EPPM 16.4

June 2014

Carbon nanotubes a commercial reality? page 33

Made in China: Chinaplas offers more diversity than ever page 11

Time to close the loop in dry cooling page 19

Turning CO2 into mattress foam page 29

The 'pull and push' of global thermoforming page 14

Overheating smartphones a thing of the past? page 26

The new ENGEL CC300

instant control at your fingertips

The more complex a machine becomes the smarter the control must be. The intelligent new ENGEL CC300 gives you full command of your production unit. The key to the CC300 is the e-move control which puts all of the machine’s and robot’s movements in the palm of your hand. Experience instant, exact and safe operation.

Discover the new ENGEL CC300.

ENGEL U.K. Ltd. | Apollo Way | Tachbrook Park | Warwick CV34 6RW | Tel. +44 19 26 33 50 00 Fax +44 19 26 33 66 77 | sales.uk@engel.at | www.engelglobal.com/CC-300

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“

FROM THE EDITOR

All-plastic cars Google takes us one step closer Google announced recently that it is testing prototypes for its ‘driverless car’.

Early images and impressions of the vehicle show a toy-town style motor, designed with a ‘face’ which Google claims makes the vehicle more friendly to look at.

According to gadget magazine Extremetech, the prototypes are “mostly of plastic construction” and are limited to 25mph. Aside from that, very little is known about the design. If the prototype is mostly plastic, will the end-project follow the same path? An allplastic body is fine for a prototype vehicle with a speed limit of 25mph. But is composites technology advanced enough (and scalable) to mass produce safe plastic cars - driverless or otherwise?

Well, the answer is, almost.

What’s the most important part of a car? Arguably the engine, but for the sake of argument, let’s go back to basics and imagine that it’s actually the wheels. Much work has been done in recent years on the development of composite wheel technology. And now, Sabic, in conjunction with Kringlan Composites, has designed a composite material which apparently works as a replacement for metal alloys. Read more on this in the composites feature in this issue.

4 • WWW.EPPM.COM • JUNE 2014

So yes, in the years it will take for Google to develop a commercially-viable platform for manufacturing and introducing driverless cars to the road, composite technology certainly has the potential to replace metal.

But therein lies the key problem. The technology we know is already virtually there. The issue is with affordability, practicality and commercial scales. And so, work is being done in this area too.

Across Europe, composites are receiving greater interest and - though perhaps not enough - more funding than ever before. While a portion of this goes into developing the technology, much of it is going towards investigating processes and platforms for manufacturing with composites in realworld terms.

The latest example of this is technology firm OCSiAl, which has cracked a new platform for manufacturing single-walled carbon nanotubes at commercial scales - and commercial prices. The full impact of this is still unknown, but it certainly starts to bridge the gap between an extremely high-tech, single-run composite technology, and the mass production of metal-replacement parts.

David Gray, Editor

News

INDUSTRY Albis to distribute Bayer products in the Maghreb region Albis Plastic, a distributor and compounder of technical thermoplastics located in Hamburg, has expanded its partnership with Bayer International to include a distribution agreement for the countries of Tunisia, Algeria and Morocco.

Under the agreement, Albis will begin marketing Makrolon-brand polycarbonates as well as Bayblendbrand PC/ABS blends, effective immediately.

Olga Baburina, Albis Plastic’s Vice President of Distribution, said: “Expanding our distribution rights to include the Maghreb not only expands our product portfolio in the region, but also deepens our longstanding and successful partnership with Bayer.”

Albis says it will offer Maghreb customers on-site technical consultation and ensure the best possible logistical services for Bayer Material Science's technical polymers.

The affiliated Tunisian logistics center will be directly responsible for handling deliveries to, and inventory storage for, the countries of Tunisia, Morocco, and Algeria.

Albis Web: www.albis.com

Renault Twizy door assembly slams the competition at Antec The Society of Plastics Engineers (SPE) has announced that a rear door assembly developed

by Walter Pack Group for the Renault Twizy electric car is the winner of the Grand Prize in its Global Parts Competition. The announcement was made during Antec 2014, which took place April 28-May 1 in Las Vegas.

The annual Antec is the world’s largest plastics technical conference, consisting entirely of original, peer-reviewed presentations on a variety of topics relevant to today’s global plastics industry. Antec 2015 will be co-located with the NPE 2015 exhibition in Orlando, Florida, and will take place on March 23-27.

NPE 2015 Web: www.npe.org

Rapidly expanding mouldmaker acquires ERMO

INglass, a specialist in automotive lighting moulds, has announced that it has acquired ERMO, a French company specialised in the production of highprecision multi-cavity moulds. The deal is expected to close in June.

The group says that the move puts INglass in a position to meet the requirements of all high demanding sectors in plastic moulding, ranging from automotive lighting to personal care, as well as cosmetics, medical and closures.

INglass says that ERMO stands to benefit from the global presence of INglass, which has a presence in over 50 countries, with local branches and production plants in Italy and China, and a third opening soon in the US. ERMO was founded in 1979 by the firm’s current Chairman and shareholder, Mr Jean Yves Picherau.

From the outset, it has concentrated its business on multi-cavity and multi-component moulds for applications that require large production volumes and low part weights.

Today the company operates in Europe with five production plants located in France and Poland.

Mr Pichereau said: “INglass’s global presence and its strong innovative spirit will enable us to offer technologically advanced products related to the high

expertise of these two companies in the whole world, especially in those countries where the demand is increasing”.

Under the transaction terms and subject to certain suspensive conditions, INglass s.p.a. will acquire 100% stock of AURCA, the holding company which owns approximately 83.25% of ERMO, together with a further portion of shares in ERMO equal to 11.7%.

Following the acquisition of the majority share, in accordance with current legislation, INglass will launch a tender offer to acquire the remaining capital of ERMO aimed at the company delisting.

The two firms will represent a group of 800 employees and are projecting an expected turnover of €110m in 2014.

Mr Maurizio Bazzo, President and Founder of the INglass group said: “Over the following years, this decision will allow the company to choose and focus its resources in a niche of high precision moulds, retracing the path taken by INglass for rotating multicolour and multi-component moulds for the automotive lighting field. ERMO, in particular, was chosen due to its excellent knowledge and the high reliability of its products, as well as the innovative spirit that we have in common”.

DuPont wins Teflon infringement case against Italian firm DuPont Chemicals & Fluoroproducts (DC&F) has announced that it has won a Teflon patent and trademark infringement case against Italian cookware and home appliances company Bialetti Industrie S.p.A. On 12th March 2014, the Court of First Instance of Milan (Italy) issued a decision in favour of DuPont. The Court found Bialetti had infringed the Teflon trademark and/or the Italian part of DuPont European patent EP 1 1016 466 B2, protecting the DuPont Teflon Platinum nonstick coating technology, and was in breach of the Teflon Trademark License Agreement signed with DuPont in 2001.

The Court awarded DuPont monetary damages and reimbursement of legal and expert fees totalling about €540,000 and ordered publication of the Court’s decision in Corriere della Sera, a leading Italian daily newspaper. The Court also granted injunctions prohibiting further infringement and rejected all Bialetti counter claims against the validity of the related patent and trademark. Bialetti was also ordered to withdraw

6 • WWW.EPPM.COM • JUNE 2014

and destroy all pans that infringe the Italian portion of EP 1 1016 466 as well as to destroy all labels, packaging, products and brochures that infringe the same patent, the trademark Teflon and that are in breach of the Teflon Trademark License Agreement. The decision is subject to appeal.

Marcel Vandennoort, Director DC&F Europe, Middle East, Africa (EMEA) at DuPont de Nemours International in Geneva, Switzerland, said: “The court case against Bialetti is a demonstration of DuPont’s commitment to protect its brands from misuse.

This decision gives us confidence in pursuing other incidents, amongst which is a similar case of trademark infringement brought by DuPont against CEM Bialetti, a fully owned subsidiary of Bialetti, whose case is currently pending before the Turkish Courts in Istanbul.”

DuPont Web: www.dupont.com

News

INDUSTRY Announcement: Dr. Dieter Freitag developed the specialty polycarbonate APEC HT, a material that is extremely resistant to heat and widely used in automotive lighting and medical equipment.

Dr. Freitag began his professional career in 1967 with Bayer AG, where he worked for over 30 years in the research and development of innovative polymer technologies. Dr. Freitag served in a variety of functions with increasing levels of responsibility during his time at Bayer, eventually becoming Head of Thermoplastics Research. He was later promoted to Head of Research and Development at the Plastics Business

Group and ultimately was appointed Head of Material Research at Bayer Central Research.

After leaving Bayer AG in 2001, Dr. Freitag joined Triton Systems, where as Chief Technology Officer he was responsible for polymer technologies.

Dr. Freitag received numerous honors in Germany and abroad for his important achievements and contributions to the growth and success of the plastics industry, including the Otto Bayer Medal, the Hermann F. Mark Medal of the Austrian Ministry of Research for accomplishments in the field of engineering plastics in general and in the area of polycarbonates

in particular, as well as an honorary doctorate from the Russian Academy of Sciences for outstanding work in polymer sciences and chemical engineering. He also was named a member of Italy’s Accademia dei Georgofili for his achievements in the field of environmentally friendly chemistry. In 2006, Dr. Freitag was inducted into the Plastics Academy Hall of Fame.

His contribution to the development of the compact disc and its rise to global dominance is recounted in the research book The Inventor Company, which the Bayer Group published last year in celebration of its 150th anniversary.

Dr. Dieter Freitag, a well-known polymer scientist and researcher, who played a key role in the development and commercialisation of the compact disc (and many other important innovations) has passed away at the age of 74.

Dr Freitag spent over 30 years of his career working for Bayer AG. “Dr. Freitag’s research resulted in breakthroughs that made possible many of the modern applications we take for granted today. He was a driving force in the development of the plastics industry,” said Dr. Markus Steilemann, Head of the Polycarbonates Business Unit and member of the Executive Committee of Bayer MaterialScience.

Dr. Freitag held or jointly held more than 400 patents (including many in the United States) that resulted in the development of new products in the field of engineering thermoplastics. These include the compact disc (CD) and multiwall plastic sheets, which are now used in greenhouses around the world. He also

Nordmann Rassmann wins PVC stabiliser contract Nordmann Rassmann has been named the exclusive distributor for PMC Organometallix's heat stabilisers and highperformance lubricants for the PVC industry.

Thermolite and Advastab heat stabilisers are suitable for the production of rigid, semi-rigid, foamed and soft PVC materials.

PMC Organometallix developed these PVC heat stabilisers for extruded vinyl siding, profiles and pipes, injection moulding, blow moulded bottles and sheets.

Stabilisers for PVC drinking water pipes and fittings - authorised by the National Science Foundation (NSF) - are also included in the range.

In addition, PMC Organometallix supplies a broad selection of high-performance lubricants for PVC manufacture. The Advalube and Advawax product series include all types of lubricant, from esters and amides to paraffin waxes. Advalube and Advawax find application in PVC piping, siding, window profiles, vinyl foils, sheets and injection moulding as well as for fence-building, floor-laying and trimming.

NRC is distributing these heat stabilisers and specialty lubricants for the PVC industry throughout Germany, Austria and Switzerland.

Nordmann Rassmann Web: www.nordmann-rassmann.com JUNE 2014 • WWW.EPPM.COM • 7

News

INDUSTRY Blow moulding sector struggling against new competing formats 100

Figure 1: Penetration of plastic blow moulded bottles per application (based on litres)

0

Industrial Chemicals

20

Pharmaceuticals

40

Tolietries & Cosmetics

60

Household Chemicals

80

Solid Food

to increasing sales of dairy-based drinks as well as new technical advancements in barrier bottle technology for UHT milk bottles.

Household chemicals are a maturing field of application and shelf differentiation is a key driver for packaging innovation. Design innovation focuses on consumer convenience and accurate dosing.

Drivers in toiletries and

Liquid Food

thirds of the market demand in units. The growth trends differ depending on both the drinks category and the geography, but the overriding trend within the beverages market in Europe is toward 'healthier options'. The demand for blow moulded beverage bottles in Europe is fuelled by continued substitution of glass bottles, cartons and cans. Moreover, consumers tend to make more impulse purchases whist on-the-go, which drives additional demand.

Liquid food is benefiting from a growing penetration of plastic bottles at the expense of cartons in white milk both in the fresh and UHT sectors. This is thanks

Beverages

A new report from industry group AMI Consulting finds that the blow moulding sector for bottle packaging is being damaged by competing formats, such as pouches and thermoformed or moulded containers.

Moreover, more concentrated product formulations as well as ‘value’ sized bottles adversely influence the frequency of purchases, the report finds. Given the high plastic penetration already achieved in that segment, AMI says that the growth in bottle demand is expected to stagnate.

Blow moulded plastic bottles is a market of nearly 4.5 million tonnes magnitude in Europe. Beverages accounted for two-

50% 42% 18% 95% 79% 29% 98% ©AMI Consulting, May 2014

cosmetics packaging are similar, but this market is still generating organic growth across Europe. Mini-bottles have witnessed accelerated growth in demand following airline hand-luggage restrictions. This format is also used for liquid make-up products, which are experiencing a packaging shift from glass to plastic.

AMI says that it's imperative for blow moulders to align with winning brandowners and fillers in order to prosper.

AMI Consulting Web: www.amiplastics.com

Addivant completes first phase of Gulf JV expansion Addivant has announced the completion of the first phase of capacity expansions at Gulf Stabilizers Industries.

Now that it’s completed, the production capacity of hindered phenolic antioxidants, ANOX 20, ANOX PP18 and phosphite antioxidant ALKANOX 240 will double to 10,500 metric tonnes.

The joint venture between Addivant and Zamil ChemPlast also announced that plans are under way to expand production capacity of the ANOX NDB product line to 24,000 metric tonnes per annum to meet growing customer demand for a range of new, higher performing products.

Peter Smith CEO and GSI chairman of Addivant said: “The rapid expansion of the Middle East polymer industry over the past two decades has been impressive and it will continue in the years ahead.”

