EPPM 17.4

June/July 2015 Volume 17 | Issue 04

APC (Adaptive Process Control) Stabilise your processes and maximise profits Cover Story | Page 8

Engineering Passion

Blown Film Technology: It’s Time to Share!

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

WITH YOU!

luigibandera.com houseofextrusion.com

34 10

24

Volume 17 Issue 4

IN THIS ISSUE Pg 6 INDUSTRY Bayer MaterialScience has revealed it will re-emerge as Covestro in September, floating on the stock market in 2016, while Europe is forced to get used to the idea of the now voted-in plastic bag legislation.

Pg 8 COVER STORY: THE CRUISE CONTROL OF INJECTION MOULDING KraussMaffei is bringing injection moulding hurtling into the digital age with its APC calculator. We investigate how Adaptive Process Control is transforming plastics processing.

Pg 10 RECYCLING MACHINERY TOMRA Sorting Recycling has given an insight into the efficiencies sensor-based sorting is bringing to recycling systems, while we take a look at some of the glowing reports early adopters of INTAREMA have passed onto EREMA.

Pg 17 INJECTION MOULDING Arguably the biggest news-generator of PLAST 2015 in Milan was Sandretto, which announced that it is entering the 3D printing market, and launching a new range of injection moulding machines, the Series Ten.

Pg 20 THERMOFORMING We share battenfeld-cincinnati’s insights into the changing landscape of thermoforming sheet processing and we touch upon some of the biggest thermoforming stories to cross our path in recent weeks, including the launch of GN Thermoforming’s high-speed thermoformer the GN800.

Pg 24 MATERIALS SPOTLIGHT Bayer MaterialScience is on a mission to restore the reputation of BPAs after 1,000 studies and a European Food Safety Authority report proved the material is safe, while we reflect on our Swedish adventure to Perstorp’s exciting new Oxo plant.

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

editorial editor rose brooke rose.brooke@rapidnews.com

production art robert wood production tracey roberts

advertising advertising managers Lisa Montgomery lisa@rapidnews.com Graham Voss graham@rapidnews.com tel: +44 (0) 1244 680222

subscriptions subscriptions@rapidnews.com qualifying readers europe - free, ROW - £115

Pg 29 EVENTS There’s always a major event on the horizon and Fakuma is just a summer holiday away, with a new-found zeal for additive manufacturing and a dedicated Thermoforming Island, while we look back on some of the biggest stories to come from Plastpol and ChinaPlas 2015.

outside qualifying criteria UK - £80, ROW - £115 please subscribe online at www.eppm.com

Address changes should be emailed to subscriptions@rapidnews.com.

European Plastic Product Manufacturer is published by Rapid Plastics Media Ltd.

Pg 34 EUREKA SERIES Exploring the Startup Garage at NPE2015, we met cycleWood and were intrigued to learn more about their plastics made using a by-product from paper manufacturing.

Their story was so interesting we wanted to feature it in our EUREKA Series.

Each issue is distributed in print and digital format to 17,845 buyers and specifiers in the European plastic processing industry. © June 2015.

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

All rights for European Plastic Product Manufacturer are reserved, and reproduction in part or whole without written permission is strictly prohibited.

BPA Worldwide Membership

WWW.EPPM.COM

3

International tool making and additive technologies exhibition and conference

Frankfurt am Main, 17– 20 November 2015 formnext.com

Where ideas take shape.

Representatives from the tool/form-making and additive technologies/3D printing sectors as well as their suppliers and partners will be showcasing their expertise to trade visitors from around the world at formnext in Frankfurt from 17 – 20 November 2015.

Benefit from this fascinating new exhibition concept in one of the world’s most spectacular halls.

For further information, call +49 711 61946-825 or write to formnext@mesago.com

From The Editor

Separating the pioneers from the dinosaurs

VISION

DEVELOPMENT

Welcome to the June/July edition of EPPM, in which I make fleeting reference to the new instalment of Jurassic Park and home in on those tyrannosaurus-sized subjects of recycling machinery, thermoforming and injection moulding. These massive corners of the plastics processing industry are continuing their evolution as machine manufacturers proceed in their perpetual quest to advance, compete and avoid extinction.

We are very proud to feature KraussMaffei as our cover star. Their Adaptive Process Control technology - the cruise control of injection moulding - is bedded into numerous systems around the world and the industry behemoth has topped this innovation off with its APC calculator, which actually shows manufacturers how much their now ultra-efficient process is saving in cash terms. It’s innovation like this that’s bringing plastics processing into the digital age and separating the pioneers from the dinosaurs.

TOMRA Sorting Recycling has provided us with a brilliant article on sensorbased sorting - both the science and the system in practice - while we look back on 18 months of happy INTAREMA users in EREMA’s customer roundup.

CREATIVE

INNOVATION

TEAMWORK

We caught up with the experts at battenfeld-cincinnati at PLAST 2015 in Milan in May where one of their experts shared some insights into the shifting sands of the European thermoforming industry, and why the foreign exchange market has provided the perfect conditions for European countries to sell machinery to South America and other dollar-led markets.

And from machinery to materials, EPPM has given Bayer MaterialScience (soon to be rechristened Covestro) a platform to share its message that despite what policy-makers and brands are saying, BPAs are in fact safe for humans - even babies, the elderly and pregnant women. Bayer MaterialScience’s experts are drawing on 1,000 impartial studies and a report from the European Food Safety Authority to get their message across, so maybe we’ll start seeing more of the right polycarbonates on shop shelves once more?

We also reflect on our visit to Sweden, where we attended the grand opening of Perstorp’s gigantic new Oxo plant - a shining silver beacon of commitment to the PVC market - and learnt more about Perstorp’s place in the Scandinavian and wider European plastics processing sphere together with its partners Borealis and AGA, the so-called Stenungsund Cluster.

Finally, we reflect on what has been an extremely busy few weeks, reviewing ChinaPlas and Plastpol, while looking ahead to AIMPLAS’s unique compounding event and Fakuma. We are already receiving preview pieces for our two Fakuma print editions so make sure and send yours along as soon as you are able to ensure it makes an appearance in print.

And with that I think I speak for everybody when I say, hold onto your butts!

Rose Brooke, Editor

WWW.EPPM.COM

5

Credit: ChinaPlas

INDUSTRY

Bye bye, baggie The European Parliament has voted in favour of cutting the EU’s usage of plastic shopping bags right down in a bid to protect the environment, but what does the new legislation really mean to plastics processors?

Words | Rose Brooke

T

he European Parliament has voted to curb the usage of plastic bags on the continent in a powerful bid to preserve the environment, but what does this mean for the future of this corner of the plastics sector in Europe?

“Changing over to reusable shopping bags reduces both raw material consumption and the accumulation of plastic waste.

In our opinion, reusable, recyclable woven plastic bags are the solution to the problems of single-use plastic bags.”

Championed by Denmark’s Margrete Auken, the new EU rules limit plastic bag consumption to 90 per person per year, but despite the vast majority of EU citizens routinely utilising ‘bags for life’, we still take home around 176 every year. The new law shines the spotlight on how this might be a more difficult nut to crack than once thought, not least for the plastics processors behind the manufacture of the millions of plastic bags Europeans use without a second thought.

She said that the cost-effectiveness and environmental benefits of utilising a durable bag should be enough to convince sceptics behind big brands.

Under the new law for lightweight bags (bags of between 15 and 50 microns thickness), EU member states must ensure that they no longer hand out lightweight bags to shoppers for free - they have until 2018 to enforce this. The alternative is to limit the use of bags to 90 per person by the end of 2019 by other means, slashing this to just 40 by 2025.

“Single use shopping bags from PE film are on their way out.

The trend is towards attractive, reusable woven shopping bags which transport the seller’s corporate image. Shopping bags from PP fabric are inexpensive to produce and popular for their strength and weather-resistance. They are durable, reusable and eco-friendly.”

Starlinger, she concluded, “doesn’t just watch trends, it sets the trend”.

It is estimated that in 2010, some eight billion lightweight plastic bags ended up as litter and the EU has calculated the new regulations will result in savings of €740 million (£531 million) annually when the new targets are in place. But while the EU will be saving money, does this mean revenue lost for plastics processors? Similarly, is the news a boon for those in the value chain for hard-wearing, woven or thicker-walled plastic bags?

But the European plastics processing industry has not always been so embracing of the change. In November 2014, Managing Director of the trade association for Europe’s plastic converters EuPC Alexandre Dangis said the industry was “disappointed that the EU institutions were not able to manage this piece of legislation in a better way” owing to the potential difficulties it could cause for the sector, not least the threat of job losses if demand dwindles seriously.

A spokesperson from global leader in woven plastic bag production Starlinger was positive about the change.

“[The EU] should work with industry and not against us,” he remarked.

Return of the Maag Maag Pump Systems has discontinued its PSG brand and liquidated Dover Pump Solutions (Europe) GmbH. Maag, which is renowned for its strong brands and specialised products tailored closely to customers' needs, sees this move as a means of enhancing its business. Customers with pending orders from Dover Pump Solutions Group (Europe) GmbH - which has now become Maag Pump Systems Ag - will be contacted directly by their designated contacts.

6

Moreover, the merger between Maag Pump Systems GmbH and Automatik Plastics Machinery GmbH in Germany has been finalised, forming Maag Automatik GmbH. Maag Pump Systems AG, Oberglatt, Switzerland, as well as Maag Automatik GmbH, Grossostheim, Germany, are both business units of Maag, which is part of the Dover Corporation.

