 1995.

Tel: +44 (0) 1793 827666

4 component Ferlin gravimetric blender model FGB5-4 For up to 500kg/hr. Piovan hopper loaders.

Email: sales@transxl.co.uk

90mm Welex single screw extruder. 5 zone vented fan cooled barrel. 200hp dc motor.

150 rpm max screw speed. 115mm hydraulic screen changer.

Web: www.transxl.co.uk

45mm Kuhne single screw extruder model K45E 30D plugged vented. 20-204 rpm. 24kw dc motor.

1040mm Welex coextrusion sheet line, comprising 90mm and 63mm extruders, 1000mm wide die, 1040mm x 600mm stack, pumps, haul off, winder.

GRANULATORS

SHEET LINES

500mm Zerma model GSH-500/600 600mm Rapid GK640KU 660 x 350mm Cumberland model 6/84.

900mm Cumberland Model 4590

2400mm Cincinnati PVC Sheet line 2300mm Omipa Pmma Extrusion Line 1800mm Virginio Mai 3 layer coex line 1650mm Kaufman Sheet line

EXTRUDERS

1500mm Bandera 3 roll stack 1350mm Welex/ Union line 890mm Welex Coextrusion Welex World Standard sheet Line. 90mm Extruder. Circa 50mm Co-extruder. Gear Pump 900mm Die. 890mm Welex Stack winder. 1998.

1850mm Battenfeld Gloenco PP PE Cast Film Line: 120mm+60mm extruders, feedblock. 1650mm Cloeren auto die, 1850mm Chill roll, haul off, winder. 1993.

890mm Welex World Standard sheet Line.

90mm Extruder. Gear Pump 900mm Die. 890mm Welex Stack winder. 1997.

6 colour Omso DM144 lid printer

70mm Battenfeld-kuhne Extruder, Electrically Heated Air Cooled 5 Zone, Plug Vented Barrel. Screen Changer.

1550mm Battenfeld Heidelberg PVC calender line. ZSE 170mm planetary extruder, 1550mm x 550mm 3 roll calender, haul off winder. 80-800 micron - 600kg/hr 1988.

500mm wide Illig RDM 50/3 lid thermoformer, Double heaters, Motor Indexing. Auto Rail Spreading, Counter/ Stacker, 1982 very good condition.

1700mm Bandera Virginio Mai PMMA ABS sheet extrusion line. 80mm extruder, 1600mm Simplas die, 2-7mm thickness. Complete line 1987.

1350mm Welex 3 roll stack 1300mm Battenfeld coextrusion sheet line.

1040mm Welex Coex sheet line.

1040mm Welex 3 roll stack 1000mm Esde 3 roll Stack 1000mm OMV co ex sheet line 890mm Welex Pet sheet line

THERMOFORMING 1016mm (40”x 60”) Lyle thermoformer

4.5” Welex single screw extruder. 30D vented., static mixer, gear pump. 2003.

540mm Kiefel KL2EH vacuum former 500mm Illig RDM 50/3 Lid Thermoformer

1000mm Omv Coextrusion Sheet Line.

120mm Omv Extruder, 60mm Coextruder, Melt Pump, 1000mm X 500mm Roll Stack, Haul Off, Winder.

DIES

605mm Kiefel KL2 SH Thermoformer, 1040mm Welex sheet extrusion line: 90mm Welex extruder with gear pump, die head, 1040mm wide Welex 3 roll polishing stack, haul off and winder.

120mm Union extruder.

120mm Kaufman Super 2 extruder 115mm Hartig Extruder, 30d 90mm Welex single screw extruder 80mm Cincinnati Titan twin screw 90mm John Brown Egan single screw extruder 70mm Battenfeld-kuhne Extruder 60mm Cincinnati coextruder 50mm Welex co extruder. 25:1 l/d ratio.

50mm Betol extruder 25:1d 45mm Kuhne model K45E 30D

40”x 60” Lyle model 240 FM thermoformer, servo drive chain index. 1997.

980mm EDI model Ultraflex HR75 915mm EDI flex lip sheet die 500mm Masterflex flex lip cast film die 1987

600mm Rapid Model Gk640 KU granulator 600 x 300mm opening.

6 Colour Omso DM 144 lid printer. UV curing.

Up to 8000 lids per hour. In feed, and stacker.

Maximum lid height - 25mm. 1997.

900 X 450mm Cumberland Model 4590.

Soundproofed Granulator, Nip Roll Infeed 1997.

TRANSXL INTERNATIONAL THORNHILL SOUTH MARSTON SWINDON WILTSHIRE SN3 4TA ENGLAND MORE MACHINERY, MORE PHOTOS ON THE WEB: www.transxl.co.uk

EPPM 35