Smith added: “With our breadth of specialty additives and formulation capabilities, we will continue to support our customers in the growth of applications in the automotive, packaging, agriculture, building and construction, and medical markets”.

Adel Alghassab, Zamil ChemPlast President and GSI Board Member said “By investing in additional capacity and new technology, we are confirming our long term commitment to growth in this sector and support for our local customers in terms of supply and technical innovation.”

Alghassab added: “ALKANOX 240, ANOX 20 and ANOX PP18 represent key building blocks of our ANOX NDB blended products, which are today’s preferred additive solution for customers in the region.”

Addivant Web: www.addivant.com 8 • WWW.EPPM.COM • JUNE 2014

Events

INDUSTRY Live demonstrations take the stage at FIP FIP Solution Plastique, taking place in Lyon, France in June, now has over 700 confirmed exhibitors and the organiser is placing special emphasis on encouraging firms to give live demonstrations of their products.

This year FIP will also branch out from the plastic industry, and will include rubber as a key exhibition area. FIP states that as plastics and elastomers are very close to the rubber and composites industries, it is natural to have the two industries exhibiting together.

The “innovation forum” will give businesses a chance to give short presentations about their products in an open space. The Techno Lab is a space where visitors can come and see the products in action so they can see the

main types of processing technologies, including: injection, extrusion, blow moulding, rotational moulding and thermoforming. This area is mainly for new innovative products and for visitors to see new areas in plastics emerging.

The exhibition is for every sector of the industry, from material to moulds and from design to machinery.

Since the last edition, FIP has grown by over 20%. FIP expects over 8,000 visitors over the four days. The show

will be held at the same time as France’s additive manufacturing show.

FIP Web: www.f-i-p.com

PMMDA flying the flag for British Plastics Show

British plastics event Interplas has announced its partnership with supporting organisation PMMDA. PMMDA's involvement in what is fast becoming the 'must attend' plastics show of 2014 reaffirms why Interplas is the unmissable event of the year and why it is relevant to the entire industry.

Organisers Rapid News Communications Group welcomes PMMDA's

endorsement, flying the flag for British plastics at the triennial event, which this year features an outstanding line-up of top flight speakers and a buzzing show floor of more than 400 exhibitors from September 30th-October 2nd at the NEC in Birmingham.

Originally formed in 1996 from eight founder companies in polymer machinery manufacturing and distribution, PMMDA's mission is to set the standards of UK manufacturers and distributors of foreign machinery.

The group has grown to more than 30 members in polymers, plastics and related technologies and continues to provide a mark of superior quality, with members fulfilling criteria proving their authority in the marketplace and working together to develop EU and ISO

standards for the entire sector. It is this indicator of excellence that makes PMMDA's endorsement of Interplas so significant.

Nigel Flowers, PMMDA Chairman, commented: "PMMDA is the Trade Association for machinery manufacturers and distributors within the Polymer Industry in the UK. Member companies carry the stamp of approval for sales, service and spares, and are pleased to be supporting Interplas 2014. Our members are confident that over the last 50 years Interplas has fully established itself in the UK, offering plastics industry professionals the opportunity to view and compare the widest range of machinery in action, covering every aspect of plastics manufacturing equipment."

Duncan Wood, COO and Event Director, Rapid News Communications, added:

"We are delighted once again to have the support of the PMMDA and its members for Interplas this year. To date we have 26 member companies confirmed on the expanded 2014 floorplan and we hope to add additional members in due course.

The PMMDA's support for the event is indicative of the strength of a resurgent Interplas and reaffirms the event as the leading event for the UK plastics industry.

We look forward to a fruitful partnership in the run up to September and beyond.

Interplas 2014 takes place at the NEC, Birmingham, UK, on September 30thOctober 2nd 2014. Visitors can register for free at www.interplasuk.com/register.html.

Interplas Web: www.interplasuk.com

Conference launched to harness ‘a passion for PET’ In advance of the Brau Beviale packaging trade show in Germany, industry body PETnology will present its first ‘PET Passion Week’. The week will be opened during the group’s 17th PETnology conference.

PETnology says that the goal of PET Passion Week is “to bundle, to exchange and to communicate expert knowledge”.

The industry meeting is aimed at all suppliers and customers along the PET value chain, ranging from material and additive production over the different machine technologies for preforms and bottles, labels and caps, decorating and filling, all the way to recycling.

As well as presentations, the event will host interactive workshops specifically designed for end-users, as well as corporate sessions with a focus on strategy.

PETnology Web: www.petnology.com

JUNE 2014 • WWW.EPPM.COM • 9

Review

CHINAPLAS

CHINA China is proving to be far more than the misconceived “commodities market” that it is too often labelled. And visitors to Chinaplas 2014 bore witness to a host of technologies, originating from both East and West, who would testify to the increasing diversity of processing requirements for China’s domestic market.

Asia’s largest plastics and rubber fair took place in Shanghai on 23-26 April, pulling in 130,370 visitors during the 4day show, up by 14.26% compared with last year’s show in Guangzhou. It also sets a new record since its debut in 1983. With the exhibition becoming increasingly international, the number of overseas visitors rose by 19.73% to 36,841, which accounts for 28.26% of total visitors.

Helmut Heinson, Managing Director, Arburg, said of the event: “We are experiencing a growing demand for highly sophisticated plastics and injection moulding applications in China.

For this reason, Chinaplas presents a perfect platform for us to present our products, knowledge, and know-how in this field. Chinaplas has developed into the second largest plastics show in the world and therefore it is an ideal venue to present the high technology state that we are in.”

Ada Leung, Assistant General Manager at Adsale Exhibition Services Ltd., the organiser of Chinaplas, said: “We are happy with the results of the show and have received very positive feedback from both our exhibitors and visitors. The continuous rise of overseas visitors reflects our show is gaining recognition from around the world, as an effective platform for industrial sourcing and for getting the latest information on market trends and technology. Furthermore, many cost-effective solutions can be found at the show with the large participation of the Chinese and Asian

10 • WWW.EPPM.COM • JUNE 2014

MORE DIVERSITY THAN EVER BEFORE

“ ”

This year, over 3,000 exhibitors from 39 countries and regions participated, of which over 400 are new to the show.

exhibitors in addition to the Europeans.

What they see, find and get from Chinaplas can support the changing needs of their business and enable them to stay competitive.”

Chinaplas also saw new records in terms of size and exhibitor numbers. This year, over 3,000 exhibitors from 39 countries and regions participated, of which over 400 are new to the show. In addition to occupying all 17 exhibition halls in the

Shanghai New International Expo Center (SNIEC), 13 additional outdoor halls and 6 exhibition suites were also set up at the Central Square of SNIEC to cope with the demand for space.

Ms Leung said: “The buoyant plastics market together with its burgeoning downstream and end-user sectors in automotive, telecommunications, home appliances, packaging, etcetera in China have a major part to play too”.

Giorgio Santella, Chief Marketing Officer at auxiliary equipment supplier Piovan said: “The show gave a very good result with lots of visitors, lots of interesting meetings with the customers at our booth. That's the indication that Chinaplas really becomes a global show with the exposure in all markets. Our expectations were very much met and we believe that Chinaplas will be growing in the years to come.”

Review

CHINAPLAS

Two featured events – “The City of Tomorrow” and “The Green Conference” were organised to promote the adoption of sustainability within the industry. The City of Tomorrow, an outdoor display, featured various interactive exhibits ranging from green applications, ecofriendly products to energy-saving machinery and best practice, etc. At the Green Conference, speakers from around the world shared insights on 3D printing, plastics recycling, and various solutions for end-of-life plastic wastes.

Ashok Jajodia, Managing Director, Cosmo Plastics PVT. Ltd from India said: “I find the show makes progress in terms of size, exhibitors and arrangement every year. Chinaplas is no longer an exhibition for the China market, but has become an important international event in plastics and rubber industries. Overseas exhibitors target not only China but major international markets like India, Turkey, the Middle East, Australia, etcetera.”

The visitor survey reveals that increased wages and high operation costs were the most difficult challenges faced by overseas visitors. Finding the costeffective alternatives was the key driver behind most international visits.

Tiago Wietholter, Purchasing Manager, Artecola Quimica from Belgium, said: “I can find more cost-effective alternatives, new and different products from

suppliers in particular from Asia for our product development. It is very difficult to find alternatives at competitive prices in Europe but Chinaplas provides us this opportunity.”

In contrast, for many Chinese visitors, finding new technologies and products to suit growing needs for innovation was the main drive for the visit.

Ms. Leung said: “Local manufacturers are keen to upgrade their technology in order to counter the stiff competition from increased foreign investment. It therefore creates a pressing demand for the high-end technology and innovative materials that Chinaplas has offered”.

She added: “Global plastics machine players such as Milacron, Engel, Sumitomo Demag, Nissei Plastic and KraussMaffei have unveiled their factory expansion plans in China at Chinaplas.

Apart from a strong export market, there is plenty of room for the domestic market to thrive. In China, per capita consumption of plastics is 45 kg whereas the USA reaches 145 kg. The gap implies a huge potential for China’s market to continue to grow”.

The 29th edition of Chinaplas will be held on 20-23 May, 2015 at the China Import and Export Fair Complex, Guangzhou, PR China.

Chinaplas Web: www.chinaplasonline.com

JUNE 2014 • WWW.EPPM.COM • 11

Review

CHINAPLAS

Davis-Standard presents pre-stretch line in China Extrusion specialist Davis-Standard displayed its recently-launched dsX stretch inline pre-stretch line at Chinaplas.

Speaking during the pre-show press conference in Shanghai, Jim Murphy, VP of Global Sales and Marketing said: “At Chinaplas 2014 we're introducing to the Asian market our dsX stretch line. It's a cast film line specifically focussed on the film market. It's a high speed line capable of producing 8 micron film at up to 750 meters per minute. In addition to this, we have a unique winder with the ability to wind ‘coreless’, without a core in the winder, and also has a pre-stretch capability.”

Davis-Standard says that the system allows manufacturers to run thinner films at higher speeds.

The two-meter wide version also has the benefit of a small footprint, says the group.

Davis-Standard Web: www.davis-standard.com

Solvay launches two new solar film grades Solvay Specialty Polymers launched two new film grades specifically designed for the solar market at Chinaplas 2014.

The new PV and UV grades of the company's Halar ethylene chlorotrifluoroethylene (ECTFE) are intended for front sheet applications for photovoltaic modules and expand Solvay's solar offering in the field.

“With our broad product portfolio we are firmly positioned as a strategic supplier to the global PV market and this new launch signals our further commitment to the industry,” said Phillippe-Jacques Leng, Global Marketing Manager for Film at Solvay Specialty Polymers. “We believe this is a highly sustainable market that requires specially designed materials to meet the PV industry's high-performance needs.”

The first of the two grades is a semi-crystalline, meltprocessable fluoropolymer resin that can be extruded into a highly transparent film with a reported light transmission of over 90%. It is said to provide an excellent water vapour barrier in a wide range of temperatures and offers a strong resistance to chemicals, excellent fire retardant properties and long-

term weatherability, with Solvay stating it is capable of more than 20 years exposure to direct sunlight.

It is said to be a “highly viable alternative” to competing materials such as glass and other fluorinated polymers, with Solvay saying it offers greater fire resistance, higher tensile modulus and lower density than its direct competitors.

In addition to the Halar PV grade, Solvay has also launched new Halar UV blocking technology, which it claims is the only solution of its kind in the industry. The new product offers the same properties as Halar PV, but also employs patented technology which the company says delivers long-lasting UV blocking performance to meet the solar industry's 25-year performance life requirements for PV modules.

Solvay's first partner in developing PV front sheet technology, Amcor Flexibles, is launching films based on the new Halar ECFTE technology for the PV front sheet market, available up to 1.5m wide and 20 microns thick.

Husky launches two new products for injection moulders at Chinaplas

technology with improved gate quality, balance, ease of use and maintainability.”

The Matrix2 controller is said to provide additional functionality to other controllers in Husky's range, as well as offering an integrated and intelligent platform for two to 254 zones of control for improved part quality and increased uptime.

“The introduction of Matrix2 to Husky's Altanium family of controllers allows us to provide premium performance and functionality over our competitors,” commented Matthew Cummings, Husky's Product Manager for Altanium. “Maxtrix2 is designed with a new intelligent feature set, which makes it smarter and more intuitive than other controllers on the market. This enables a more customised moulding solution and helps customers achieve the most consistent, repeatable and accurate temperature control possible, regardless of their moulding needs.”

The Unify Manifold Systems technology is said to provide a simple, one-step installation of a hot runner manifold into a mould without the need to pre-heat the system. This, says Husky, provides a saving on installation time of up to 70%. The Unify system is said to allow for simple hot runner maintenance, therefore reducing downtime. It also benefits from Husky sealing technology for continuous leak-proof operation.

“We are very excited to introduce the Unify Manifold Systems to our customers in Asia Pacific. With this new technology, we are responding to our customers' need for a hot runner with the easiest possible installation,” explained Chiaia.

Engel discussed its newly founded 100%-owned subsidiary Wintec during Chinaplas. The group confirmed that Wintec will manufacture injection moulding machines aimed at high-commodity, standard applications.

Speaking at the Chinaplas pre-show press event, Peter Neumann, CEO Engel Austria said: “There is still a huge market for standard sized solutions, especially here in Asia. Therefore we have created a new line of machines; Chinaplas is the introduction for Wintec.”

The first machines are slated to be produced in the summer.

Amongst the machines will be a range called the t-win series, which, the group claims, have the same quality as an Engel build, but with a lower specification.

Features include a fast locking mechanism and opening and closing movements, as well as a 26% improvement in total cost of ownership against comparable machines. The series also uses Engel's servo-drive technology, resulting in a reported potential for 61% energy savings over similar machines.

The firm will operate from a new production plant in Changzhou. Whilst the target market is China itself, Engel says Wintec will also target customers in Asia, Korea, Taiwan and India.

“Our goal for Wintec is to appeal to processors looking for relatively standardised machines with a limited range of options. This strategic decision allows us to open up a new target group for Engel and strengthen our foothold in Asia at the same time”, said Neumann.