WWW.EPPM.COM

Covestro: Bayer MaterialScience new identity revealed Bayer has announced the new name of its MaterialScience division. Bayer MaterialScience will become Covestro from September 1st 2015, floating on the stock market by mid-2016 at the latest.

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

Bayer announced the decision - which was widely known as the 'worst kept secret in plastics' - to float Bayer MaterialScience as a separate company in September 2014 in order for it to focus on its healthcare and agricultural operations.

Really?

STAGE 1

Heat

STAGE 2

Vacuum

STAGE 3

Blanketed Retention Hopper

Covestro was chosen as the hotlyanticipated new name after splicing the words collaboration, investment and strong, representing the business's values.

Being a separate company gives Covestro a greater flexibility to independently pursue its business goals.

CEO of Bayer MaterialScience and CEO designate of Covestro Patrick Thomas said: "Covestro represents a bold new direction and bright future for an innovation-driven polymers company. We are a company that is underpinned by strong and experienced management with a proven track record of excellence and full commitment to value creation. We have loyal and dedicated employees with whom we are confident we can build our future success.

"The new name is part of a brand and identity that is the result of listening to our customers, employees and others close to our business and which reflects our innovation, talent and big thinking. I am absolutely convinced that our colourful identity and positive vision will help inspire and motivate us on our new path to the future."

MIN

Model VBD-150

Really! Just 35 minutes for our versatile, 3-stage VBD-150 vacuum dryer versus 4+ hrs for desiccant dryers. Oh, and at 60% LESS energy consumption, that makes Maguire Vacuum Dryers the most time saving, energy saving, cost saving, and footprint saving dryer in the market. Bar none!

• Dries resin six times faster than desiccant dryers, and uses 60% less energy • Unique, patented 3-stage drying technology with “zero maintenance” required • Double-insulation on all vessels prevents heat loss • “High speed, no stress” drying eliminates material degradation

ADING

INDUSTRY LE

AR 5 YE RANTY WAR

STANDARD

WWW.MAGUIRE.COM The perfect blend of simplicity and control.

USA: 610 459 4300 | CANADA: 905 879 1100 | EUROPE: +44 1827 265 850 | ASIA: +65 6848 7117

MAGUIRE_EPPM_VBD150_9_14_M.indd 1

WWW.EPPM.COM

9/4/14 1:12 PM

7

COVER STORY

The cruise control of injection moulding Adaptive Process Control is helping plastics processors to not only make substantial efficiency gains, but the innovative new APC Calculator from KraussMaffei is helping manufacturers see their gains in euros per hour.

Words | Rose Brooke

A

daptive Process Control - or APC - is bringing to injection moulding, what cruise control brought to long-distance driving.

KraussMaffei’s APC system promises zero-defect injection moulding production, and targeted adaptation of the changeover point and the holding pressure profile in each cycle. How? Because APC keeps the weight of the finished part, as specified by the mould-setter, consistent during on-going production regardless of external factors. And now, KraussMaffei has developed the APC Calculator, which automatically estimates annual savings in euros by inputting shot weight and cycle time parameters and the price for new material.

Rejection rates are closely watched in the injection moulding process and could make or break a manufacturer’s bottom line.

External factors such as changes in room temperature, humidity and raw material properties when using recycled materials can be factors in processes with even stable configurations. To compensate for any variations in the manufacturing process, KraussMaffei’s APC system configures the ideal process, detecting any deviations and making constant alterations.

Offered for all series from KraussMaffei, the system eliminates all faults, allowing the manufacturer to retain consistently high product quality - and with the calculator function, manufacturers know exactly what their efficiency gains amount to in cash terms.

After a material change, injection moulding machines without APC show significant fluctuations in output quality (top) whereas constant good quality can be achieved with APC (bottom) >>

8

Two steps to consistent component quality Step 1: Analysis APC analyses the current process status, enabling the machine to keep a configured process stable if the external factors such as batch fluctuation change the viscosity of the material or the flow resistance in the mould. These changes are detected by recording specific key parameters such as the melt pressure curve of the machine.

Step 2: Control Through clever evaluation of process data gathering in Step 1, the machine can respond to the current process state within the specified limits. APC adjusts the changeover point and the holding pressure profile to the existing melt viscosity and current flow resistance in the mould. This makes it possible to compensate for deviations online and in the same shot. Among other benefits, this results in a significantly more robust production process.

APC produces uniform shot weights within a very small tolerance, leading to the consistent component quality that can already be seen in various KraussMaffei customer projects.

“Injection moulding processes are validated mostly under the premise of constant process parameters,” explained KraussMaffei’s Head of Machine Technology Dr Reinhard Schiffers. “An adaptive intervention in the process and a change of the relevant parameter is therefore a controversial practice and may even represent a paradigm shift. Nevertheless, products become more complex by functions integration, usage of multi components and more complex materials.

“Manufacturing becomes more prone to disturbances and machine makers are forced to meet customer needs to continue providing high quality machines, so reception in the market has been good from the beginning as the benefits were obvious. Once operators on the machines understood the mechanism behind the technology, they easily adopted it.”

WWW.EPPM.COM

package, KTW acquired the MX 2300, which produces wheel house shells from recycled materials for a large German automaker. In order to gain experience with the new features during day-to-day production and to apply these experiences to the development process, KraussMaffei equipped this large machine with the APC process control system.

The polyolefin recycled material produced by KTW for wheel house shells is stored in 80-tonne silos. Depending on their origin, the recycled materials vary in terms of grain size, consistency and bulk density, leading to substantial fluctuations in viscosity.

KTW uses the APC system to intervene in the production process automatically, within definable limits, so that a change in material viscosity does not lead to fluctuations in component weight.

<< During the manufacture of pallets, APC produces annual potential savings of more than €205,000.

On a KraussMaffei MX 2300, KTW produces wheel shells made of recycled material for a large automaker.

While doing so, the APC Adaptive Process Control system ensures zero-defect production.

The new numbers game The APC calculator function - which was launched in May 2015 is available in five languages (English, German, Spanish, Chinese and Russian) online and automatically estimates annual savings in euros by entering data including cycle time and shot weight parameters, and material price. The function then immediately compensates for fluctuations in the injection moulding process resulting in fewer rejects. The overall substantial savings can be made in regard to time, costs and material. Higher recyclate proportions can also be processed.

Offering maximum flexibility, all data can be changed at any time, automatically adjusting the result.

“Let’s take a specific practical example, i.e. tube shoulders,” said Hans Malinowsky, Product and Technology Manager at KraussMaffei. “With a throughput rate of 27 kg/h, a new material price of 1.10 euro/kg, a 1.5 per cent reduction in the reject proportion and a two per cent increase in the recyclate proportion, this produces annual savings of €4,207 (£3,060).”

These savings are even more substantial with higher throughput rates during the production of pallets (throughput rate of 440 kg/h, new price 1.15 euro/kg), for example, annual savings of more than €205,000 are attained.

APC tests its automotive mettle One application where APC has proved it is a valuable tool in the plastics processor’s arsenal is in automotive.

In 2012, KTW Kunststofftechnik Weißenburg and KraussMaffei commenced a joint project aimed at reducing the rejection rate in the injection moulding process. This is because over time external factors were affecting component quality, particularly when using recycled materials.

To compensate for these fluctuations in the process, KraussMaffei brought its APC system into the production stage with KTW. KTW is a medium-sized Tier 1 automotive supplier specialising in high-quality exterior and interior components such as finishers, panelling covers, air ducts and wheel house shells, which are manufactured using both standard injection moulding and special processes involving multi-component technology, over-moulding of film or fabric and variotherm technology.

The Weißenburg-headquartered company processes approximately 5,000 tonnes of thermoplastic per year on more than 20 injection moulding machines. Since 1998, the company has relied solely on KraussMaffei injection moulding technology, installing 14 fully-automated machines in the clamping force range of 80 to 2,300 tonnes between 1998 and 2012. In 2011, as part of a larger

“The use of the APC function enabled us to substantially improve continuous monitoring of melt quality, significantly reduce the subsequent rejection rate and guarantee precise traceability of the components down to the individual shot,” said Albert Burghart, Plant Manager of KTW in Weißenburg.

“This project involved close collaboration between our two companies that proved to be fruitful for both parties. Our insights and wishes were successively applied to the development of the new machine function. Everything went off without a hitch.”

Going mobile?

APC technology took off in Europe thanks to KraussMaffei’s close relationship with a number of local industry partners but the innovation has since been adopted by injection moulders in the US and Asia - and there is still no real competition on the marketplace.

“The goal of APC development was to improve process robustness and component quality,” said Schiffers. “Though, condition-based switch-over is not new to plastics, [a system like APC] has never been achieved before by a machine maker. KraussMaffei is unique with this technology on the market.”

So what next for APC? Schiffers suggested there is scope for evolution but it is important to bear the traditionalist injection moulding sector mentality in mind.

“Further development regarding process robustness and process capability are absolutely essential,” he remarked. “Nevertheless, the machine-making industry is recognised as being conservative, therefore [developments such as] mobile applications must give customers immediate benefits.”