Wintec CEO Peter Auinger added: “The requirements of Asian commodity manufacturers for energy efficiency, precision as well as supplier services have increased sharply over the past years. With Wintec we are in an excellent position to achieve this.”

Husky Injection Moulding Systems Web: www.husky.co

Engel Web: www.engelglobal.com

Husky Injection Moulding Systems has introduced two new products to its hot runners and controllers portfolio, which it launched to market at Chinaplas 2014.

The new Altanium Matrix2 temperature controller and Unify Manifold Systems technology are to be “innovative products and services” that Husky has developed as part of a strategic drive to solve “key challenges” facing injection moulders.

“Our new Unify Manifold Systems and Matrix2 hot runner controller continue to prove that we are world leaders in the industry by continually driving innovation,” said Gerardo Chiaia, Husky's President of Hot Runners. “Customers continue to benefit from our 12 • WWW.EPPM.COM • JUNE 2014

Solvay Web: www.solvay.com

Engel launches 'commodity brand' Wintec

Review

CHINAPLAS Chinaplas responds positively to Chinese environmental policy Jinhui Zhaolong, a plastic division of China's Jinhui energy firm discussed its first ever appearance at Chinaplas. The group placed a strong emphasis on green technologies, as part of the over-arching theme of ‘greenovation’, which dominated at this year's show.

The group says that pollution and ecological damage may have cost as much as CNY200 billion per year.

“The cost of disposing of waste plastics is five times that of production costs” said a spokesperson for the group. “We need to ask ourselves, what kind of environment should we leave for our children - landfill or greenfield? There are two ways in China to handle garbage - combustion or landfill. Neither is an ideal solution. Burning waste plastics produces large quantities of toxic gas, causing secondary pollution.

The additives from degradation further pollute soil and water. We need to stop the pollution at the source.”

To that end, the firm has developed a new high-barrier film which uses carbon dioxide copolymer as the major component. Jinhui Zhaolong believes that production of the film will bring to market a high-barrier and degradable composite based on polypropylene carbonate, which can be used as a modified insulation material.

Thermal and mechanical properties and barrier function are improved over conventional EVOH, and the material could reduce costs by two thirds whilst maintaining oxygen resistance, claims the group.

Other properties include non-toxicity and flameresistance. Target applications include medium- and long-term storage of food, drugs, chemicals and precision instruments. Further development of the synthetic catalytic technology will continue in order to add further uses for the material.

In the biopolymers field, Jinhui Zhaolong was the first company in China to produce polyalcohol from bio-

glycerol using advanced processing technologies.

“The technology has a great significance for carbon emission reduction. In theory, the consumption of one tonne of bio-propylene, which is an important material widely used as a chemical intermediate containing three carbon atoms from the atmosphere is equal to consuming 1.157 tonnes of carbon dioxide,” said Professor Wu Jialin from Donghua University. The product is currently used internationally in the household, chemical and food industries.

The Biotech Industry Development Plan, published by the State Council of China in 2013, sets the goal of producing major bio-based products from non-food raw materials, and stipulates the objective of building up million-tonne annual outputs of bio-based materials, as well as ten million-tonne production capacity of biobased finished products.

Ms Li Yajuan, Vice President of the Jinhui Group said: “Planning into the future, we have drawn up a detailed development blueprint to meet market demands stipulated by the sustained economic growth and urbanisation in China. We aim for the healthy development of the industry, by the means of increasing investments in capacity expansion, technology, service, cultivation and infrastructure construction, and working closely with our customers and partners to create sustainable solutions.”

The group also displayed its 'Ecoworld' PBAT biodegradeable compostable film material during the show. PBAT is a terpolymer made of 1, 4-butanediol adipic acid and terephthalic acid. The film features 120% tear-resistance and 130% impact strength compared with polyethylene, as a result of its benzene ring, says the group. Applications for the film in China include agricultural mulch film, bin liners, cling film, compostable plastic bags and disposable food

packaging products, including food storage boxes, and cups.

Jinhui Zhaolong says it can be decomposed into carbon dioxide and water within 180 days by microorganisms under compostable conditions (defined as conditions which allow biodegradation by microorganisms and absorption of organic substances).

Production of the film is carried out using a 'one-step' polymerisation process. The technology also makes gains in film-forming properties, ageing resitance and safety, claims the group. The material meets the EU bioplastics standard EN13432.

JUNE 2014 • WWW.EPPM.COM • 13

Thermoforming

INDUSTRY FOCUS

GLOBAL THERMOFORMING Words by Conor Carlin, Editor of Thermoforming Quarterly, and International Sales Manager, CMT Materials

The thermoforming industry is traditionally defined by its two processing segments: thin-gauge (roll-fed) and heavy-gauge (sheetfed). This simple definition based on sheet thickness, however, is no longer sufficient to describe a process that is used in a very wide spectrum of applications.

Much of thin-gauge thermoforming is bound up in food packaging where consumer demands and the brand equity of global companies pull innovation from package designers, material scientists and equipment suppliers. From North America to Southeast Asia, thin wall packaging is an important driver of growth. In heavy gauge thermoforming, there is a very large variety of materials that must be processed (10-15x more than thin gauge) so machinery must be able to process all material types.

While the automotive sector continues to extract innovation from the heavy-gauge thermoforming ecosystem (resin suppliers, material suppliers, converters, OEMs), the medical, building materials and logistics sectors also contribute to the increased adoption of thermoformed solutions.

Several recent market studies suggest year-on-year growth rates of between 24% for the industry in aggregate, while deeper analysis shows broad variation in growth rates among discrete market segments. For example, the food packaging sector shows higher rates of growth than retail packaging while the medical sector (both thin-gauge and heavy-gauge) shows higher profit margins than the appliance or marine sectors. Moreover, a newly-released study from BCC Research suggests 14 • WWW.EPPM.COM • JUNE 2014

thermoformed electronics packaging is a fast-growing sub-segment with a CAGR of 4.9% through 2019.

Let’s look at thermoforming from two different perspectives: the ‘pull’ of market demands and the ‘push’ of industry suppliers (machinery, tooling and materials).

Thin-Gauge Thermoforming Because it is widely viewed as the largest market segment by material processed (~7bn lbs in 2012) and by revenues generated ($12.8bn in 2012), thin-gauge

thermoforming for packaging is a good place to start discussing broad trends.

And while these numbers are for North America only, similar research suggests that the sector (which includes dairy and beverage) commands the largest slice of the thermoforming pie in both Europe and Asia.

There are several converging elements that create a basis for continued growth and innovation in thin-gauge thermoforming. As food is grown further from its ultimate point of consumption, packaging, and transportation become

critical elements in the global supply chain. The change in consumer habits in terms of how and when food is eaten has resulted in package design innovations that incorporate increased shelf life, tamper-evident “intelligent” packaging and high visibility. These factors constitute the pull of the market and have been widely acknowledged and discussed in the industry press. The Kcup is an excellent example of product innovation that led to a mini-boom in thermoformed processing. When viewed in combination with the push of

Thermoforming

INDUSTRY FOCUS

“

A recent eye-tracking study conducted by Klockner Pentaplast used statistical methods to show that consumers fixated for longer periods of time on products packaged in thermoformed clamshells instead of those packaged in paperboard boxes.

”

suppliers, however, we can get a more comprehensive view of the industry as a whole.

Innovations in materials, tooling and machinery have allowed package designers to benefit from new technology. Multi-layer, barrier and now oxygen-scavenging films are arguably the biggest contributors to thermoforming’s growth, especially when you consider that such films cannot be processed via injection moulding.

Several technical papers have been published on this topic in both the Society of Plastics Engineers’ “Thermoforming Quarterly” and major plastics and packaging industry outlets.

The science behind these developments is typically being done at large resin companies or in some cases at university research labs with strong polymer departments.

The application of new inks and printing technologies, as well as thermoformed inmould labeling (T-IML), mean that thermoforming as a process remains attractive to major global brands such as Yum Brands, Starbucks, McDonalds, Dannone, Mondelez and Nestle for food, dairy and beverage packaging. T-IML allows plastics to displace cans, opening new opportunities for thermoforming converters. The increased adoption of fast-cycling, tilt-mould machinery means that tooling must be precision-engineered to very tight tolerances with servo-driven plug assists for optimal material distribution. Better material distribution leads to lower part weights. Downgauging is therefore an important resource - and cost-efficient tool for designers and cost accountants.

The use of air-save technology is just one of the new innovations in thermoform

tooling. On the topic of air consumption, new high-volume, dual circuit pressure forming valves allow air to flow in and out of the mould cavities for faster cycle speeds leading to a significant reduction in air consumption and, by extension, energy and operating costs.

The importance of retail displays and shelf space are major concerns for these brands, as well as for supermarket inventory managers. Clarity is a key driver. A recent eye-tracking study conducted by Klockner Pentaplast used statistical methods to show that consumers fixated for longer periods of time on products packaged in thermoformed clamshells instead of those packaged in paperboard boxes.

The data revealed a strong correlation between fixation duration and the ultimate purchase decision.

Beyond the food sector, medical packaging has set a high bar for

performance due to the critical nature of this market sector. Regulatory compliance, product safety, package performance, cost and quality are equally important to medical device manufacturers and, by extension, to processors who serve them.

Thermoformed trays, therefore, are designed with these concerns in mind.

As is the case in other market sectors, low tooling costs and fast turnaround times mean that thermoforming is the logical and cost-effective choice for companies who need to bring new and innovative products to market on a regular basis.

Developing Markets Data from Euromonitor International show the fastest rates of growth for thermoformed packaging are in China and Southeast Asia. It is important to distinguish among the different countries

and regions in Asia as distinct trends can be observed. For example, water cups are the single largest thermoformed item in Southeast Asia, with Indonesia as the standout country. With a population of 246MM and growing, the demand for packaged water is a significant driver of thermoforming activity in this country.

Thailand and Vietnam are two other countries where high levels of investment in packaging factories and the required machinery (from Chinese and Korean conglomerates, in many cases) contribute to high rates of growth. The investments in technology required to serve this market are significant: highspeed European machines with precision plug-assisted tooling. Conversely, the requisite training to efficiently operate these sophisticated machines is not yet widely adopted.

Continued on page 16 JUNE 2014 • WWW.EPPM.COM • 15

Thermoforming

INDUSTRY FOCUS

“

Turkey has overtaken France and is now on pace to become the 2nd largest plastics converter in Europe, so the moniker of ‘developing’ market might be dropped in the near future.

” 16 • WWW.EPPM.COM • JUNE 2014

SPE CEO Wim de Vos suggests that China is a special case among emerging markets. He sees a wide variety of thermoformers of which a big portion, perhaps half, is supplying the lower-end, lower-demand section of the domestic market. The other portion is supplying to international OEMs and brand owners and they have to fulfill the more demanding specifications of international brands. The former group is using domestic technology for machinery and tooling. As any visitor to Chinaplas in Shanghai this year will tell you, the growth in the number of OEMs is impressive. While the technology is clearly not up to western standards yet, the presence of Eastern European buyers in the booths of Chinese machinery companies suggests that Chinese equipment is finding acceptance beyond the borders of the Middle Kingdom.

Turkey has overtaken France and is now on pace to become the 2nd largest plastics converter in Europe, so the moniker of ‘developing’ market might be dropped in the near future. With 9% growth in the value of thermoformed goods in the domestic market, Turkish OEMs, toolmakers and converters are enjoying robust expansion. Visitors to K 2013 saw many Dusseldorf Sbahn and U-bahn trains plastered with promotions for the Turkish Pavilion.

In Eastern Europe and Russia, the expansion of major supermarkets brings new stores and

distribution centers, increasing the need for thermoformed packaging. As Marek Nikiforov, European Sales Director for GN Plastics has pointed out, Western Europe has many more supermarkets per capita than Eastern European, including Russia. OPS continues to be the polymer of choice due to its low cost, but also because the recycling infrastructure that we associate with both North America and Western Europe is not yet developed.

Data Analytics The advent of big data is a hot topic in many industries for the abundance of information and analytics now available to marketers, engineers and managers.

Is it relevant in thermoforming? What sort of data is most important to processors?

How does that data get analysed and by whom in the organisation? We are starting to see some emerging trends in the application of information technology to thermoforming. Having the ability to meter and monitor data from various sensors, gauges and scanners can help operators dial-in the process to minimise waste and optimise start-up. Companies like uVu Technologies from the US and Illig from Germany appear to be innovators in this space with more sensors, more data points and new, integrated data analysis designed to perfect a notoriously variable-filled process. There are a few early adopters of this data-driven approach, but it is perhaps too early to tell if thermoformers will embrace (and pay for) greater insight.

Sustainability: Megatrend or Not? There is no question that sustainability is more than just a buzz word or a passing trend. In fact, as a business practice, evidence continues to mount that companies who fully embrace sustainability enjoy greater returns than peer companies who do not. A 2009 report by consulting firm AT Kearney indicated that companies demonstrating

a long-term commitment to the health of their business instead of focusing on short-term gains outperformed the industry average in 16 of 18 categories.

This ‘performance differential’ amounts to approximately $650MM in market capitalisation per company.

The demand for products that have a lighter carbon footprint has not abated.

Continuing R&D in materials science ensures that polymers of the future will perform as well or better than their petroleum-based analogs. Brand owners from food service to automotive design recognise that thermoforming offers a cost-effective solution to many of their engineering challenges. For the thermoforming industry, increased recycled content, use of bio-based or biodegradable materials, light-weighting of parts and down-gauging of materials are the major trends we see today, though it should be pointed out that these trends are not universally evident across all regions. The lack of recycling infrastructure and price sensitivity to biopolymers, for example, mean that entrepreneurs and business owners in developing markets will be more likely to focus on short-term economic sustainability.

That said, there is tangible and measurable momentum among global multinational corporations toward acknowledging that their activities have an impact on the environment. This trend toward sustainable business practices suggests a larger, fundamental shift in the way companies and individuals perceive their actions in relation to the broader environment. There are myriad opportunities for new business development including resource efficiency, carbon accounting / management, LCA strategies, new software development, environmental consulting, bio-based materials development, ‘green’ chemistry and more. The thermoforming industry has an important role to play now and in the future.

News

MACHINERY

Nothing goes to waste, says Starlinger at Interpack Starlinger demonstrated a sustainable packaging concept, the PP*STAR bag, during this year’s Interpack in Germany.

The pinch-bottom bag, developed by Starlinger’s consumer bags division, has been designed with the aim of bringing together material savings, product protection and presentation. The key characteristic however is that the bags are made from a composite of polypropylene tape fabric and reverse printed OPP film. This makes them lightweight and at the same time durable and tear resistant. They feature design appeal and provide reliable protection against external influences, especially for sensitive bulk goods such as pet food or fertiliser.

During the show, the bags were shown in free fall. While other bags may burst when dropped – for example in the process of lifting them from a shopping cart into the car boot – a PP*STAR bag can fall off a shelf several metres high without breaking.

Specially designed for packaging sensitive dry bulk goods for consumer use such as dog food, cat litter, or flour, the PP*STAR bag is designed to protect its contents from external influences such as moisture or insects. Its barrier properties prevent leakage of grease after long storage periods.

Another focus for the group during the event was the processing of waste generated during the production of plastic packaging — such as film remnants, rejects, injection moulded parts — as well as the recycling of consumer goods packaging and household waste. The new C-VAC module has been designed for degassing and purification efficiency during the extrusion process. It can be installed as an add-on to all Starlinger extruders and permits high quality recycled material from highly contaminated or heavily printed plastics.

Also discussed during Interpack was the PET sheet line viscoSHEET, developed

by Starlinger viscotec, which produces sheet for food packaging from up to 100% recycled PET. Processing rPET, virgin PET and PIR (post-industrial regrind), the line produces sheet compliant with the prevailing FDA (US Food and Drug Administration) and EFSA (European Food Safety Authority) standards for food contact applications.

Starlinger Web: www.starlinger.com

“

The new C-VAC module has been designed for degassing and purification efficiency during the extrusion process. It can be installed as an addon to all Starlinger extruders and permits high quality recycled material from highly contaminated or heavily printed plastics.

JUNE 2014 • WWW.EPPM.COM • 17

Temperature Control

MACHINERY

Air chillers for blown film extruders offer 20-50% energy savings Eurochiller’s new AIR+ Project range of process air chillers with cooling batteries is designed specifically for air blown film and sheet extrusion lines, and is being launched to the UK market by IsoCool.

Developed as an evolution of the ABF and BRA range of process air chillers, Air+ Project comprises two main elements, the new AIR+ chiller itself, a stand-alone unit that produces cold air, through a direct expansion refrigeration system, and BRA+ cooling batteries. The latter are constructed within a closed framework for maximum insulation and superior bubble cooling performance on blown film lines, says IsoCool.

The AIR+ operates by using cooling water from an air blast or adiabatic cooling system at 2035°C. Due to the unit employing the same technology that is featured on the existing ABF line of air process chillers, significant energy savings can be achieved when applied to a typical air-blown film extrusion process, claims the group.

Other benefits for manufacturers running blown film lines include uniform process temperature throughout the year, a minimum air temperature of 5°C and HGBP (hot gas by-pass) cooling technology.

The latter ensures condensate is prevented from freezing on the surface of the evaporator coil when the system is operating at low load conditions.

Further features of the new chiller include a fully functional control panel with full system diagnosis, an air filter with large surface area, and an ergonomic and compact design. There are seven models in the new AIR+ range offering maximum air flow rates from 1000 to 7000 m³/hr and cooling capacities from 13.5 to 93.8 kW. Air+ is supported by BRA+ batteries (cold water for the battery is typically provided by a chiller). BRA+ batteries feature a large surface area for maximum heat exchange, an integral diffuser for low air velocity and removable air filters for ease of maintenance.

ICS Cool Energy celebrates 25 years with new range of efficient chillers ICS Cool Energy is marking 25 years as a European supplier of temperature control equipment to the plastics industry by releasing a new range of chillers geared towards improved efficiency for the end-user.

Originally formed in 1989 by Jeff Spolnik and Phil Wilson, ICS opened with two offices, providing coverage in both the north and the south of the UK. Expansion continued in the mid-nineties when the team opened an office in Ireland to manage all aspects of sales, service and rental. By the late nineties, the group had a posted turnover of £20million in the UK and Ireland.

In the mid-2000s, Cool Energy, a specialist temperature rental company was formed, later expanding into Europe after merging with ICS to form ICS Cool Energy Ltd. This led to the formation of three main business units: sales, rental and service. Today the company is led by Adam Spolnik, Kevin Whyte, Mike Jones and Russell Wilson, and says it is “forging ahead with the agreement of significant deals and new partnerships”, whilst also launching the latest edition to its fleet, the ‘i-chiller’.

ICS Cool Energy’s Company Director, Adam Spolnik, comments: “We are proud to ring in our milestone 25th 18 • WWW.EPPM.COM • JUNE 2014

Other design features include a proportional three-way valve for precise temperature control, a thermometer that monitors ambient temperature and a collection tank with drain port for condensate.

There are 13 models in the BRA+ range of batteries offering air flow rates between 250 and 17,000 m³/hr and cooling capacity between 2.4 and 169 kW. IsoCool Web: www.isocool.ltd.uk

The ICS management team

year with the announcement that we are bringing our new i-chiller range to both UK and European markets.

Over the last quarter of a century we’ve supported industries across the globe, providing temperature control solutions and specialist advice on process heating and commercial cooling projects. The need for businesses to improve efficiencies across the board has never been more prevalent, with seemingly everincreasing energy prices and tighter regulatory directives being introduced.

“The i-chiller represents an evolution of our longserving cooling range by placing efficiency at its core, using the very highest grade components in each and every one of the range’s 17 strong chiller models as standard, to ensure that ‘out of the box’ levels of reliabilty and productivity can be sustainably and consistently achieved.”

The new chiller has cooling capacities starting at 0.9kW and ranging up to 122.4kW. ICS says that it offers greater flexibility than its predecessor, and is available in two new versions to offer high efficiency (HE) and dual frequency variations for different requirements. The new range also includes a high-pressure axial fan and an oversized hydraulic tank as standard, enabling the chiller to compensate for any imbalances caused by changes in load demand whilst in operation.

In support of the European Union’s legislation regarding the phase out of environmentally unfriendly R22 gas, the i-chiller range predominantly utilises more sustainable R410A refrigerant, with R470C and R134a gases used within the smaller capacity models.

Spolnik said: “Proactive businesses making the change away from R22 by embracing more sustainable alternatives, not only ensure total compliance with the change in EU legislation, but also help to develop processes in favour of a much more environmentallyminded, energy efficient practice.

“By positioning efficiency, sustainability and reliability at the heart of our temperature control systems we’re making every effort to ensure that we can continue to support our customers’ businesses both at home and abroad, well into the next 25 years and beyond.”

IsoCool Web: www.isocool.ltd.uk

Temperature Control

MACHINERY

Moving in the

RIGHT DIRECTION

Take time to revisit closed-loop, dry-cooling systems – and come out ahead As European plastics processors adapt to change and shake off the difficulties of recent economic times, they continue to search for ways to reduce operating costs and take every step possible to improve profitability and gain a competitive edge.

It’s a strategy that has clearly proved its worth, and naturally, there are plenty of places to look for improvement. In fact, one area that calls for attention is process cooling, given its contribution to overall productivity and product quality.

Many processors can come out ahead by revisiting closed-loop, dry cooling systems. Most already have the systems in place, and are generally pleased with the results they’ve delivered over the years. They also accept the intrinsic limitations that go with virtually any technology. Yet manufacturers of closed-loop process cooling systems continue to innovate, and there is no time like now to catch up on the technology in preparation for potential retrofits, expansions or new plant installations.

Words by Fabio Ferrari, Strategic Accounts Manager, EMEA, Frigel Firenze S.p.A. Trends drive need for better process cooling A typical closed-loop, dry-cooling system operates by pumping water returning from the process into fin-andtube heat exchangers and cooling it with ambient airflow. The process provides clean water at temperature sufficient to cool most process machines year round.

When compared to traditional open cooling towers and/or central chillers used by a many European operations years ago, closed-loop systems help processors dramatically reduce water consumption and save energy, which is in addition to lower process cooling equipment maintenance and ecological benefits.

In order to overcome high summertime ambient temperatures, most manufacturers of closed-loop dry cooling systems have developed so-called “adiabatic” or “evaporative” dry-coolers. These use water-spraying devices to reduce the air inlet temperature, thanks to the effect of water evaporation. Taking it a step further, one closed-loop process cooling system manufacturer designed its system so that the adiabatic spray chamber is totally enclosed. As such, it virtually eliminates heat exchanger scaling and dangerous waterborne diseases, such as legionella.

Some additional factors are nowadays driving the need for improving closed-loop systems performance taking them to a higher level than systems of years past. They include: Continued on page 20

JUNE 2014 • WWW.EPPM.COM • 19

MACHINERY

• Customer preference for eco-conscious

suppliers: Increasingly, customers throughout the world prefer to work with suppliers who are strongly eco-conscious. Many look favourably on those who have earned ISO 14000 certification, which helps organisations minimise how their operations negatively affect the environment. A technically advanced closed-loop process cooling system can play an important role in the ISO 14000 certification process, while separating a processor from its competition.

• Being “green,” not just saying it: More and

more processors promote their commitment to sustainability given the increasingly intense focus on the “green” movement. A newer closed-loop system that conserves resources at a higher level and delivers the best possible ecological benefits demonstrates that action speaks louder than words.

• Government incentives: Governments in a

number of countries now incentivise investments if a process cooling system can illustrate water and energy savings. By installing the latest closed-loop system, users will reap the benefits of a faster return on investment.

• Fewer resources, escalating costs: There are fewer natural resources available, which is a trend that no one expects to change.

Consequently, the cost for water and electricity consumption is only expected to climb. A closed-loop process cooling system that shaves an additional 10 percent of the total water and energy consumed in a year translates to substantial cost savings – in addition to more intelligent use of scarce resources. The savings and ecological benefits grow exponentially as the plant consumes less and less water and electricity.

Advances put processors ahead of the curve Another major reason to take another look at closedloop, dry-cooling systems has to do with the technology and the way in which systems are engineered around the needs of individual companies and their operations.

Incremental improvements in the technology in recent years have resulted in higher equipment efficiencies, allowing users to further conserve resources and cut operational costs.

As an example, some adiabatic coolers include a booster system when required for cooling tower temperatures. The booster provides a “boost” of additional water within the enclosed adiabatic chamber, yet it still allows companies to save as much as 95 percent of process cooling water when compared with open-looped systems. It also eliminates potential maintenance issues associated with scaling or dangerous biological emissions.

Some closed-loop systems can also be more readily configured to a processor’s unique business goals, plant requirements and local climate. That means there is absolutely no reason to settle for anything less than a system that delivers what is needed for an existing or new plant, whether it’s higher energy savings, improved sustainability or lower maintenance.

The configurability of newer closed-loop, dry-cooling systems cannot be understated. The key to success for plastics processors is flexibility as they adapt to change and constantly look for ways to improve profitability. A technically advanced system that can be configured to each operation gives processors another extra edge.

And in the plastics industry, every advantage counts.

So go ahead. Ask your local expert for a full survey and technical analysis of your existing or planned facility to determine whether it’s time to capitalise on a solution that puts you ahead of the curve, not behind it.

20 • WWW.EPPM.COM • JUNE 2014

Frigel launches 3DK closed-loop adiabatic liquid cooler As part of its push to drive closed-loop cooling technology, Frigel has launched the new Ecodry 3DK Closed Loop Liquid Cooler, which can be configured to match manufacturers’ specific requirements, reportedly delivering higher energy and water savings, environmental benefits and other advantages. Ecodry 3DK can also be configured to occupy a 30% smaller footprint than the Ecodry model it replaces.

As an alternative to conventional process cooling, Ecodry 3DK is the primary component of an integrated, closed-loop intelligent cooling system that provides clean water at the right temperature to industrial processes year round. The closed-loop approach can reduce water consumption by as much as 95% when used instead of a cooling tower, says Frigel. Compared to an air-cooled central chiller, it can reduce energy consumption by as much as 95%. Ecodry also eliminates chemical discharges and dangerous waterborne diseases, such as Legionella.

The modular Ecodry 3DK, which is housed outside a customer’s facility, is the closed-loop system’s central cooler. It uses heat exchangers and an internationally patented adiabatic chamber to cool water circulated to it from process machines. The adiabatic chamber precools ambient air on hotter days before it enters the unit’s heat exchanger compartment. Cooled water is then re-circulated to a facility’s process machines. The microprocessor-based controller automatically maintains precise cooling temperatures.

News

Ecodry 3DK incorporates a number of enhancements and options so it can be readily tailored to each manufacturer’s business goals and plant requirements.

Available fan exhaust diffusers located on top of the Ecodry 3DK keep exhaust air from being drawn into the adiabatic chamber at the bottom of the unit – while also allowing it to consume as much as 28 percent less energy compared to the standard axial fan model.

New options enable Ecodry 3DK to maintain precise cooling temperatures, regardless of local climate.

Options include a patent-pending adiabatic booster for water temperatures equal to cooling towers and/or in hotter climates; varied heat exchanger configurations for milder climates; and self-draining coils with recirculation pump stations for non-glycol applications in freezing climates.

A new acrylic coating is applied to the heat exchangers for added protection against harsh environments, and to further reduce the need to maintain the already lowmaintenance system. An optional polyurethane coating provides an even higher level of protection.

With exhaust air diffusers, multiple Ecodry 3DK units can be positioned more closely together. When air diffusers are not used, roof panels are another spacesaving option. The panels allow the multiple Ecodry 3DK units to be positioned closely together because they keep exhaust air from flowing down and into the adiabatic chamber. Optional extended legs can also facilitate airflow in tight spaces. The result is a footprint as much as 30 percent smaller than the previous Ecodry model, depending on the configuration.