Albert Burghart, Plant Manager at KTW in Weißenburg >>

WWW.EPPM.COM

9

RECYCLING MACHINERY

Sensor-based sorting: breaking new ground in plastics recycling TOMRA Sorting Recycling’s automated sorting technology is being adopted across Europe. Frédéric Durand explains just how innovative sensor-based sorting and automation is improving both efficiency and the end product.

Words | Frédéric Durand, Plastics Segment Champion at TOMRA Sorting Recycling

D

evelopments in automated sorting technology are making it possible to achieve exceptional purity results in plastics recycling – from coloured and clear types of plastic such as PET and HDPE, to other polymers like polypropylene, polystyrene and PVC. With the right combination of automated sorting technology, it is possible to achieve previously unfeasible purity levels of over 99.99 per cent.

Recovered end fractions can be used to produce recycled products such as fibre for the textile industry or to make new sheets or bottles. This closed-loop approach, which reduces demand for virgin materials, is working very effectively in a number of European countries such as Austria, Germany, France and Belgium. These countries have not only introduced effective waste legislation, but have invested heavily in their waste infrastructure and, in particular, in the right sorting facilities and technology.

Let’s take a look at some of the more challenging areas of plastics recycling where sensor-based sorting is helping European recycling companies achieve ground-breaking results.

Flake sorting for food-grade material At TOMRA Sorting Recycling, we have developed the AUTOSORT flake sorter – a world-class plastics recycling solution that is enabling reprocessors to achieve the high purity and quality levels demanded by customers for food grade recycled PET (rPET) flakes.

The unit combines a visible range spectrometer (VIS) to detect colour contaminants and a near infrared (NIR) spectrometer to detect different polymer types such as PET, HDPE, PP, PVC, PA, PS, PLA etc. Flakes as small as 2mm can be identified and sorted, contamination is eliminated and a consistent yield of super-clean recycled PET can be delivered at unparalleled purity levels.

TOMRA is currently involved in a project for French company Regene Atlantique – part of the SUEZ Group. Regene Atlantique operates a PET recycling plant in Bayonne in the south west of France where four AUTOSORT units and the latest AUTOSORT flake technology are installed. Using this combination of technology, Regene Atlantique can achieve the quality levels required by some of the biggest soft drinks companies in the world. Contamination

10

levels are set by these customers of below 10ppm (parts per million) on PVC, below 3ppm on metallic (ferrous and non-ferrous particles) and less than 200ppm on other unwanted material such as other colours or polymers.

Flake sorting is likely to be a major growth area in many European countries in the future as it offers a highly effective final opportunity for recycling companies to improve their material quality and satisfy customers’ requirements. On the back of the success of PET flake sorting, TOMRA is now developing a similar solution for PE and PP flakes.

Black plastics Black plastics is another area where sensor-based sorting technology is breaking new ground. Many packaging companies favour black plastics for certain items but infrared cameras cannot detect the carbon in black plastics so historically this material has not been recyclable. Now though, studies are looking at adding a pigment or marking to the bottles or trays that would make the material detectable and recoverable using AUTOSORT.

Opaque PET Throughout Europe, the use of PET continues to grow and PET bottles are widely replacing HDPE bottles. Opaque is used in PET bottles to protect the contents from light and oxygen but this can cause problems when it comes to recycling, as the opaque bottles can easily be confused with HDPE by the human eye. However, the AUTOSORT unit is capable of detecting and recovering all types of opaque PET bottles from transparent colours, making it possible for the first time to recycle this increasingly popular plastic material.

PET trays Currently, PET trays, which are normally used for meat products, are not sorted out separately or recycled, however the latest sorting technology is capable of detecting this kind of multi-layered PET product. Although the recovered material is still classed as waste, work is underway to determine how this co-polymer can be properly recycled.

WWW.EPPM.COM

Plastic films The AUTOSORT unit is capable of detecting and recovering all types of opaque PET bottles from transparent colours, making it possible for the first time to recycle this increasingly popular plastic.

A good example of closed loop recycling in practice is the recycling of plastic foils from packaging. Using the latest automated technology, it is now possible to achieve 100 per cent recycled content clear films or high purity PE films which are suitable for extrusion and use in new product manufacturing, completely closing the loop on plastic foils. A major French PE foils manufacturer is already using TOMRA’s technology with great results.

RECYCLING Solutions Efficient + Flexible

Detecting different types of PE Sensor-based technology is also capable of detecting different types of PE and one application that is generating a lot of interest is separating food and non-food packaging. TOMRA has developed a pioneering unit that uses an extended wavelength scanner to detect the difference between homo- and co-polymer. This process makes it possible to separate the non-food containers, which would be almost impossible to do manually using visual inspection. It is effectively separating two polymers within one polymer group.

This solution is already in place at Australian packaging and resource recovery company, Visy Industries Australia Pty. The company has installed a bottle-to-bottle recycling facility in New South Wales, Australia, for the food-grade production of PET and HDPE regranulate. The plant is the first of its kind in Australia and produces 2,500 – 2,900kg of recycled food-grade PET pellets and up to 1,500kg recycled food-grade HDPE pellets per hour. It operates using a PET recycling extruder and HDPE decontamination equipment from Starlinger, a Sorema washing line, and sorting equipment supplied by Stadler Anlagenbau GmbH and TOMRA Sorting Recycling. The input material consists of PET and HDPE bottle waste from kerbside, commercial and industrial waste collection. The recycled PET pellets are used by Visy in its own preform production, while the food grade rHDPE pellets from milk bottles are sold to customers worldwide.

Granulator SB Series with Forced Feeding Device

Q

30 % – 100 % more capacity with the same granulator cutting chamber size. Up to 50 % less power consumption. Suitable for dry and wet operation.

Plastcompactors Series HV

Future innovation With continued investment in R&D, a commitment to a culture of innovation and close collaboration with plastics manufacturers and recycling companies, TOMRA is continually striving to identify new plastics recycling opportunities.

Q Q Q

Agglomeration of bottle flakes, powders, fibres, film and foam materials Re-crystallisation of PET flakes Thin-film drying from post consumer washing lines

PLANTS for washing, separating and drying of dirty and mixed plastic waste Q Q Q Q Q

Agricultural films Plastics from post consumer waste PET bottles Bottles and hollow components out of PE/PP PE films, also stretch ch films 20152 FFaakuma 656 002 5202 6 o A o 6 B th oth HabbllooA 2 am 0122500115 inoggrdhha2m 0645 elfin BEBirirTm m M R P M RRW 0 N W Cth6G9 Boo4oth Haallllb12o8obth H

Herbold Meckesheim GmbH Industriestraße 33 D-74909 Meckesheim Tel.: +49 (0) 6226/932-0 Fax: +49 (0) 6226/932-495 herbold@herbold.com

www.HERBOLD.com WWW.EPPM.COM

11

RECYCLING MACHINERY

Birmingham Granulators posts H1 rise in Inan machinery sales NEC BIRMINGHAM, UK | 26-28 SEPTEMBER 2017

INJECTION MOULDING

EXTRUSION

ROTATIONAL MOULDING

BLOW MOULDING

RECYCLING

THERMOFORMING

M AT E R I A L S

VACU UM FOR MIN G

DESIGN

FILM EXTRUSION

B

irmingham Granulators has posted a steady increase in sales for its new Inan Plastik machinery for the first half of 2015, with particular interest in its pulverisers and thermoforming line.

Istanbul-headquartered Inan Plastik has been manufacturing plastics recycling machinery for over 25 years and selling worldwide, but the machinery Birmingham Granulators has been importing and selling into Europe has proved there is a much larger market to be tapped for this hardware.

"The post-sales feedback we are receiving is very pleasing," said Birmingham Granulators founder Tim Aaronricks. "We are delighted our customers feel they have real value for money."

Aaronricks admitted it can be tough introducing new machinery to the marketplace, as it takes time and confidence to build a solid foundation of customers. "[As we are] becoming even more competitive in the European market," he stated, "we can offer a better deal all round."

EXHIBIT NOW www.interplasuk.com 12

WWW.EPPM.COM

"Since we have imported various sizes of granulators and ancillary items to our premises, customers can take the opportunity to view and trial their product and inspect every aspect of the machines to ensure suitability prior to purchase. The post sales feedback we are receiving is very pleasing and we are delighted our customers feel they have real value for money," Aaronricks noted, adding: "We are also able to offer service plans if required by our fully trained electro/ mechanical engineers and provide a full range of spares, including blades, screens, blowers, cyclones and pipework. Together with our blade sharpening service and fully equipped workshop facilities for repairs and refurbishment we feel we can offer a good all-round service."

RECYCLING MACHINERY

Megaport Ltd, Bulgaria

INTAREMA 18 months on...

I

t has been a year and a half since EREMA made its big splash at K 2013 with the INTAREMA plastic recycling and extrusion system, which promised maximised productivity, flexibility and ease of operation underlined with consistently low energy consumption.

1108 T is a considerable improvement in terms of the amount of edge trim to be processed. It is impressive to see that although it is virtually the same size as its predecessor you can process one third more material without any reduction in the quality of the recycled pellets produced."

PolyKar Industries in Canada were already "very satisfied" with their TVEplus, which they had installed in 2011, leading to their investment in an INTAREMA 1310 TVEplus with SW RTF melt filter.

Vice-President of Business Development Amir Karim said: "Based on this positive experience, we decided in favour of an INTAREMA in the course of extending our capacity."