Frigel Web: www.frigel.com

MACHINERY Mould temp control platform solves complex part issues Targetting applications with high melting points, as well as long glassfibre reinforced parts, materials handling specialist Piovan has developed “Dynatemp”, a mould temperature control system for moulds with conformal cooling circuits.

Using pressurised water, it performs a two-stage process: in the first step, the mould is heated so as to facilitate the inflow of the melt and allow even filling (even in moulds with complex geometries, says Piovan) and eliminate thermal stress. In the second step, the mould is cooled to allow the injected material to solidify; this facilitates separation of the part from the sides of the mould and thus makes it easier to eject.

The system, which can be used as auxiliary equipment with any type of injection moulding machine, has a control unit that drives both the heating and cooling of the water by means of an electrical resistance and its forced

Temperature Control Things heat up with new MD at Single Karsten Sauer has been appointed as new Managing Director of temperature control business Single.

German born Sauer has taken over from Frank Spork who was appointed as Temporary Manager in December 2013.

According to the company, the 41-yearold will bring extensive technical and management experience.

He has held several executive positions including Head of Lean Manufacturing at Fresenius Medical Care Deutschland and Manager of Automotive at A.T Kenny.

Single has been developing, producing and selling high-performance temperature control systems for more than 45 years.

The company’s product portfolio consists of water and oil-operated, high-quality temperature control systems, cooling technology as well as tailor-made and customised solutions.

Single Web: www.single-temp.co.uk

circulation in two separate circuits (one for heating and the other for cooling), under different temperature conditions, up to 180°C in the heating phase and down to 20°C in the cooling phase.

The system works automatically, according to set parameters, using software which, interfacing with the machine’s working parameters, governs temperature and pressure values at any given time.

Piovan explains that the system allows the surface of the moulded part to remain free of defects and irregularities, removing the requirement for finishing processes.

Dynatemp can also permit lower clamping forces compared with those needed when using traditional processes, claims Piovan.

Piovan Web: www.piovan.com JUNE 2014 • WWW.EPPM.COM • 21

Injection Moulding

MACHINERY Negri rolls out update for the large ‘Vector’ series

Negri Bossi has announced details of a series of modifications to its Vector series of mid to large injection moulding machines, which first came to market in the late 1990s.

Following on from the recent introduction of a smaller 650 tonne model, the range has now also been given enhanced modularity.

The centre line heights have been standardised to allow a wider range of possible clamping and injection group combinations. Secondly, a new clamping group has been developed to serve both 1000 and 1300 tonne models, with 1350mm between the top bars as standard.

The most significant modification comes in the form of a wide platen variant of these two models, featuring 1600mm between the top bars. This move was driven by the introduction of larger, more complex tools, particularly within the automotive sector, where tie bar clearance is often of a higher priority than locking force. The need to standardise back plate sizes to allow for rapid tool change times has also contributed to the need for machines with greater flexibility, says Negri.

Negri Bossi Web: www.negribossi.com

Arburg investing and expanding in Western Europe Arburg is continuing to grow around its headquarters in Western Europe.

The group recently broke ground on a new assembly site at HQ in Lossburg, Germany, and has also now opened a new technology center in Austria. While many firms are looking to expand in the key emerging markets of Eastern Europe and Asia, Arburg (which, incidentally has also invested heavily in those regions recently) is maintaining a healthy interest closer to home.

The new assembly facility in Lossburg will expand the central production location by 13% to just under 165,000 m2. Initial excavation work began in March 2014 and the completion date has been set for the autumn of 2015. The new site is destined to meet growing demand for larger injection moulding machines and complete production cells, says Arburg.

“Growth means preservation, means actively securing the future,” said Michael Hehl, Managing Partner and Spokesperson for the Arburg Management Team. He added: “The capital investment for the new building section, to the tune of many tens of millions of euros, demonstrates our clear commitment to Lossburg as a production location and is an indicator of the longterm, targeted strategy for which Arburg has been famous for decades and makes us a reliable partner.” The group indicates that significantly more time and space is required for the assembly and testing of large injection moulding machines up to a clamping force of 5,000 kN and complete turnkey systems.

The group says that in all construction plans, it places great emphasis on functionality and aesthetics, in addition to environmental protection and the conservation of resources and energy.

22 • WWW.EPPM.COM • JUNE 2014

LEFT: Breaking ground on the new facility in Lossburg BELOW: The opening ceremony for the technology center in Austria

“With the new building, we are implementing highly integrated facility management, which will reduce the primary energy requirements to a minimum and therefore further expands our environmental protection activities,” said Hehl.

The waste heat produced from the site will be utilised for heating the hall, for example. Collected rainwater will be used by the gardeners and will cover all requirements for the sanitary facilities.

Furthermore, the facility will act as ‘buffer storage’ for the industrial cooling required for the building. North-facing shed roofs reduce the thermal load and minimise the need for electric lighting.

The natural cold of the ambient air will be used for air conditioning purposes – via a facade design which employs natural ventilation instead of ventilation systems.

Furthermore, extension of the photovoltaic plants to generate a further 340 kWp (kilowatt-peak) is also in the pipeline, according to Arburg.

The new building will match the assembly hall built in 2000 as part of the Arburg II plant expansion. At the time, Arburg claims that to have been employing a ‘modular’ construction

concept, which means that the new building will be integrated into the existing complex with relative ease.

The other new development for the group’s recent wave of expansion is the a new technology center in Micheldorf near Kirchdorf an der Krems, Upper Austria. This new location brings the technical centre, spare parts service and training rooms under one roof and is situated in what Arburg describes as “one of Austria’s booming regions for the plastics industry”. During the opening ceremony, Arburg Managing Partner Juliane Hehl emphasised the importance of the new Austrian facility for the company. To mark the occasion, around 100 guests were invited to attend a reception in the Benedictine abbey of Kremsmünster.

“The opening of the ATC in Micheldorf is an important milestone for our presence in Austria,” said Ms Hehl during the ceremony. “Today’s event is intended to emphasise the significance of customer proximity for our efforts, both in physical and mental terms. Proximity to the customer and customer satisfaction are top priorities for us.”

Arburg’s Austrian subsidiary was established in 2010, and the sales and service team was expanded; numerous projects have been completed since then, says the group.

“The new facilities represent a significant expansion of our services in the areas of technical support, spare parts logistics and training,” said Eberhard Lutz, Managing Director Arburg Austria. “The new ATC in Micheldorf provides a central focal point and ensures that customers in Austria always have a direct line to us.

They can contact us with questions about our technology or training courses, or place orders for spare parts for fast delivery. The technical centre lies at the heart of our service, enabling customers not only to see the latest machine technology at first hand, but also, crucially, to prototype their moulds. In addition, the demonstration room is the ideal place for providing practical training in all aspects of Arburg technology here in Austria.”

There are several important educational institutions close by, such as the TIZ Technology and Innovation Centre in Kirchdorf, which promotes technologyoriented companies, improved technology transfer and cooperation between commerce and science. In addition, Micheldorf is located close to the A1 Western Motorway and the A9 Pyhrn Motorway.

Arburg Web: www.arburg.com

Injection Moulding

MACHINERY On the road with Haitian’s new Zeres series

offer upgrades, and it can now offer sizes up to 66,000 kN, and upon request Haitian says it will offer the standard edition of the Jupiter II at 88000 kN. The first JU66000II, which the group claims is one of the largest injection moulding machines sold in the world to date, has recently been delivered to a wellknown Chinese manufacturer, which is using the machine to mould a large part made of PE for the construction industry. In addition, a second JU66000II is also about to be completed.

The Open House for the exhibition will begin officially on Thursday, June 26, 2014 at 11:30am.

Haitian Web: www.haitian.com

Injection moulding machine manufacturer Haitian is currently running a European tour with its new ‘Zeres’ electrical series of machines.

The new Zeres electrical series is designed to open up applications which were previously associated with hydraulic machines.

“With the Zeres, we now offer a perfect entry into the world of electrical technologies to those processors who are oriented towards hydraulics” said Uwe Bär, General Manager at Haitian Europe. Identical in design to the Venus II Series, the Zeres uses energy-saving servo-electric drives for injecting (up to 350 mm/s), for dosing, and for mould movement. The hydraulics of the Zeres are intended to offer flexibility for the planning and production of plastic parts with, for example, core pulls, as well as other technical precision parts.

The tour will include a stop at the Zhafir plant in Ebermannsdorf, Germany, on June 26-27.

During this leg of the tour, Haitian and Zhafir will exhibit their complete range of machines, including premium and standard machines with packages tailor-made for customers.

In the whole range, clamping forces currently range from 350 kN to 66,000 kN. Energy-efficient drives now come as standard equipment, across all models and technologies.

The groups will include the latest upgrades to the Jupiter II series in the line-up. The new editions are designed as high performance machines, which target specific applications by applying a range of features across clamping force sizes.

The new Jupiter High Performance edition, which is available in 10,000, 12,000 and 16,000 kN, is designed specifically for large, flat parts, mainly in the automotive industries.

The key feature is a substantially larger mould space area, allowing users to run bigger moulds. The tie bar distances have been increased by up to 20% and the whole clamping unit has been modified so that heavy moulds can be handled more easily.

The new series now also comes with the group's energy-saving “Mars” drive technology as standard, at no extra cost. As well as the larger mould space, Haitian has used a new clamping system for more flexibility when adjusting height, as well as parallel locking between the tie bar and the plate.

The Mars series also now has a high-performance edition, which can be seen on the group's stand. With this machine, Haitian is concentrating on packaging applications, specifically standard-shaped thin-walled components made of PP, PS, ABS and PET. Clamping forces available are 1,700, 2,100, 2,700 and 3,300 kN. The machine features a tailored injection unit for injection speeds of up to 180 mm/s, special screw designs that can be selected depending on material and requirements, and an increased mould space area for moulds with high cavities.

The standard Jupiter II series, which was first launched at last year's Chinaplas, and uses two-platen technology, has received great interest from the market, especially in the medium and large clamping forces, says Haitian. This has been the driver for the group to

Precision for Mouldmaking.

How to turn old IMMs into gas injection machines A new gas injection technology (GIT) module has recently been integrated into a relatively old large existing Engel machine.

Under the name ‘Engel gasmelt’, Engel, in conjunction with gas specialist Bauer Kompressoren, offers complete integrated systems for injection moulding with gas injection technology. A recent project with mould-maker Haidlmair has been used to demonstrate that older systems can also be upgraded for GIT. The Engel gasmelt process and the individual gas feeds can be controlled and monitored via the injection moulding machine’s display. During mould trials, Haidlmair says that it particularly benefits from the leakage monitoring system integrated as a standard in the Engel gasmelt cell. Especially in the case of large moulds with several gas injectors, being able to map the alarm messages to the control loop facilitates troubleshooting in the event of leakages.

A specialist in moulds for drink crates, large containers, pallets and high-quality automobile components, Haidlmair already uses gas injection technology.

Christian Wolfsberger, Technology Manager at Engel said: “In these areas of application, the potential for

We enable the easiest way to build moulds – with agility, innovation, simplicity and performance. All of our products and services are developed as a complete system designed to meet your needs.

In other words: we enable with system.

increasing efficiency is particularly great. Engel gasmelt reduces the amount of raw material used and shortens cycle times by producing outstanding component stability and surface quality.”

He added: “In view of the ever increasing cost pressure at plastics processing companies and the demand for more process stability and sustainability, we see a huge amount of potential for Engel gasmelt. We will therefore continue to develop the technology with our partners and to make this a priority.”

Engel Web: www.engelglobal.com

More than 700 employees work to set the standards of tomorrow – and to give you advantages: 6LPSOLÀHG GHVLJQ DQG DSSOLFDWLRQ +LJKHU TXDOLW\ DQG PRUH ÁH[LELOLW\ - Market-driven innovations ,PSURYHG HIÀFLHQF\

HASCO Hasenclever GmbH + Co KG Römerweg 4, D – 58513 Lüdenscheid T +49 23 51 957-0, F +49 23 51 957-237 info@hasco.com, www.hasco.com

JUNE 2014 • WWW.EPPM.COM • 23

News

MACHINERY

Self-cleaning screen changer purges while it works

An automated, hydraulically powered backflush system enables the V-Type screen changer from Nordson Kreyenborg to purge even heavy contaminant from the melt filter element while maintaining extrusion throughput, minimising operator intervention, and avoiding downtime in constant-pressure processes like film and fibre extrusion or strand pelletizing, the company claims.

In Nordson Kreyenborg’s V-Type screen changer, melt flow from the extruder splits into four streams for filtration in two pairs of screen cavities, then the streams rejoin with no significant change in melt flow.

Each pair of cavities is mounted in a piston which positions both cavities so that they can filter their respective melt streams, or removes one of them from the process to remove contaminant build-up by means of backflushing. In normal operation, polymer is flowing through all four cavities. While one of the cavities is changed, the other three remain in the process.

In addition to the two screen-bearing pistons, there are four hydraulically actuated displacement pistons that operate during backflushing. When the differential pressure across the screen changer increases to a pre-set level because of contaminant buildup, the backflush sequence for all cavities will be started automatically. For each cavity, the corresponding displacement piston on the outlet side of the screen retracts, creating a reservoir of filtered molten polymer.

This material is hydraulically compressed and

“

The V-Type screen changer carries out backflushing and screen changing functions even as extrusion continues with no change in volume flow and pressure.

discharged in reverse direction, back through the screen, carrying away contaminant for removal from the system. The sequence is performed for each cavity one after the other.

This “power backflush” technology purges filter media even in extrusion lines running highly viscous polymers, claims Kreyenborg. It also minimises the amount of material consumed in backflushing, and lengthens the working life of filter media, according to Stefan Wöstmann, the firm’s Research and Applications Engineer. Rheologically optimised flow channels avoid excessive residence time and stagnant zones in the system.

”

As in the case of backflushing, the process for changing screens is initiated when a pre-defined number of backflushes is reached. This triggers the outward movement of the screen-bearing piston so that the screen pack can be removed and a new filter element is put in its place. Also as in backflushing, three of the cavities remain in the process while a new screen pack is installed in the fourth.

“The V-Type screen changer carries out backflushing and screen changing functions even as extrusion continues with no change in volume flow and pressure,” said Wöstmann. “As a system for achieving a high rate of productivity even at a time of rising regrind percentages and increasingly contaminated feedstocks, it is an investment that quickly pays for itself.”

Nordson Kreyenborg Web: www.kreyenborg.com

JUNE 2014 • WWW.EPPM.COM • 25

Electronics

APPLICATIONS

MASTERBATCH

for the Electronics Market

By Bob Thomas, Technical Director, Colloids

Flame retardant - for corrugated pipes carrying electrical cables in construction - ensures minimal risk as well as legal compliance.

Formulating and supplying the best masterbatch and additives requires unrelenting discipline, including: • delivering the properties that are required to underpin performance; • recognising commercial pressures to give clients competitive edge at the right price; • always observing the environmental and legislative environment to ensure compliance.

The electronics market is a good example, where intense competition means that the right solution - with the right properties such as antistatic or flame retardancy - can set the leaders apart from the field.

That’s why Colloids, together with our parent group Tosaf, have developed a range of masterbatches and additives specifically aimed at the electronics sector.

Antistatics The use of antistatic is essential if problems due to electrostatic discharge are to be avoided.

Common thermoplastics like PE or PP act as natural insulators. So, in order to make them antistatic in nature they need to be modified in some way.

Antistatic or insulating effects typically operate around the 109 – 1012 Ohms range. The surface resistance of many unmodified polymers is typically 1013 Ohms or greater.

The right choice of antistatic additive for electronic packaging applications (for example) is key to their success since many antistatic additives can corrode electronic components.

Colloids offer a specific Tosaf grade for this application called ST 0248PEP which has a pink tinge, commonly used to identify its use in this type of market. This antistatic masterbatch for use in PE films contains a mixture of antistatic agents, which provide short and long term antistatic effect. The masterbatch contains amine-free additives that are non corrosive to electronic components. The masterbatch is therefore especially suitable for use in films designated for electronic packaging, and is active even at low relative humidity.

The same product is also used in PE foam and bubble wrap. The carrier resin is low density polyethylene (LDPE).

Colloids also offers a range of permanent natural or coloured antistatic maserbatches. Unlike conventional antistatics, the effect is permanent because the antistatic agent does not migrate to the surface. One such grade is the Tosaf masterbatch ST 0247 PE: a permanent antistatic masterbatch for polyethylene films.

This non-migrating antistatic masterbatch provides

New plastic will help stop mobile phones overheating, says scientist Problems with overheating mobile phones could be reduced significantly thanks to a plastic being developed by Loughborough University scientists.

The plastic is called ultra-high molecular-weight polyethylene (UHMWPE) which is used to make a variety of products, from prostheses to body armour.

The new plastic, unlike the ones currently used in mobile phone covers, dissipates heat created by the lithium batteries and reduces the likelihood of injury to the owners.

Dr Sara Ronca, the principal investigator for the research into the plastic, said: “The current plastic cases do not dissipate heat and have been known to get too hot, with phones doing strange things.

“For example, when you heat up plastic too much it will deform. If the plastic dissipates heat this will happen less.”

Dr Ronca has developed a method of synthesising and processing the plastic so that it acts as a better heat conductor.

Dr Ronca said the new plastic is vital because the drive in electronics towards miniaturisation has increased the need for smart materials than can cope with things like heat dissipation.

The team believes that it could be a major boost for manufacturers of all kinds of electronic devices like computers, as well as electric motors and generators,

26 • WWW.EPPM.COM • JUNE 2014

solar panels, batteries and heat exchangers in power generation.

It can be used as a heat sink in computers as a replacement for metals, which are expensive, heavy and also conduct electricity, and composite materials which are not only costly but are also harder to recycle because of the fillers they contain.

She said: “We know that it works, we know it is thermally conductive, because we already have the data. What we have to do now is find out how we can tailor the material for any industrial application.”

Dr Ronca, from the Department of Materials, is building on work started by Professor Sanjay Rastogi.

She has received a £98,000 grant from the Engineering

immediate and permanent anti-static effect. It does not affect the mechanical properties of the polymer and is not dependent on humidity. It is especially recommended for use in the skin layers of multi layer films. The carrier resin is polyethylene (PE).

Flame Retardancy Flame retardants increase resistance to ignition to minimise the risk of a fire starting in the first place, or slow down combustion if an adjacent material has ignited, and often prevent the fire from spreading to other items.

Flame retardants are widely deployed in electronic applications. One such area is for corrugated pipes which are used as conduits for electrical cables in construction.

Such conduits have to meet the European Flame Retardant Standard IWC 61386-1.

Tosaf have just launched a new range of flame retardant masterbatches that meet the requirements of this new greener specification In the past, the efficient and low-cost chlorinated paraffins had been the additives of choice to achieve this purpose.

But these chemicals have come under attack from two important regulations: firstly, the REACH regulation has banned the use of short-chain chloroparaffins as they have been classified as Substances of Very High Concern (SVHC). At the same time, increasing numbers of pipe producers are trying to make their products comply with the Low Smoke Zero Halogen regulation (LS0H; IEC 607541).

After intensive research, Tosaf has recently introduced a new range of products that meet all of the following targets set out at the beginning: • no use of chlorinated additives; • LS0H norm met for standard pipes; • high efficiency to reduce dosing requirements; • no additional costs for the pipe producer.

These products represent the most advanced and costeffective products on the market for this application.

They are available without colouration (natural), or in a variety of colours, according to customer preference.

Colloids Web: www.colloids.com

and Physical Sciences Research Council (EPSRC) for the two year project whose aim is to get the plastic ready for industry, with the participation in kind of Teijin Aramid of the Netherlands.

But Professor Rastogi and Dr Ronca have developed a synthetic/processing strategy that allows achieving less entangled and highly aligned polymer chains, which promote the heat transfer via ‘lattice vibration’.

She said: “We have devised a synthetic strategy that enables us to directly obtain UHMWPE with a reduced number of entanglements.

“It is easier to process this material in a way that chains are extended and nicely aligned.

“When you get this type of structure the polymer is not conductive electrically but it can conduct thermal energy by lattice movement.

“We have demonstrated that this material can be easily processed, without the need for any solvent, to give tapes and filaments with high chain alignment.

“The question is, can we get a material that has different thermal conductivities according to the polymer’s molecular characteristics?

“And can we tailor thermal conductivity by tailoring the material properties?

“The results from the project will enable us to realise a lightweight, cheap, easy to process and to recycle material where the thermal conductivity can be tuned in a range of useful values by suitable modifications of the synthetic processing steps.”

Loughborough University Web: www.lboro.ac.uk

Electronics

APPLICATIONS CASE STUDY: Blending PC and PET in electrical power units Three years ago Styron announced the formation of a strategic partnership with Pan-European distributor Resinex. The two firms recently collaborated on materials for a power distribution unit for a leading German electrical plug and socket provider. This provider experienced issues with the production of its current distribution units and called upon Styron and Resinex, who consequently developed their first commercialised PC/PET blend in an electrical application.

The Application The power distribution unit is fully covered and 100% waterproof, and is used in industrial and food processing areas. The wires within the unit remain completely covered as it is cleaned three times a day with a high pressure waterbased solvent. Furthermore, the product uses a high impact polymer for a glossy surface and maximum aesthetic appeal.

The Issue Prior to the assistance of Styron and Resinex, the German producer had been experiencing ongoing issues during the

production of these power distribution units. The moulds had originally been developed for polycarbonate (PC). The specific PC chosen had proven ineffective in terms of its chemical resistance, forcing the customer to switch to a PC/PBT blend, for improved stress cracking resistance. With this material however, the customer experienced dimensional stability issues.

Due to higher shrinkage of PC/PBT, the final dimensions of the box were different, causing a blockage of the locking mechanism inside the box.

The Solution Styron and Resinex worked with the customer to understand the application’s requirements and overcome the relevant issues.

Essentially, the customer needed an alternative material that behaved like a standard PC grade in terms of shrinkage, so it would be suitable for their existing moulds. Additionally it needed to offer enhanced chemical resistance versus PC, high toughness, good surface finishing and ignition resistance.

Emerge PC/PET 9500 CR was introduced as a solution. Styron’s Emerge series was originally developed for use in the medical industry, for applications which require enhanced

chemical resistance to aggressive disinfectant agents. Therefore, Styron stated that Emerge PC/PET 9500 CR would also be able to combat the issues the power distribution unit faced in its industrial and food processing environments.

Giorgio Bettoli, Business Manager EMEA Performance Plastics added, “This case is extremely exciting as it shows our ability to work with Resinex and leverage the success of a PC/PET grade from the medical industry to overcome the challenges that our customer in the Electrical industry faced. This successful collaboration across different market segments truly highlights the strength and insight brought upon by the Styron and Resinex partnership.”

The Future The application is Styron’s first commercialisation of a PC/PET grade in Europe for an electrical application. “We are excited about this accomplishment and value our exclusive partnership with Resinex as it continues to move us in the right direction of growing and expanding our Performance Products business. We are confident in our ability to build upon this success and continue to meet our customers’ needs in several upcoming projects,” said Philippe Belot, Global Business Director Performance Plastics.

Sabic gets smart with transparent conductive PC film Sabic, alongside Cima NanoTech, a Singapore and US-based company, have announced the joint development of a transparent conductive polycarbonate film for the smart materials sector. The firms claim that the film is a first for the industry, and “has the potential to revolutionise the materials used in consumer electronics, household goods, automotive, architecture and healthcare.”

Ernesto Occhiello, Sabic Executive Vice President, Technology and Innovation, said that the new material could enable faster response touch screens for consumer electronics, transparent “noline” anti-fogging capabilities for automotive windows, better EMI shielding effectiveness for electronics, and transparent WiFi/Bluetooth antennas for mobile devices like smartphones, tablets, laptops and all-in-one computers.

Sabic engaged in a joint collaboration with Cima NanoTech in the latter half of 2013 to develop the new material, which will be available for customer trials later this year.

“Transparent conductive polycarbonate is a breakthrough material that customers in consumer electronics and other important industries have been

seeking,” said Matt Gray, Director of Marketing, Consumer Electronics for Sabic’s Innovative Plastics business.

“Our work with Cima NanoTech is strategically aligned with our commitment to continuous innovation in areas of importance to our customers,” he added.

The collaboration, leveraging both Cima NanoTech’s proprietary Sante nanoparticle technology and Sabic’s Lexan polycarbonate film, has resulted in the development of a new series of transparent conductive materials that are said to be lightweight with excellent transparency, outstanding conductivity and high flexibility.

“We are very pleased to be working with

Sabic to bring the key advantages of Sante nanoparticle technology forward into a number of diverse consumer and industrial markets,” said Jon Brodd, Chief Executive Officer, Cima NanoTech.

Sante technology, a patented selfassembling nanoparticle technology platform, provides high transparency with ultra-low electrical resistance, which the group claims is ten times better than the incumbent indium tin oxide (ITO).

“In addition to its ability to meet optical grade specifications for display and touch applications, Sante nanoparticle technology is also more cost effective as coating is performed via a wet coating, roll-to-roll process versus sheet-to-sheet,” Brodd said. The conductive Sante network is also mechanically robust, thus allowing it to withstand flexing, stretching, torsion and tension for flexible applications. The substrate can also be thermoformed into various curved and 3D form factors.

Sabic Web: www.sabic.com

New biomaterials under scrutiny for electronic parts Bugworkers, an EU-funded project, coordinated by Aimplas, the Technological Institute of Plastics, aims to develop plastic parts based on biopolymers produced by fermentation from agro-industrial residues and using eco-friendly production routes.

The Bugworkers Consortium has reportedly succeeded in developing compounds based on poly (3hydroxybutyrate) PHB that meet the requirements of electronic applications (specifically audio and video door entry systems and white goods) in terms of processability, dimensional accuracy and performance.

PHB has been produced by bacterial fermentation using, as a raw material, sugar hydrolysates extracted from agroindustrial sources such as wheat straw.

The reduced cost of the wheat straw plus an optimised fermentation process with increased productivity has allowed for the production of PHB at a lower cost.

Additionally, alternatives for the extraction and purification of the polymer have been developed based on the use of green solvents that reduce the environmental impact of the PHB production process.

The PHB is compounded in order to increase its mechanical properties and improve its processability. After compounding, it is ready to be processed by traditional plastic technologies such as injection moulding, sheet extrusion and thermoforming, for the production of different case-study parts. A microphone holder, a button rod, a refrigerator eggbox, a refrigerator water storage cabinet and a washing machine knob are parts that have so far been manufactured using the newly developed PHB compound.

Co-extrusion and co-injection with other biomaterials have also been tried successfully, and were found to further complement the characteristics of PHB with the introduction of external layers.

The cost of the final PHB compound is estimated between 4 and 5.5 €/kg, which Aimplas claims is in same range as other biopolymers on the market, and lower than commercial grades of PHB. The project is now reaching its end. After 44 months of intensive research, results and final parts will be presented at the final meeting of the project in June 2014.

Aimplas Web: www.aimplas.es

Cima NanoTech Web: www.cimananotech.com JUNE 2014 • WWW.EPPM.COM • 27

News

MATERIALS

A Guide to Risk Assessment of

NON-INTENTIONALLY ADDED SUBSTANCES The plastics industry is highly regulated and for good reason. Consumer safety is paramount and significant measures are taken to ensure that potentially harmful materials are not used for the wrong application or at incorrect levels. Victoria Sayer, regulatory manager at ColorMatrix, looks at some of the methods for carrying out a risk assessment and provides an overview of the criteria that must be met by companies supplying additives for plastic food contact applications.

Words by Vicki Sayer, Regulatory Manager, ColorMatrix

For many years the European food contact regulatory framework has been in place and it requires that adequate risk assessments be carried out for materials and articles that will contact food. More specifically, there has been a positive list of monomers permitted for use in plastics manufacturing for many years and an incomplete list of additives has been in place for well over a decade.

This list of additives became a ‘closed list’ in January 2010. Before this time, unlisted additives could still be used providing they had been assessed for compliance with the framework regulation 1935/2004 and did not affect the organoleptic properties of the food or adversely impact human health. The positive list of additives does not, however, include colorants, solvents and catalysts (polymerisation production aids).