The INTAREMA 1310 TVEplus with Laserfilter installed at Copo-Plast Heinrich Winkler in Spring 2014 was described by Heinz Winkler, Managing Director, as "magnificent", with the Laserfilter being singled out as "absolutely perfect when it comes to [sorting] impurities". BPU Recycled Products, who also had Laserfilters installed but this time with an INTAREMA 2018 TVEplus, was similarly impressed. Operations Director for Recycled Products Ken Oswin said: "We are delighted. EREMA is a first-class company providing a brilliant machine which we know will give us many years of production and provide great value for money."

And INTAREMA continues to make the headlines, with customers all over the world adopting this innovative technology and seeing their production processes greatly advanced as a result of the investment.

More than 150 INTAREMA systems featuring EREMA's newly developed and worldwide patented Counter Current technology have been shipped and installed across the planet, from as far afield as South Africa and Canada.

One of the first installations was made at SML Maschinengesellschaft in Austria for in-house recycling. Product Manager for Cast Film Extrusion and MDO Thomas Rauscher said: "The new INTAREMA

Bulgarian Megaport said of their INTAREMA 1714 TVEplus with Laserfilter - which was installed in spring 2014 for post consumer recycling - that the installation provided them with "exceptionally good quality" pellets. Founder Miroslav Angelov said: "The price/performance ratio is remarkable and operating the system is very easy. The efficiency of the new Laserfilter is also very impressive."

WWW.EPPM.COM

13

RECYCLING MACHINERY

Bunting Magn e Europe innov tics a Recycled UK’s tes sorting Bunting Mag

Bulletin: s for n io t lu o s t r a Sm s efficiency gainnamic recycling

line is dy R A ST co in re recycl g both new Starlinger’s of the plastic cy en ci degree fi ef e th anks to its high th lly transforming ta en nm nt operation, and enviro e and consta economically bl lia re g input rin n ensu the types of of automatio ty regarding ili ib ically ex at fl m d to an s s down au higher output starts and shut amic R yn A D ST co its re d e chnology an materials. Th te rt 10 ta tS by ar n umptio tive Sm using innova h energy cons as ty sl ci n pa ca ca e er ag ck ART feed Automation Pa g increased SM rin su its en n, le tio hi di w ad dow, all the per cent. In in w g s, in es at oc er ible to pr rger op makes it poss results in a la quality. “This t uc at has varying od th f pr uf nt fl te consis regrind or of er m su on -c st al Manager for example, po said Elfriede Hell, Gener ls,” moisture leve gy. cling technolo cy re r ge Starlin

netics Europe ’s magnetic se has been adop parating tech ted by Recycl nology ed UK, enhanc metal separa ing the compa tion and rem ny’s oval operatio Production D ns. Recycled irector Paul UK’s Cotton starte Bunting at In d discussions terplas in 2014 with on how to ta issue of metal ckle the on-g contamination oing and the Wolve business has rhampton-bas now installed ed two magnetic Magnetic Pulle separators. Th ys convey mat e erial into a mag ferrous metal netic field whe is held to the re belt as non-m continues on agnetic mater its normal ial trajectory w hile Plate Magnets remove and capture fine iron filings from conveyed plastic. Sinc e their installation, Recycled UK has reco rded no stoppages du e to metal contamination.

Presona launches LP 60 VH baler has UK Presona new a in d me lco we the LP 60 VH ly popular LP series, addition to its global The machine’s ess technology baler. energy efficient pre-pr -press force pre a h d press force wit key feature is its enhance , giving the nes ton 60 of in press force of 25 tonnes and a ma allowing ile g it easier to handle, wh t thus bale extra density makin igh he in es of six or more bal e LP Th it to be stored in stacks ts. cos on ati ce and transport re ssu saving on storage spa pre nnel ly-designed friction cha ile wh t, 60 VH features a new pu gh ou quality, density and thr control to improve bale of wasted wire, it reduced the amount un the sustainable tying e within the st expensive consumabl as baling wire is the mo baling operation.

ARTEC redesig addresses ris n in demand for re g cycling Austrian

machine manuf acturer ARTEC system a rede has given its re sign in order cycling to better addr pressure on th ess the increa e plastics recy sing cling market, as to grow. The ne demand contin w-look machine ues is now even be processing plas tter equipped tics with higher for degrees of co moisture cont ntamination an ent, allowing fo d r agricultural from post-indu film and trimm strial film prod ings uction or PET EPS material packaging an in d all its forms. Th e modular system consists of six units in differe nt sizes and capacities, whi ch can be combine d flexibly based on specific recycl ing tasks.

14

Madrid hos t recycling co s plastics nference Plastics recy cling indust ry

forerunners counterparts will join with in the paper their recycling se Madrid this ctor at a su autumn. Th mmit in e 2015 Paper Europe and Recycling C 2015 Plastic onference s Recycling has been co Con nfirmed to ta ke place at th ference Europe Tower Hote e Eurostars l in the Spa Madrid nish capital and 29th 20 on October 15, where p 28th olitical decis owners, recy ion-makers, clers and oth brand er stakehold value chain ers through will come to out the geth the industry and recycled er to discuss the futu re of as a comm plastics and odity. This paper mater year's outi ials markets for ng w established and emergin ill examine the commoditie g recovered s, in additio n to growin scrap efforts and g trends, co recovering llection scrap from obsolete elec tronics.

WWW.EPPM.COM

INTAREMA® The new system generation from EREMA.

Needs less. Gives you more.

INTAREMA® systems protect your resources: thanks to ecoSAVE® technology as a standard feature, with up to a remarkable 12 % less energy consumption, reduced CO2 emissions and lower production costs. Plus you have an overview of energy consumption at all times – with the practical energy display on the operating panel of your INTAREMA®.

CHOOSE THE NUMBER ONE.

CUSTOMIZE YOUR OUTPUT

Flexible, intelligent and powerful

25 % humidity | 100 % printed | heavily contaminated Challenging recycling applications are our business Ins_220x156_260515.indd 1

member of GAWGROUP

ARTEC – The Plastics Recycling Specialist

www.artec.at 26.05.15 13:12

WWW.EPPM.COM

15

Protect your process and equipment with separation equipment from Bunting!

Eddy Current Separator

Separation of small aluminum chips from shredded and ground plastic flake materials.

Busted!

This company’s QA program AND reputation

FF Series Drawer Magnets

Plastics industry’s most popular choice for extrusion, injection and blow molding equipment for the removal of ferrous material.

Features temperature-compensated, Rare Earth magnets for superior high temperature operation.

With our broad spectrum of physical testing machines, software, and technical support, Tinius Olsen can help you assure quality from material to end product. To international standards and your toughest specifications. Reputations (yours and ours) depend on it.

quickTRON™ 03R

Economical, compact design for Hot Runners and other demanding plastics applications. Detects and rejects fines as small as 0.4mm in diamter.

The first name in materials testing.

Tel. +44 (0) 1442 – 875081 Fax +44 (0) 1442 – 875009 www.magneticseparation.co

www.TiniusOlsen.com

EPPM UK qtr page ski boot 107 x 158 Apr 2015.indd 1

3/19/2015 4:58:08 PM

Birmingham Granulators Ltd supplies new and used machinery to the plastics manufacturing and recycling industry UK and Ireland agents for Inan Plastik range of granulators, extruders and pulverisers

We carry out servicing, electrical and mechanical breakdowns, repairs, refurbishment, blade change and blade sharpening (24 hour express service offered) n Granulator and shredder blades n Blade sharpening n Screens n Pipework n Fans and cyclones n Bag Stands n New and used granulators and shredders n Extruders n Compounders n Agglomerators n Pelletisers n Pulverisers

Telephone: 01827 838840 16

Email: info@granulators.org WWW.EPPM.COM

www.granulators.org

Perfect TEN: Sandretto unveils new injection moulding system

INJECTION MOULDING

Sandretto has unveiled its new Series TEN injection moulding machines on home turf at PLAST 2015, bringing clamping innovation and a holding force of up to 500 tonnes to the market.

Words | Rose Brooke

W

ith a stadium-like stand in the heart of one of the busiest plastics shows in Europe, Sandretto was already attracting attention - with or without the announcements that would send industry media into an enthusiastic froth.

Sandretto chose PLAST 2015 as the perfect opportunity to launch its Series TEN injection moulding system on home turf, just east of its birthplace of Turin, along with an exciting new 3D printing venture.

Herculean holding force The Series TEN systems have a holding force of between 30 and 500 tonnes and are covered by two patents. They feature a brand new clamping unit, an innovative injection unit and a strong, rigid base structure that can resist the acceleration of masses. The clamping unit comprises numerous clever features including the five-point toggle with nitriding steel pivots and bushings with lubricated inserts.

The electrical-hydraulic system offers energy savings of up to 25 per cent over traditional variable displacement systems and significant noise reduction. It consists of a liquid cooling brushless servomotor coupled with a pump with internal gears activated by an inverter, guaranteeing higher performances compared to systems with variable displacement pumps.

This highly dynamic solution also gives users the power to control the exact load displaced by the pump, while a proportional mixer has been added to the mould axis in order to guarantee high performance combined with an optimal level of control and repeatability.

Made in Italy Sandretto is now owned by Photonike Capital SA, which is listed on the Paris stock exchange. New management has organised the nearly 70 year-old company vertically, concentrating manufacturing in its Pont Canavese plant, extending over more than 40,000 m sq, 25,000 of which are undergoing extensive reconstruction as Sandretto continues to develop, expand and innovate plastics processing.

The company's 'Made in Italy' mantra forms its identity. By maintaining its Italian headquarters and cooperating with national partners - not to mention ensuring an unmissable presence at the biggest plastics processing show in Italy - means its emphasis on maintaining both high-quality manufacturing skills and good design set the bar.

Sandretto enters the 3D printing fray Along with making waves in the injection moulding segment while at PLAST 2015, Sandretto set off a veritable tsunami in the additive manufacturing world on the announcement of its foray into 3D printing with its new Delta 3D printing technology.

On the vast Sandretto stand, Additive Manufacturing COO Roberto Moretti told EPPM that the smallest of the series of three machines can extrude 35 grams of material per hour, while the largest can build with 160 grams of material per hour using its exciting new nozzle technology, which will be revealed at a later date.

“What you see here is new, new, new! You will never find anything like it in the whole industry.”

Moretti claims there is only one other machine that can match Sandretto’s technology for speed, the machines are perfect for not only the prosumer market, but the product design sphere and short-series manufacturing.

With some Belgian funding and the sharp minds of the developers in the Sandretto Skunk Works Lab, the new printers come in at €2,000 (£1,427) - or “less than a MakerBot”.

WWW.EPPM.COM

17

INJECTION MOULDING

Sumitomo (SHI) Demag

king

cord-ma stuns with re i e ff a M s s u ra K stallation Swiss IMM in

nery world by oulding machi m n io ct seen je in e pe fittings yet has stunned th r extra large pi fo KraussMaffei .000 ne 01 hi /1 ac 00 m rgest ever 3200 - 101.0 and installing the la ems. The MXH st nd la Sy er ng itz pi Pi Sw for GF weight in ot sh d to an in Switzerland up e rc ameter of st clamping fo ttings with a di fi pe pe pi has the greate pi of e g m lu lin hand re large-vo sures reliable e can manufactu L340 robot en rd-breaker du 0 co 50 re KR s is IR Sw Its a so al at is 500 mm. ity ch hi nit Util to 120 kg - w of Business U fittings of up 340 kg. Head of challenge”. d al ci oa yl pe pa “s a stment as ve in to its maximum e th ed rib her desc GF Claude Fisc

is Smart to future-pro

of

Sumitomo (SHI) Dema g’s all-electric IntElect Smart range has been enhanced by the introd uction of the Series 5.

Comprising six marketleading features, the ma chine is designed with high-precision trade moulders in mind and tac kles key obstacles that might have previously put moulders off from making the leap to ele ctric. This new addition to the IntElect Smart ran ge overcomes the need for hydraulic cores, while delivering accura te dosing and a strong, fast and precise ejector mechanism. UK Managin g Director Nigel Flowers commented: “We’re entering an era where precision and quality are n’t confined to the electronic or medical device market and dem and for shorter cycle times, coupled with en ergy efficiency savings and precision is driving customers towards ele ctric injection moulding machines.”

Husky launches PET preform barrier module Husky Injection Molding Systems has announced the beginning of a phased approach of its PET preform barrier module, build on the industry-leading HyPET HPP5 platform. The introduction of this technology offers manufacturers with new possibilities to explore PET as a packaging material for products requiring enhanced barrier properties. Husky’s Vice-President of Engineering and Business Development Robert Domodossola said: “With our barrier technology, our customers can now consider PET as a viable paclaging material for a greater variety of products and still take advantage of the industry’s fastest, most capable and reliable, integrated injection moulding solution.”

Meusburger launches new micro moulds

Leading manufacturer of standard parts Meusb urger has launched a new product group of ready-to-use micro mo ulds. These standard moulds for micro inje ction moulding are esp ecially designed for use on Babyplast machi nes with an ejector set that enables precise positioning with an optim al guiding system. The mould tools are easy to configure and can be ordered via Meusburger’ s online catalogue.

Meusburger also provid es the CAD data for all its products. The standardised ejector set s are unique to the ma rket and the cavity plates are available in a wide range of materials enabling their use in a variety of applications.

18

Milacron’s Ferromatik

world tour continues

ernational campaign the momentum of its int Milacron is maintaining suring its cuttingen brand Ferromatik, by n ctio inje its te mo to pro d the world at major technology is seen aroun edge injection moulding Ferromatik injection springboarding the new shows, with NPE 2015 Klear Can produced e ether with the innovativ moulding machines, tog ace. In addition to tpl rke ology, into the ma hn tec n ctio inje cong usi has been given a high Ferromatik technology the Florida showcase, Poland, while Milacron in Italy and Plastpol in profile at PLAST 2015 ON Evolution range EC its Ferromatik EL TR uce rod int to ing par is pre to market.

WWW.EPPM.COM

INJECTION MOULDING

Micro-Epsilon colour measurement system ups efficiency Micro-Epsilon’s inline colour measurement system is enabling plastics processors to check the colour of injection-moulded parts automatically, upping time and productivity efficiency.

An innovative, inline colour measurement system from MicroEpsilon is helping plastics processors to optimise their productivity and slash cycle times.

The colorCONTROL ACS7000 colour measurement system automatically checks the colour of plastic injection moulded parts early on in the process, measuring the parts at high speed as they are extracted from the mould without having to wait for the parts to cool.

This dramatically reduces cycle times, allowing for 100 per cent colour quality control.

Even with a temperature difference of just 20°C, colour deviations of more than 2 ∆E units can occur depending on the colour monitored. Colour measurements carried out using the colorCONTROL ACS7000 system and temperature measurements using the infrared thermoMETER CT sensor from Micro-Epsilon, enable a master curve to be generated at several different temperature levels that describes the thermochromic behaviour of the coloured polymer.

This allows colour values determined on a warm component to be converted to the actual room temperature colour values.

When parts that are supplied from different manufacturers and made from different materials are combined, it is essential that the colour values of these parts are exact.

If they are not, quality assurance can become an issue.

In order to provide 100 per cent control of the exact product colour shade during the injection moulding of plastic parts, German company SKZ (Süddeutsche Kunststoff-Zentrum) has developed and tested a method to correlate the difference in colour of an object at different temperatures (thermochromism behaviour).

These pre-calculated ‘cooling curves’ stored in the system software allow the colour values determined during the de-moulding process to be converted into a reference temperature (@20°C). This enables the colour to be automatically checked earlier in the process, which reduces cycle time and optimises productivity and output, compared to conventional sample checks.

A

T HE

COMPANY

AOP INTERNATIONAL

FACTORY ADDRESS AOP INTERNATIONAL ZA En Beauvoir, 255, imp. des Perdrix 01500 Château Gaillard, FRANCE

IS SPECIALISED IN THE

CONTACT FACTORY +0033 474 362 514 aop-int@orange.fr

MANUFACTURE AND RE - SHARPENING SERVICES OF CUTTING STOOLS FOR MORE THAN

20

YEARS .

M ANUFACTURING

AND RE - SHARPENING SERVICES OF

PULVERISER DISKS AND GRANULATOR BLADES , FOR ANY TYPE AND ANY BRAND OF PULVERISER OR GRANULATOR .

WE

ARE LOOKING FOR DISTRIBUTORS , COMMERCIAL

AGENTS OR TECHNICAL SALES REPRESENTATIVES .

WE

SPEAK

COMMERCIAL ADDRESS AOP INDUSTRY LTD Guardian house,42 Preston New Road Blackbum, Lancashire BB2 6AH CONTACT SALES +0033 468 610 314 cindy.aopinternational@orange.fr

E NGLISH

A

WWW.EPPM.COM

19

THERMOFORMING

Waiting for the customer to catch up Thermoforming sheet for packaging is in demand and companies are racing to develop machinery that can work harder and faster for customers. battenfield-cincinnati is an industry leader that is setting the pace.

Word | Rose Brooke

I

ndustry champions in fields as competitive and in-demand as thermoforming have to be constantly developing to maintain their lead. The experts at battenfeld-cincinnati never stop fine-tuning their extrusion systems for thermoforming sheet, providing their customers with some of the best machines in the world for this sort of application, but every once in a while there is a breakthrough.

At battenfeld-cincinnati's Packaging Division at its plant in Bad Oeynhausen to the west of Hanover in Germany, thermoforming sheet extrusion is one of the largest applications.

EPPM took the opportunity to sit down with Regional Sales Manager for Packaging Hartmut Hachmeister at PLAST 2015 in Milan to learn more.

"Thermoforming sheet in general is a much broader manufacturing technology than is applicable just for packaging. Because of the widespread use of PP, PS, PET and ABS, its final uses are very broad and what battenfeld-cincinnati has done over the last couple of years is develop a high-speed single screw extruder for sheet production, mainly for thermoforming," Hachmeister said.

What battenfeld-cincinnati has done over the last couple of years is develop a highspeed single screw extruder for sheet production, mainly for thermoforming.

Quantum leap in extruder technology battenfeld-cincinnati's high-speed extruder - where 'high speed' refers to screw speeds over 400 rpm - has been dubbed "a quantum leap in the history of their extrusion technology". This is not something companies can say very often, as often it is a case of gradually evolving and fine-tuning a system rather than introducing something ground-breaking to market.