In 2011, all previous directives relating to plastic materials (monomers, additives and migration test conditions) were consolidated into a single legal text.

This is known as the Plastics Implementation Measure (PIM), and also referred to as regulation 10/2011.

This new regulation incorporated a new obligation for unlisted materials to be adequately risk assessed.

This is outlined in Article 19 of the legal text: Assessment of substances not included in the Union list.

“Compliance with Article 3 of Regulation (EC) No 1935/2004 of substances … which are not covered by an inclusion in Annex I to this Regulation shall be assessed in accordance with internationally recognised scientific principles on risk assessment.”

This obligation may apply not only to material explicitly excluded from scope (colorants, solvents etc), but also to impurities present in materials used to manufacture plastic articles.

So where should you start? Clearly the key questions to be asked are what materials need to be assessed, and at what level are they safe. Risk is based on both hazard and exposure.

28 • WWW.EPPM.COM • JUNE 2014

Listed below are the key pieces of information useful in carrying out such a risk assessment: • Gather information on the chemical identity of the unlisted substances and/or the impurities • Gather information on any regulated uses of the material (clearance for food contact use in other jurisdictions, clearance for use in cosmetics etc).

• Determine the level of exposure of the material.

This will require information on how the material migrates from the polymer.

This will differ depending on the polymer type, food types for which the material is intended for use with and the conditions of use.

• Actual migration testing may be required, but in many cases either migration modelling or ‘worse case’ migration calculations can be utilised.

• Gather information on the hazardous nature/toxicological properties of the materials.

Sources of information will be: • Material Safety Data sheets • REACH dossiers • Publically available toxicological databases.

Useful toxicological end points are: • Material Safety Data sheets • LD50 • DNEC (Derived No Effect Concentration) • NOAEL (No Observed Adverse Effect Level) • TDI OR ADI derived (Tolerable Daily Intake or Acceptable Daily Intake • Genotoxicity and mutagenicity All such information that demonstrates safety of the material in the intended use should be documented and will form part of the risk assessment. Once such information is known it may be possible to immediately make a risk assessment. For example, if the migration is significantly lower than the ADI or TDI. It may be possible to determine your own TDI based on toxicological data gathered, for example:

If the availability of toxicological information is limited, an alternative approach may be required. Materials can be assigned to one of three ‘Cramer Classes’.

Class I - Substances with simple chemical structures and for which efficient modes of metabolism exist, suggesting a low order of oral toxicity.

Class II - Substances which possess structures that are less innocuous than class I substances, but do not contain structural features suggestive of toxicity like those substances in class III. Class III - Substances with chemical structures that permit no strong initial presumption of safety or may even suggest significant toxicity or have reactive functional groups.

In addition, materials can be screened for functional groups known to be associated with genotoxicity. Such an approach is based upon known chemical functionality that has the potential to have adverse toxicological effects. Software tools are available to automatically assign materials to the appropriate Cramer Class based on their chemical structure.

Once a Cramer Class has been assigned, this, combined with the known migration and calculated exposure, can be used to assess the materials.

Acceptable value in µg/person/day

Acceptable value in µg/kg bw per day

0.15

0.0025

with structural alert for genotox

18

0.3

Organophosphates and Carbamantes

90

1.5

Cramer Class III

540

9

Cramer Class II

1800

30

Cramer Class I

So, for a material assigned to Cramer Class III, a calculated exposure below 90µg/person per day would be acceptable. Using an assumption that an individual may consume 1kg of packaged food a day, this equates to a migration value in food of 90µg/kg.

Such an assessment may be complex and will need to draw on data for many sources. Other parameters will also affect exposure, such as how widespread the use of a material is. Ideally the assessment needs to be conducted by an individual with experience of toxicological data assessments and food contact exposure calculations. This information is not intended to provide a comprehensive risk assessment, but covers some useful tools and guidance for gathering data that can be used in a risk assessment.

News

MATERIALS Breakthrough PET catalysis technology changes PET production around the world A new titanium catalyst technology for the industrial production of polyethylene terephthalate (PET) polyester is now being adopted around the globe as PET manufacturers and processors seek to eliminate the use of the heavy metal catalyst antimony oxide.

The technology was developed by Catalytic Technologies Ltd. (CTL), a company established in late 2010 on Teesside in the UK. To date the company has invested over £1m on research and development and in 2013 it launched its patent pending UP-Technology platform which exhibits performance unlike any other PET catalyst. UP is a catalyst technology platform that allows CTL to produce catalysts with unique chemical composition and that eliminates undesired side reactions in this application.

In addition to eliminating antimony oxide, the new catalyst is said to offer high polymer thermal stability, improved brightness and clarity owing to lower

impurity content, a significant net reduction in the overall process energy required to produce plastic packaging and lighter bottles without compromising on bottle strength.

The company’s UP-Technology platform is being exploited on industrial scale plants in Asia with further commercial trials scheduled and worldwide pilot unit testing on-going.

The group invested in a continuous pilot unit catalyst trial on Uhde InventaFischer’s state of the art polyester 2RMTR pilot plant. The trial reportedly enabled substantial testing of CTL’s new UP-catalysts by independent PET polyester production specialists to demonstrate the benefits of the catalyst technology compared to the industry antimony reference.

CTL’s new products target the markets for mainstream, high intrinsic viscosity PET resin and sheet used for the production of bottle and packaging plastics. Their use is currently greater than 30 million metric tonnes per annum. Dr. Alan Cooper, Technical Director, said: “The eco-credentials of our new UP-Technology are indisputable. The UP Technology platform can be modified to act as a drop-in replacement to current heavy metal catalysts for all PET production processes without any compromises. This new UP-Technology benefits everyone along the supply chain; PET resin manufacturers, resin processors and the packaging consumers. Importantly, all of these wide ranging advantages can be achieved without an increase in cost to the consumer.” CTL says it aims to take over 50% of the PET resin and sheet market within the next five years, and also has plans to apply the platform to other organo-titanium and zirconium areas.

Catalytic Technologies Ltd. Web: www.ctl8.com

French homewares group switches to BPA-free copolyester Due to ongoing legislative developments in France to ban bisphenol A (BPA) in food contact applications, French homewares group Saint Romain turned to Eastman Chemical Company and its Tritan copolyester as an alternative material to polycarbonate (PC). Tritan provides toughness, dishwasher durability and clarity, whilst avoiding the use of BPA. Saint Romain specialises in designing and producing plastic tableware and cookware applications for commercial usage in hotels, public institutions, nursing homes, hospitals and nurseries.

The company is developing new applications with the copolyester material to add to its tableware and drinkware product lines.

As of January 1, 2013, France has banned the use of BPA in food contact materials intended for use by children up to three years old. In that same legislation, France will extend the ban to all food contact materials and applications, regardless of age, beginning January 1, 2015. Until that time, all food contact materials and articles containing BPA will need to carry a health-warning label.

Because of the legislation, in addition to developing new products made with Eastman Tritan copolyester, Saint Romain is also starting to replace PC with Tritan in some of its existing products.

“As we switch from using PC to Eastman Tritan copolyester for our tableware and drinkware products, we are thankful for the ongoing technical support Eastman provides,” said Richard Saint Romain, owner. “We appreciate a raw material supplier who is willing to work with us. If we have production-related or end-user questions, we know we can reach out to Eastman.”

“We’re pleased to offer customers Eastman Tritan copolyester as a BPA-free material, whether it’s legislation or customers — or both — dictating the need,” said Ferdi Faas, Market Development Manager, Specialty Plastics-Durables and Consumer Goods, Eastman Chemical Company. “As more and more companies consider the material, Eastman will provide technical support and expertise to its customers who have an immediate need for our BPA-free material.”

Saint Romain’s products are available in approximately 30 countries. The company sells directly to dealers and distributors, who in turn sell directly to institutions.

Eastman Web: www.eastman.com

CO2 into plastic: Bayer ploughs €15m into ‘Dream Production’ Bayer MaterialScience has announced plans to invest €15m into commercialising its technology platform ‘Dream Production’, for turning waste CO2 into useable polymer. “The first major field of application will most likely be mattress production,” said Dr. Karsten Malsch, Dream Production Project Manager at Bayer MaterialScience.

The platform promises to turn greenhouse gases into a basic building block for plastics.

The latest injection of cash will go towards the construction of a production line at the group’s Dormagen site, which will use CO2 to produce a precursor for premium polyurethane foam. The line will have an annual production capacity of 5,000 metric tonnes. The permit application will be submitted to the Cologne district authority in the next few weeks.

Bayer claims that the first CO2-based polyols should enter the market as early

as 2016, and says that processors of polyols and polyurethanes have already expressed “considerable interest”.

High-quality polyols based on CO2 are not currently available on a commercial scale. The new polyols from Bayer MaterialScience are said to display the same level of quality as their ‘conventional’ counterparts.

In addition to putting waste CO2 to use as a chemical building block, the

process also permits a reduction in the amount of the petroleum-based raw material propylene oxide, which polyols are normally made entirely from.

“Improving the sustainability of everything we do is an integral part of our business strategy and this principle is implemented in our Dream Production project. We have succeeded in turning a waste gas that is potentially harmful to the climate into a useful raw material.

That helps the environment and mankind, and we all benefit,” said Bayer MaterialScience CEO Patrick Thomas.

Bayer MaterialScience developed the manufacturing process in collaboration with partners in industry and academia.

The company discovered the catalyst that brings about the chemical reaction with the required level of efficiency, and developed it together with the CAT Catalytic Center, a research facility in Aachen, Germany. The process was tested extensively in a pilot plant at the Leverkusen site as part of the publicly funded Dream Production research project. This was accompanied by a study of market demand.

The new polyol is used for the production of polyurethane foam, which finds applications in upholstered furniture, shoes and automotive parts, and is also used to insulate buildings and refrigeration equipment.

Bayer MaterialScience Web: www.materialscience.bayer.com

JUNE 2014 • WWW.EPPM.COM • 29

News

MATERIALS Silvergate Plastics launches colour match app

Silvergate Plastics, a European customcolour manufacturer, has launched an app that allows users to request a colour match via their iPhone.

Masterbatch customers can now log a colour match request to Silvergate from anywhere in the world using the app.

The Silvergate app can be found on the Apple app store (an Android version is yet to be launched) by searching for “Silvergate”. Requests for a colour match will be dealt with by Silvergate’s team, who will work with the customer to obtain the exact colour match.

Silvergate Plastics Web: www.silvergate.co.uk

Nine-layer barrier film offers 20% weight savings over seven-layer alternatives Reifenhäuser Kiefel Extrusion and DuPont have developed a nine-layer barrier film for thermoforming applications that is said to offer a weight reduction of up to 20% and improved packaging performance over seven-layer PA/PE structures.

The film was developed using Reifenhäuser’s 11/9-channel Evolution barrier blown film technology and a new high stiffness DuPont Surlyn ionomer sealant resin, which allows for sealing at lower temperatures and provides a broad operating window. The two firms say that further advantages include superior perforation and abrasion resistance as well as an improved fat barrier, making the new film a first choice for vacuum packs containing hard and sharp products, such as cheese or meat with bones.

Due to the high stiffness of the Surlyn sealant layer, film thickness can be downgauged by 20% with no loss in stiffness. Whilst common seven-layer film structures for thermoforming applications have typical thicknesses of around 240 µm, the thickness of the new nine-layer film is 200 µm.

The groups claim that despite this reduction, “the new film feels just as robust as current structures”. The product also reportedly displays higher gloss and transparency than competitive materials.

The firms are promising that the material costs for the new PA/Surlyn structure are around 10% lower compared to sevenlayer PA/PE structures.

The seal performance of Surlyn acts against liquid or powder contamination, meaning that the number of rejects along the distribution chain is also reduced.

DuPont and Reifenhäuser are claiming that for processors looking to invest in the technology, the initial outlay for a nine-layer blown film line will pay back in the short term, because the costs for a system including nine extruders and

ExxonMobil Chemical targets Asia with application collaborations • thin, tough cast power pre-stretch machine wrap packaging film using Exceed mPE and Enable mPE resins and Vistamaxx PBE at the Xinle Huabao booth; • high clarity tissue overwrap film with Exceed and Enable mPE resins at the Hubei Light Ind. booth; • and tough shopping bag film with high output using Vistamaxx PBEbased masterbatch at the Huashan booth.

ExxonMobil Chemical demonstrated a large portfolio of grades and packages for a variety of applications for the Asian market during this year’s Chinaplas.

Products on display included the Exceed and Enable metallocene polyethylene resins (mPE), Vistamaxx propylenebased elastomer (PBE), ExxonMobil polypropylene (PP) resins and Santoprene thermoplastic vulcanizates (TPVs), aimed collectively at the flexible and rigid packaging, automotive and polymer compounding markets.

However, in addition to displaying resins and applications on the stand, ExxonMobil Chemical used the event to demonstrate its grades in application use, via a number of machine runs at the booths of leading machine manufacturers, including: • thin, strong collation shrink multipack films using Enable mPE resin at the Sun Centre booth; 30 • WWW.EPPM.COM • JUNE 2014

The firm also teamed up with Milacron Plastic Machinery in China to demonstrate production of high-quality beverage cups with excellent impact performance using Vistamaxx PBE. Running on an Elektron 350T automatic injection moulding machine, the two companies demonstrated the manufacture of high-quality beverage cups using polypropylene (PP) that has been dry blended with Vistamaxx PBE at high speed. The combination produces cups with improved impact resistance and reduced stress whitening compared to PP cups in which Vistamaxx PBE has not been used to enhance performance.

The EE350 is a fast and efficient, multistep process machine designed to achieve short cycle times and improved output with the same energy consumption compared to similar products. Because it is a clean process that generates low noise, it is well-suited for assembly areas with a high density workforce.

“The combination of ExxonMobil Chemical’s Vistamaxx and our highly efficient manufacturing technology offers a solution that produces beverage cups with excellent performance, while saving energy,” said Jack Tang, senior application engineer, Milacron Plastic Machinery (Jiangyin) Co. Ltd. “The cups exhibit enhanced impact resistance for less breakage and reduced stress whitening for better aesthetics.”