The single screw extruders BC 1-75-34 DV and BC 1-75-40DV provide users with up to 20 per cent energy savings, shorter changeover time thanks to the reduced volumes required, improved quality and a smaller footprint, all of which comes down to simply adjusting the screw speed and the performance of the drive unit.

20

"battenfeld-cincinnati was one of the first to really push this kind of technology into the middle of the market back in 2004 and since then we've supplied a few hundred of these systems all over the world, first starting in Europe and then spreading out from there," Hachmeister explained.

High-speed extrusion systems for PS, PP and PET are becoming more popular, and since 2004 a number of battenfeld-cincinnati's competitors have followed in its footsteps.

"We believe we are a bit ahead of them because we started earlier and we believe we have more hands-on experience," Hachmeister noted.

WWW.EPPM.COM

With our Multi-Touch system, we can achieve even tighter thickness tolerances, as well as very good sheet flatness and constant control of shrinkage.

"There will always be tough competition" Competition can only be positive, however, not least because suppliers who are unique in the solution they provide run the risk of customers being afraid of committing to a technology over concerns no other plastics processor has made the business decision to back the same horse.

Indeed, battenfeld-cincinnati is maintaining its strong position on home ground in Europe and thanks to its facility in the US, battenfeld-cincinnati USA, it is penetrating the American market much more easily than if it was targeting the US from across the pond.

Hachmeister was even optimistic about the notoriously competitive Asian market, where demand for thermoforming systems for packaging applications is still very high thanks to the large population.

"Of course, there will always be tough competition in Asia regarding price - China and Taiwan in particular - but with our high-speed single screw extruder concept we are focused on bringing more machinery into the Chinese, Japanese and Thai markets," he said.

When asked if battenfeld-cincinnati is enjoying the back-to-Europe mentality some companies have been experiencing as a result of a return to familiar, closer-to-home service and high quality after switching to cheaper options amid the financial crisis, Hachmeister was realistic.

"Every time there is a project, you have to fight for it because even those who have had a good experience with you before still think about other suppliers. Not just those who are more local, but those who are lower on price, so every time you have to really look after your customer.

"Right now, the foreign exchange market is supporting the machinery business. Due to the exchange rate, more people are interested in European equipment. Countries in South America and Asia, where the US dollar is the dominant currency for example, who were more interested in short term investment, have gone for a European machine because of the weakness of the euro against the dollar. You really see more activity when the exchange rate drops like this and it has proven to be a small push for us."

Unique roll stack design battenfeld-cincinnati's leading technology coupled with the favourable foreign exchange climate are not the only factors helping the company to maintain its strong global position. Its Multi-Touch roll stack is also helping to move thermoforming sheet technologies along.

"For foodstuff packaging," Hachmeister explained, "you have to have a very good sheet tolerance, as well as a very constant shrinkage. Because form fill seal (FFS) machines have to be adapted to the quality of the sheet, if the sheet quality changes during processing you're in trouble."

This is where battenfeld-cincinnati's Multi-Touch roll stack comes in, creating uniform cooling on both the top and bottom of the sheet and offering excellent functionality and handling for optimal sheet production results.

"With our Multi-Touch system, we can achieve even tighter thickness tolerances, as well as very good sheet flatness and constant control of shrinkage. This equipment is proving really popular with customers who produce a lot of FFS sheets.

While the favourable conditions in the foreign exchange market will not stay the same forever, battenfeld-cincinnati is maintaining its lead by building fast machinery and developing innovations such as Multi-Touch, but does Hachmeister have news of any new ventures on the horizon for battenfeld-cincinnati's Packaging Division?

"To be honest, I think we're at a very high level - I wouldn't say we cannot make another big jump, but I see a lot of customers still using old equipment, which is really far from the level we are at right now," Hachmeister remarked. "Also there's work to do to convince customers to make a modification, a change, and that an investment would make sense, because for a lot of producers highspeed extrusion is still very, very new, even if it has been on the market since 2004. Some customers we talk to are still surprised to learn about it - so there's plenty of work still to be done."

WWW.EPPM.COM

21

THERMOFORMING

Bulletin: Lightweight LEXAN XHR LIGHT sheet to take to the skies

SPE Thermoforming invites student competition entries

Brown Machine introduces Advanced Canopy System

Summit Systems partnership fills niche

22

WWW.EPPM.COM

GN Thermoforming Equipment launches high-speed GN800

THERMOFORMING

GN Thermoforming Equipment has made its intentions to lead in the form/cut/stack market with the introduction of the GN800 thermoformer.

The machine is the first from GN that offers movable top and bottom platens and is an expansion of the company’s plug-assist machine offering.

The first GN800 - which was developed in partnership with Agripak in Italy - has already been sold to a European PET container processor and GN confirms the growing use of form/cut/stack technology by packaging manufacturers and noted that a partnership with Argipak offered the fastest entrance into the market for GN.

GN bought the rights to Agripak’s original machine design and has added new features and technologies.

Jerome Romkey, GN Marketing Manager, explained: "We saw the changes in the marketplace so we wanted to move swiftly to counter the competition.

Our strategy was to adapt and enhance Agripak's proven technology to meet the requirements of today’s processors and gain a strong foothold in this highly attractive market."

"We used their proven design, and combined it with GN’s own proven technologies,” said Romkey. The enhancements offered in this new thermoformer came in response to input from customers and tool makers to ensure GN’s new machine would meet today’s changing market conditions.

The GN800 has a, 800 mm x 570 mm forming area capable of forming 150 mm and above and below the sheet line and the cutting force of the forming and cutting stations if 75 tonnes.

The GN800 handles sheet widths up to 880 mm. It can run sheet thicknesses ranging from 0.25 mm to 1.5 mm. The unit comes fully equipped and handles all thermoformable grades of PET, OPS, HIPS, PLA, PP and PVC. The company is currently targeting food, medical, and industrial packaging.

“The most important thermoforming centre in Italy” The Marchesini Group has put strategic investment plans in place that will culminate in the inauguration of "the most important thermoforming centre in Italy" in October 2016.

The first brick has already been laid on what will become Italy's first thermoforming centre. Located in Carpi, near Modena and less than 100 km from Marchesini's headquarters in Pianoro, the company has invested €15 million (£11 million) in this new centre, where all its experts will be based.

These experts were at ACHEMA 2015 presenting BLISTEREVOLUTION and how Marchesini is a solid potential partner for the blister packaging industry. New machines - the Integra 220 and 320 lines - have already made waves in the

blister packaging marketplace thanks to their robotic capabilities, integration, flexibility and speed, while the Integra 520V was also given an outing at ACHEMA. The machine has the ability to package 520 blisters and 500 cartons a minute - one of the fastest systems on the market.

According to Marchesini, the blister packaging market is set to continue in its current growth trajectory, expanding by 7.6 per cent between 2013 and 2018. The added investment borne of this growth will further advance Marchesini's development work and the company believes the "Made in Italy" stamp will add a further seal of approval to its innovations, on top of a reputation of strong R&D, experienced staff and social responsibility.

WWW.EPPM.COM

23

MATERIALS SPOTLIGHT

Restoring consumer confidence in BPA BPAs are among the world’s most thoroughly-investigated chemicals and yet out-of-date opinion pedals misinformation about the material’s safety. Bayer MaterialScience is on a mission to set the record straight.

Words | Rose Brooke

B

isphenol A-free, or BPA-free, has become a familiar slogan throughout Europe and North America, as popular opinion maintains the chemical compound contains hormone-like properties that are linked to numerous diseases.

However, popular opinion lies in stark contrast to a significant body of scientific evidence. As one of the leading producers and users of BPA, Bayer MaterialScience is making its customers aware of the fact the substance is proven to be safe, and may well be safer than some of the alternatives due to the fact it is now one of the bestresearched chemical compounds on the market. Indeed, more than 1,000 independent studies have been carried out on BPA to confirm or refute the risks associated with the material, which has been on the market for more than half a century.

BPA plays an indispensable role in the makeup of polycarbonate a widely-used transparent and shatterproof plastic material.

With a global consumption of approximately 3.8 million metric tonnes of polycarbonate per year, BPA is one of the world’s most important industrial chemicals. As a key building block of polycarbonate, it is firmly bound within the structure of the material. There is no equivalent compound that can carry out the same role as BPA and produce material of the same properties. The other major application of BPA is epoxy resins, which are also based on BPA. So why has one of the most widely-used chemical compounds on the planet become so vilified? And how can scientific evidence which has been shelved in favour of a hypothesis that has been all but put to bed by laboratory research - restore confidence in BPA?

“No health risk to consumers” This year, the European Food Safety Authority (EFSA) concluded that BPA “poses no health risk to consumers because current exposure to chemicals is too low to cause harm” and that dietary exposure is between four and 15 times lower than previously estimated by the EFSA. Animal studies show that daily feeding of high doses of BPA (a dose orders of magnitude above safety level estimated by the EFSA) is likely to cause adverse effects to the kidneys and liver, as well as the mammary glands of rodents. But these effects are caused by a concentration of BPA so high that it does not represent anywhere near a realistic exposure rate to consumers.

Bayer MaterialScience references studies demonstrating that the minute traces to which humans are exposed to are in fact quickly metabolised and inactivated in the body and subsequently eliminated with urine within a day - and even sensitive members of the population such as infants, the elderly and pregnant women are fully capable of metabolising BPA safely.

24

Baby bottles: Despite regulations banning BPA in baby bottles and sippy cups, BPA can still be detected in infants but it is metabolised safely.

WWW.EPPM.COM

One of the best-investigated chemicals in history

Expelled from the body

Klaus Dreesen, Director of Bayer MaterialScience’s Polycarbonates Unit, and Dr Sven Gestermann of the company’s Product Safety and Regulatory Affairs department, expressed their disappointment at the fact that despite such a thick dossier of scientific evidence showing BPA is safe, the material is still perceived as a health risk by the general public.

BPA is absorbed through the intestinal wall, where it is metabolised and converted into an inactive sugar with no known biological activity. Any trace BPA residue is converted into the same inactive sugar by the liver before entering the bloodstream.

Within 24 hours, it is then eliminated through urine.

“BPA is one of the best-investigated chemicals of all and we have been using it for more than 60 years,” said Dreesen. “It’s been investigated by a lot of companies, research institutes and universities and the curious thing is that the results are pretty good but the politicians continue to call for a reduction of its use.

It does not make sense.”

Gestermann added: “The EFSA has issued a very clear statement that there is no risk to consumers based on a comprehensive, scientific evaluation of the all data available on BPA. In addition to the 1,000-page scientific report, they even sent out a very welldesigned fact sheet to explain in even clearer terms to laymen that there is very consistent scientific evidence proving that BPA holds no risk to consumers.”

Throwing the baby out with the bathwater Gestermann can see the irony in the fact that despite the clear EFSA opinion, manufacturers are forced to develop hasty substitutions that have not undergone as much scientific scrutiny as BPA. These alternatives are not always well understood and may be linked to potential risks yet be discovered, he remarked.

“BPA-free plastic materials to replace polycarbonate are by far not as well-investigated, and furthermore are inferior in relevant technical properties”, he remarked. “So we warn not to throw the baby out with the bathwater.”

Bayer MaterialScience states that in studies involving volunteers, no free BPA could be detected in their bloodstreams even when they were exposed to much higher levels of BPA than would be possible in daily life through food intake.

It is only in laboratory tests with animals or cells involving unusually high levels of BPA that the chemical’s oestrogen-like activity could be measured - conditions that would be “impossible” to replicate in real life through food consumption. In addition, Bayer MaterialScience stated that many foodstuffs expose the consumer to higher levels of naturally occurring hormone-like substances, namely phytoestrogens that are present in garlic, coffee and carrots, which contain 800-times more oestrogen-like compounds than the same amount of beverages consumed from packaging with a BPA-based coating.

Exposure well below safety level In its report for 2015 - improving on findings from 2006 - the EFSA has allowed its expert panel to make more exact and less conservative assumptions for exposure calculations. BPA exposure, it revealed, is highest among infants and toddlers, but these estimates are four-and-a-half times below the safety level, which was lowered from 50 micrograms per kilo body weight per day to just four micrograms.

Canned food and non-canned meat and meat products to a lesser extent, have been identified as the main contributors to dietary BPA exposure for all age groups. This could explain why a recent study by scientists at Johns Hopkins University found that even though baby bottles and sippy cups have been BPA-free since the ban in 2012, infants still have BPA in their systems.

Nevertheless, the study published earlier this year in The Journal of Pediatrics, revealed babies are capable of metabolising BPA and expelling it. Of the 44 healthy newborns tested between December 2012 and August 2013, 70 per cent had BPA in their urine, but this form of BPA was already metabolised and rendered biologically inert.

The two points made in this latest study are that not only is the current BPA ban failing to reduce exposure to BPA in newborns, but the minute quantities of BPA they are being exposed to are excreted from their body quickly regardless.

“No health risk” The EFSA has concluded that BPA poses “no health risk” to consumers, as current exposure to the chemical is too low to cause harm. For all population groups, dietary exposure on its own is more than four-and-a-half fold below the safety level.

EFSA included a safety factor of 150 in that safety level.

Bayer is convinced there is “no reasonable scientific basis for any health or safety concerns” regarding BPA exposure from polycarbonate and Dreesen and Gestermann are keen to change the record, allowing manufacturers to stick to the material they know is safe and right for the job.

“This controversy is driving more companies, consumers and policy makers away from the science,” added Gestermann.

“It’s not the best way to act. In terms of consumer safety, what else should matter if not the best knowledge available. And for BPA, really solid information is available.”

WWW.EPPM.COM

25

MATERIALS SPOTLIGHT

The Oxo plant is born In May, Perstorp invited investors, affiliates, the media and its Valerox project team to celebrate the opening of its Oxo plant in Stenungsund, Sweden. A unique plant that demonstrates Perstorp’s commitment not only to PVC plasticisers, but to nurturing the Stenungsund Cluster.

Words | Rose Brooke

T

he brisk Nordic wind polished the sky to a high shine, dusting away the rain in time for the long-anticipated celebrations in the Swedish harbour town of Stenungsund last month.

On May 19th, investors, partners, customers, employees and members of the media gathered at the Stenungsbaden Yacht Club where Perstorp began the day's festivities, which would culminate in a symbolic ribbon-cutting at the new plant.

The inauguration of the new Oxo plant in Stenungsund - a town an hour to the north of Gothenburg - is an occasion that has been nearly a decade in the making and serves to strengthen the global specialty chemical innovator's PVC plasticiser offering, making use of the Stenungsund Cluster of affiliated companies.

EPPM was lucky enough to attend the event on behalf of our sister magazine British Plastics & Rubber where we took our place among the rest of the invited media to learn more about how the new Oxo plant will help Perstorp in its drive to push the envelope in terms of both innovation and sustainability and live up to its slogan "winning formulas".

A proud investment "Today we are celebrating hard work and determination," remarked Steen Lyck, Vice-President Sales EMEA and the day's Master of Ceremonies, before inviting Jan Secher, Perstorp CEO on stage.

"I feel extremely proud to be here," said Secher. "We have worked very hard to make the sun shine...

"This is a very sizeable investment. The trigger came a couple of years ago when the legislative landscape changed and customer requirements changed. We wanted to respond to that. It was natural to make a choice to continue to invest in the plasticising market. We needed to improve our competitiveness and make sure we have a fully-integrated supply chain."

26

However, the 'Valerox' project as it was known, ground to a halt in 2008 when the financial crisis reared its head, but a temporary economic glitch was never going to put up a permanent wall preventing Perstorp from realising its goals for PVC plasticisers.

Indeed, as Lyck told me later that day, as an historic nation of foresters, Swedes are built for seeing long-term projects through and reaping what they sow after years and years of care and consideration.

The care and passion that has lifted the Oxo plant out of the pine-blanketed hills of western Sweden has amounted in SEK 2 billion (€214 million, £150 million) of investment that will increase Perstorp's overall capacity by more than 150,000 tonnes a year.

The data gathered to help quantify what a feat of engineering the Oxo plant is helps put matters into some perspective: SEK 1 billion in investment from Perstorp, SEK 1 billion in investment from other industries from Stenungsund, 300 contractors, 6km of stainless steel pipe, 22km of carbonised pipe, 3,200 valves, 44 heat exchanges, 250km of cabling and 800,000 man hours - or 450 man years.

I feel extremely proud to be here. This is a very sizeable investment.

In a question and answer session with the press later that day, Secher said: "[This project was completed] ahead of schedule and under budget - that in itself is something to be proud of. We are the first to take this technology plant to such a size."

Conserving the cluster The Oxo plant is a shining silver beacon of what Swedish industry can achieve, and serves to galvanize the Stenungsund Cluster, which is unique to the Nordic countries supporting inter-business cooperation, competitiveness and innovation, and includes partner companies Borealis and AGA.

WWW.EPPM.COM

"The new production plant is the single largest investment in Perstorp's history and clearly demonstrates Perstorp's commitment to the PVC industry. This is a lifetime investment and we see many more application areas [opening up in the future]. Come back in five years I am sure you will see more change. What ever your needs as customers, are our needs as a company - it all starts with the customer," Secher remarked.

With the Oxo plant - a gargantuan, shining maze of pipes, silos, chimneys and scaffolding - Perstorp now has one of the few fully-integrated platforms in Europe, giving its customers access to plasticisers that are not only high-quality, but are sustainable and cost-effective.

In addition, the plant is a source of products for other key markets: 2-propyl heptanol (2-PH) for the production of lubricants, adhesives and surfacants; and n-valeric acid, which is made in the plant directly from valerdahyde and is used in lubricants, pharmaceuticals and fragrances.

Emoltene 100 and Pevalen 100 are the star plasticisers to be produced at the flagship plant. Emoltene 100 is one of the most well-tested plasticisers on the market and is intended for outdoor durable applications such as cabling and roofing membranes. Pevalen is an innovative non-phthalate plasticiser, which is partially derived from renewable resources meeting safety and performance requirements of 'close-to-consumer' PVC applications such as flooring and coated fabrics.

The plant has been running since the beginning of the year and is now running at full regime, delivering high-quality material according to plan.

24th Fakuma International trade fair for plastics processing

The place to be Ahead of the official opening ceremony, the Swedish Minister of Enterprise Mikael Damberg said of the Oxo plant: "This investment proves Sweden is the place to be. We are as much into research as investment and are making new products and facing new challenges. This industry has an important role to play."