Vistamaxx PBE can easily be blended with PP. The improved flexibility and toughness obtained by blending Vistamaxx PBE with PP, results in a simpler moulding process which is important for complex shapes, such as deep-draw cups, claims the group.

The low melt temperature and high flow of Vistamaxx PBE reportedly allow processors to reduce the processing temperature and to increase the processing rate compared to neat PP. This can reduce energy consumption during the manufacturing process and can improve processing efficiency. The better flexibility provided by the use of Vistamaxx PBE helps to increase the draw ratio resulting in fewer flow marks, better product quality and lower scrap rate. The scrap rate can also be reduced because the elastomer shrinks less than PP, making the production process easier to control.

ExxonMobil Chemical Web: www.exxonmobilchemical.com

blending units as well as a bigger die head are only 10-15% higher than those for a seven-layer line. Taking into account resin savings of 10%, the payback time for these additional costs will be less than six months, claim the firms. This can be further accelerated if higher sales prices for the superior films can be achieved.

At the DuPont and Reifenhäuser labs the optical, processing and application characteristics of the new nine-layer structure, produced with Reifenhäuser’s Evolution barrier blown film line, and with Surlyn on the internal surface, were compared to a standard seven-layer structure with a PE sealing layer, both combined with a PA layer.

In these tests, the new nine-layer structure provided a gloss gain of 10% and a 13% higher transparency over the conventional structure, and also exhibited improved thermoforming performance. Due to the stress-strain behaviour of the Surlyn sealant’s specific chemical structure with ionic crosslinking, the strength of the stretched areas of the film increases.

Thanks to this 'strain hardening', film thickness in the bottom corners of the thermoformed packs is higher than for PE-based sealants, which get weaker in stretched areas. Thus, despite the fact that the conventional seven-layer film was 20% thicker before thermoforming, both structures had identical film thicknesses in the corners after thermoforming.

The structure also responds well under point loads caused, for example, when the edges of vacuum-packed hard cheese, dry meats or bacon constantly press against the film. Under such conditions soft polymers in the structure can be displaced, weakening the film and creating micro holes over time. This is especially true for polyethylene copolymers used for high performance sealing applications. However, DuPont says that its Surlyn sealant polymers withstand such mechanisms, resulting in a 10% higher perforation resistance for the nine-layer PA/Surlyn structure compared to the 20% thicker seven-layer PA/PE based film.

Reifenhäuser Kiefel’s Evolution Ultra range of extruders were developed for easy processing of complex film structures with all kind of resins. The machinery supplier says that the range provides “outstanding flexibility in terms of choice and amount of high performance polymers including highbarrier grades, adhesives and sealants, so allowing use of the most suitable materials at minimum costs”.

The range allows for combinations of up to 11 channels, enabling the production of asymmetric films with minimum curling.

Reifenhäuser Kiefel Extrusion Web: www.reifenhauser.com DuPont Web: www.dupont.com

Injection Moulding Rotational Moulding Extrusion Blow Moulding Thermoforming Vacuum Forming Film Extrusion Recycling Materials Design

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30 September-2 October 2014

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News

MATERIALS

INTERVIEW: Sabic enters a new market — renewable polyolefins Sabic has launched its first ever portfolio of certified renewable polyolefins.

EPPM spoke with the global petrochemicals firm to discuss the first grades, sales and marketing plans, as well as the future of renewables.

The portfolio, which includes renewable polyethylenes and polypropylenes, is aimed chiefly at the packaging industry, though the group says that the technology is applicable to all of its polyolefins grades — and potentially all market applications.

Mark Vester, Sabic’s Business Unit Director LD/LLDPE, Europe, told EPPM: “In principle there should be no difference between these new polyolefins and existing grades, in relation to applications. However in the end it is the customer who needs to test for suitability in the applications.”

In terms of market potential, and the future of Sabic’s foray into renewables, Vester said: “The market is still relatively small when compared to the rest of the polyolefins market. But it has the potential to grow.

“This project sits perfectly within our mission to obtain a leadership position in sustainability. So we plan to drive this forward as much as we can.”

Sabic says it is the first petrochemicals company to be able to produce renewable second generation PP and PE; it attributes its progress to its position in Europe, which allows the group to be able to crack heavy

32 • WWW.EPPM.COM • JUNE 2014

renewable feedstocks made from waste fats and oils in its assets.

“Sabic’s market-leading move into the certified renewable polyolefins area is linked to the needs of our customers who increasingly require sustainable packaging solutions in response to both consumer and regulatory demands”, said Mosaed Al-Ohali, EVP Polymers, Sabic.

“It is a winning solution for our customers, as these materials can be converted readily on their existing equipment with no investment needed, and can contribute to an improvement of sustainability of their products”, he added.

“We have optimised our technology to allow the production of renewable PP and PE using renewable feedstocks, which are made from waste fats and oils and are not in direct competition with the food chain, with equal performance to those produced with fossil fuels,” said Vester.

“This technology has the potential to revolutionise both the plastics and packaging industry across Europe and around the world,” he continued.

In addition to external, third-party audits to obtain the renewable certification, Sabic undertook an internal Life Cycle assessment.

Speaking with EPPM, Dr. Steven de Boer, Director Innovation and Sustainability, Polymers explained the process: “For the process certification we worked with the ISCC (International Sustainability and Carbon Certification (ISCC) organisation), and of course there’s all kinds of requirements, especially with regards to our handling of the feedstock, and the business systems behind it. So we went through two steps: first, we had to show how our business works, and where our feedstock comes from, and then we had to have on-site audits to confirm that our systems comply. The whole process can be compared with obtaining an ISO certification.”

“Sabic is a big company, and we have internal resources on par with any LCA institute. A typical LCA would go from cradle-to-gate, but in this case we were able to cut short the analysis, because the product leaving our gate is essentially the same as a fossilfeedstock product. So we focussed the LCA on the upstream processes.”

In addition, Sabic worked closely with the Dutch Ministry of Economic Affairs under a Green Deal, on the concept of ‘sustainability certificates’, with the objective of encouraging the production and use of bio-based polyolefins within the industry.

The ISCC Plus certified polypropylene (PP) and polyethylene (PE) materials will be produced initially at Sabic’s production facilities at Geleen in the Netherlands. Sabic confirmed that the grades will be made available through existing sales channels.

Sabic Web: www.sabic.com

Composites

MATERIALS Single wall carbon nanotubes a commercial reality, says tech firm OCSiAl, an international technology firm headquartered in Luxembourg with manufacturing operations in Novosibirsk, Russia, claims it has developed a “breakthrough technology” for the production of single wall carbon nanotubes (‘SWCNTs’), which enables large scale, commercial production of SWCNT. Carbon nanotubes, which are thought to offer huge potential for the plastics and composites industries, could open up new fields of application as well as vastly improving mechanical properties of finished parts.

Estimated production of the SWCNTs is one tonne for the first year, which doubles current global production levels according to different estimates. Potential annual capacity of OCSiAl production is currently 10 tonnes.

The group says that this method is easily scalable and capable of producing an unlimited quantity of SWCNTs at a very low cost.

The announcement of the new synthesis process was made at the Institute of Materials, Minerals and Mining

by OCSiAl spokesmen Yuri Koropachinskiy, President, and Mikhail Predtechenskiy, Chief Technology Officer and inventor of the new synthesis method. OCSiAl’s production method is said to be based on notable findings in plasma chemistry and physics, combining to produce high-performance synthesis of SWCNTs, which

the firm promises will allow “literally unlimited output and unrivalled low production costs”.

Nanotechnology company, Zyvex Technologies, has already begun integrating OCSiAl nanomaterials into its products. “The use of SWCNTs could open the door to fundamental change in many industries, but there has always been an invincible obstacle: SWCNTs were only available in small quantities at sky-high prices, and quality wasn’t guaranteed. OCSiAl helps make nanotechnology applicable for many companies desperate for a commercially viable materials innovation,” said Lance Criscuolo, President of Zyvex Technologies.

The output, ‘as produced,’ will be sold under the brand name Tuball, yielding 75% and more of top quality SWCNTs, with impurities from catalyst particles encapsulated in carbon shells. The content of free metal particles does not exceed 1%, claims the group.

Numerous laboratory and industrial tests have reportedly proved Tuball’s ability to serve as a universal additive, enhancing mechanical strength and the thermal and electrical conductivity of materials that include composites, polymers, rubbers, metals, batteries, transparent conductive films and others.

Improvements in performance have reportedly been observed with addition rates of 0.001%-0.1% of Tuball.

Yuri Koropachinskiy said: “The unique combination of technical properties makes Tuball a sort of high-tech panacea which can drastically improve any known material’s properties even if added in very-lowquantities. By introducing Tuball OCSiAl sets a standard for a whole new product class that was never seen before. These are premium quality single wall carbon nanotubes supplied in sufficient amounts at commercially viable terms.” He added, “If single wall carbon nanotubes were discovered today they would have been called graphene tubes.”

Free samples of Tuball can be ordered now and shipped from OCSiAl stockhouses in Europe, Asia and the US. The commercial price for Tuball starts from $2000 per kg (€1458 at publication).

World’s first plastic car wheel on the horizon Sabic, Kringlan Composites and other industry partners are making progress in the development of the world’s first thermoplastic composite wheel. The wheel uses Sabic’s proprietary Ultem resin and Kringlan’s proprietary threedimensional composite design platform to create a material that can be used to replace metal and aluminum alloy, helping reduce weight and emissions in automotives and other applications.

“This ongoing collaboration with Kringlan is an excellent example of how we identify innovative companies with unique technology to collaborate on developing industry for the benefit of the downstream industries that we serve,” said Thierry Materne, Vice President, Technology & Innovation for Sabic’s Innovative Plastics business. “Combining Sabic’s highperformance Ultem resin with Kringlan’s proprietary three-dimensional manufacturing technology for carbon composites offers OEMs the opportunity for reduced weight, lower production costs, as well as material recyclability.

When compared to other thermoplastic materials, the Ultem resin composite concept offers superior strength at high temperatures, dimensional stability as well as resistance to chemicals,” added Materne.

To advance the wheel’s development, Kringlan and Sabic have been working on a prototype for a German automotive manufacturer. The significant weight savings made possible through Kringlan’s wheel design, coupled with the material technology employed, can improve fuel economy. In addition to emissions reductions, the wheel can also be manufactured with less environmental impact compared to conventional processes, and it offers full system recyclability.

The design of the part allows for the wheel to be mounted with either traditional metal spokes, or spokes with carbon fibre-reinforced Ultem resin composites, potentially enabling even greater weight savings.

The full composite wheel design complies with current standards set for metal wheels by the German testing institute TüV, which reportedly gives the firms the opportunity to work with additional global automotive OEMs for the prototyping of lightweight wheels according to their specific design and specifications.

“This new material technology resulting from the ongoing collaboration between Kringlan and Sabic has the potential to be a breakthrough for OEMs in multiple industries,” said Steffen Heinecke, CEO of Kringlan.

“Sabic’s support is critical to the success of this project. In addition to their world-class material technology, they provide application and secondary

operation expertise. Already, in the automotive industry alone, several OEMs have shown interest in the carbon composite wheel application, which can enable the reduction of CO2 from a passenger car by two to three percent.”

As well as the potential for the automotive sector, in consumer appliances, OEMs are focused on designing their products to achieve energy efficiency certifications.

In washing machines, for example, this new three-dimensional carbon fibre composite technology can reduce the inertia – the amount of energy needed – to start the machine drum moving, compared to current metal alternatives, which can mean greater efficiency, and potentially a lower carbon footprint for the machine. Additionally, by considering the use of the Ultem resin-based carbon fibre composites with Kringlan’s manufacturing technology, appliance manufacturers can potentially save costs by reducing the number of secondary operations required to develop key parts.

“We are very excited about our on-going collaborative work with Kringlan,” added Materne. “We share with them a passion to constantly drive innovation in thermoplastic applications. Our work with Kringlan demonstrates how we constantly strive to deliver added value, drawing upon our deep and relevant portfolio of material technologies, our in-depth expertise in materials science and engineering and the strong understanding that we have of our customers’ challenges and requirements. It is this know-how in materials and applications combined with our collaborative approach that allows us to fulfil Sabic’s promise to deliver chemistry that matters.”

Sabic Web: www.sabic.com JUNE 2014 • WWW.EPPM.COM • 33

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

1350mm Welex 3 Roll Stack. 300mm diametre rolls. Silent chain. Dc drive.

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1120mm wide EDI close approach PET sheet die model H100 with Flex lip and decals. Lip heater. Lip gap up to 2.5mm 1996.

60mm Betol Extruder Model BK60.

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34 • WWW.EPPM.COM • JUNE 2014

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250ltr Motan Luxor 80 Dryer with twin desiccant beds which provide consistently low dew-point air to process, while reducing energy consumption.

300mm wide Schwarbentham 2 roll laboratory mixing mill. Polymix 110 P.

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

100mm Union single screw extruder.

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250mm Speedex vacuum unit 125mm Speedex vacuum unit 125 Speedex Saw unit 75mm wide Betol Haul off Betol servo cutter

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ADVERTISERS’ INDEX Company Abbey Masterbatch

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Lanxess

7

Mashinenhandel Borowski

35

Plastic Investments

35

Tinius Olsen

24

Rawmec

35

visit www.plastrep.com

Rud Chains

35

and join the world’s fastest-growing plastics community for free!

Starlinger

13

TransXL

34

eppm To advertise here, or place display adverts in print or online Contact Lucinda Nicholls Tel: +44 (0) 1244 680222 Email: lucinda.nicholls@rapidnews.com

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To list a directory entry online,

JUNE 2014 • WWW.EPPM.COM • 35

23rd Fakuma – International trade fair for plastics processing

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Injection moulding machines Thermal shaping technology Extrusion plants Tool systems Materials and components

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14. – 18. OCT. 2014 . FRIEDRICHSHAFEN www.fakuma-messe.de