Markku Korvenranta Executive Vice-President Base Chemicals at Borealis too extolled the benefits of Borealis' partnership with Perstorp.

"Sweden is a very, very, very important place for Borealis and I have to congratulation Perstorp on building a plant here in Stenungsund - it's a fantastic decision and it will add new products to the market."

Borealis invested â&#x201A;Ź25 million in the Oxo plant project in order to show Perstorp its support, because Perstorp's success strengthens Borealis' own position as part of the Stenungsund cluster.

The delegation travelled by bus to the Oxo plant side atop a coniferous hill overlooking the serene Stenungsund harbour. There, Site Manager for the Stenungsund plant Christer Andersson, Chairman of the Board at Perstorp Fabrice Faultier, Chairman of the Municipality of Stenungsund Sofia Westergren and Jan Secher cut the ribbon and pushed the big red button proclaiming the plant officially open to applause and the clinking of glasses - full to the brim of Swedish pear cider, naturally.

"This is what we have actually built - a fantastic plant that is continuing to expand," said Secher. "Nobody has built a plant like this before and we are extremely proud."

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

13. â&#x20AC;&#x201C; 17.

OCT. 2015 FRIEDRICHSHAFEN www.fakuma-messe.de

WWW.EPPM.COM

27

Milliken’s antioxidant MATERIALS SPOTLIGHT

helps meet green targ ets

Milliken’s Milliguard AOX-1, the polymer-bo und antioxidant for polyurethane, has bee n developed to meet strict environmental and health requirement s while still deliverin g excellent thermal stabilisation performa nce at low loadings.

It offers unparalleled efficiency in stabilising free radicals that can degrade PU foam and is highly synergistic wit h other antioxidant cla sses. The technology provides producers and foam manufacturers wit h a powerful tool for interior vehicle componen ts.

Bulletin: nes

gi Start your all-plastic en

metal replacement dership role in bringing lea a en tak has y lva So t. Polimotor 2 aims to in a collaborative projec polymers to automotive - around 41 kg less than ing no more than 67 kg develop an engine weigh Specialty Polymers lva ine. President of So y eng n ctio du pro ard nd a sta said: “Through this gusto Di Donfrancesco Global Business Unit Au daries, showing all the ther challenge our boun partnership we will fur utions in reducing ance polymers are sol orm erf h-p hig r ou t tha more r-cylinder, doublel consumption.” The fou weight and lowering fue ally be installed in a r 2 engine will eventu overhead CAM Polimoto ing at Line Rock 2016 for competitive rac by car t cep con 0 M-2 Norma Park, CT.

Now in glorious technicolour

ASTIC is making its development AF-COLOR, a branch of AKRO-PL ent a priority and in May 2015, it biopolymer technology developm tification for its AF-Eco product successfully achieved Vinçotte-cer oeuvre freely within the certified range. This allows AF-COLOR to man tion is becoming increasingly pigment pool. Biopolymer pigmenta with the almost exclusive use y toda important and is only achieved of polymer carrier materials and of colour masterbatches made up erials end up as single-use carrier corresponding pigments. The mat rtant role in the degradation rate bags - as wall thickness plays an impo >90 per cent within 180 days) and of a polymer (which is required to be ry. in food packaging and disposable cutle

DSM and Ascend form polyamide 66 compound alliance DSM and Ascend Performance Mat erials have formed a global alliance for the supply of compounds base d on polyamide 66 (PA66). The agreement positions Ascend as DSM’s PA66 strategic supplier for its Akulon PA66 compounds for engi neering plastics. Moreover, DSM will distribute Ascend’s portfolio of PA66 compounds sold under the brand Vydyne. Ascend’s President of Nylon Business Phil McDivitt said : “We are very excited by this new allia nce ... It enormously expands our reach into applications that until now have been under-served and it gives us better access to global cust omers.”

eurotec understands importance of colour performance Words | Cihan Topkaya, R&D Project Manager, eurotec

T

he performance of colour compounds is the essence of eurotec's work, increasing the Turkish company’s product diversity day by day and maintaining consistently high quality in its intelligent solutions.

A leader in engineering plastics, eurotec offers "ultimate performance" in precoloured products, with special care being taken with regard to UV durability, temperature stability, chemical stability and design criteria. This diligence is especially important where factors such as long storage times, time of melt compound, barrel temperature, and hot runner temperature are concerned, as all can affect colour masterbatch, leading to changes in shade, yellowing and

28

even burning. These unfortunate scenarios can come about as a result of the decomposition of the pigment chemicals in the masterbatch. eurotec colourises its compounds depending on the parameters of their plastic processes, while the eurotec team is well equipped with the knowledge to find customers a solution for colour-related quandaries. Backed by its own research and development facility and years of technical experience, eurotec accurately checks the quality of all inlet colour masterbatches. Frequent colour controls are performed in production lines as the Turkish engineering plastics leader understands the importance of ensuring exact colour matches.

WWW.EPPM.COM

Eastern European promise at Plastpol

EVENTS NEWS

Kielce played host to the sixth Plastpol event last month, where companies across the plastics supply chain from 30 countries were represented, including some of the biggest brands in the international market.

T

he sixth edition of Plastpol has just come to an end, taking place from May 26th-29th at Kielce, to the south of Warsaw. Plastpol represents an important cross section of the Eastern European plastics processing marketplace, but the show also represents the wider international marketplace, hosting exhibitors from more than 30 countries across the plastics processing supply chain and welcoming some 17,000 visitors.

Poland is a key market on the global plastics stage, coming in sixth place in Europe behind Germany, Italy, France, Spain and the UK in terms of plastics consumption.

EPPM’s choice Plastpol announcements: Arburg presents extensive range of production Arburg’s Plastpol exhibit demonstrated the manufacture of one-off parts through to the mass production of medical technology items.

The Freeformer was on display to showcase how additive manufacturing can be employed in one-off and small-batch manufacturing applications, while the hybrid Allrounder 520 H was producing syringe barrels at speed next to an Allrounder 420 C Golden Edition demonstrating entrylevel automated injection moulding production using a toy buggy.

BOY’s injection moulding hat-trick BOY presented a hat-trick of injection moulding machinery to Plastpol, presenting the BOY 25 E, the BOY XS and BOY 2C XS at the event.

The BOY 25 E represented versatility with its attractive equipment versions, servo drive and small footprint. The BOY XS - the smallest BOY injection moulding machine - served to demonstrate high precision in minimum space and showcased the production of osteosynthesis plates for medical on-site. Finally, the BOY 2C XS enlightened visitors as to how it can be mounted onto numerous machines providing a more cost-efficient entry into multicomponent injection moulding.

Demag presents efficient IML production Demag Plastics Group showcased its impressive El-Exis SP 200 for the production of IML-decorated food containers at Plastpol. The injection moulding machine as combined with handling equipment from Polymac Robotics to form a compact production unit, facilitating the production of containers in less than 3.5 seconds. The PP cups produced on-site were made in a 4-cavity mould manufactured by Otto Hofstetter with a shot weight of 6.2 grams.

TPEs for E&E at HEXPOL debut HEXPOL TPE equipped its stand with solutions for the electrical and electronics market at its first ever Plastpol. The materials specialist shone the spotlight on its Dryflex and Lifoflex TPE compounds at the event. Both offer excellent colourability and durability with resistance to UVm flex-fatigue, wear and tear. European Sales Co-ordinator Sven Druwen said E&E is an interesting market for TPEs, with significant demand coming from Eastern Europe.

Netstal presents max-precision for medical Represented by Muehsam-Elektromech presented Netstal’s all-electric ELION 1750 for maximum precision for medical applications at Plastpol, where polyoxymethylene parts were manufactured on a 16-cavity mould from Kebo in a cycle time of around 8.5 seconds.

WWW.EPPM.COM

29

EVENTS NEWS

ChinaPlas 2015: A new dawn for sustainability ChinaPlas 2015 took place in Guangzhou and shone the spotlight on the entire plastics processing chain while taking a fresh look at sustainability, beginning a new chapter for the Asian superpower’s industry.

Over the course of the four-day show in Guangzhou, an estimated 120,000 visitors from both China and overseas flocked to the 29th ChinaPlas, the world's second-largest plastics and rubber event and the biggest of its kind in Asia.

ChinaPlas has continued to grow, with this year's outing warranting around 240,000 m sq in floor space to accommodate more than 3,200 exhibiting companies from across the entire supply chain from 40 different countries. The rate at which ChinaPlas has been expanding is testimony to its success, taking 60 per cent more floor space than the 150,000 m sq recorded just five years ago. As organisers await the crucial final figures, it is hoped visitor numbers will exceed 2014's cohort of 130,370 delegates.

initiative, which demonstrates the value German plastics and rubber machinery manufacturers can offer China in terms of efficient technology. Both organisations have enjoyed a partnership that started at the first ever ChinaPlas in 1983.

The VDMA’s support and its member firms’ presence at ChinaPlas are vital.

ChinaPlas comes second only to Düsseldorf's titanic K Show in terms of scale, but the fact both China and Germany host the two largest plastics processing events in the world is a metaphor for the strength of both countries' plastics industries, a point the German plastics association the VDMA made while in Guangzhou last month.

The VDMA and ChinaPlas organiser Adsale highlighted both nations' achievements thanks to their innate efficiency, citing VDMA's Blue Competence

Adsale Chairman Stanley Chu said: "Germany is a trailblazer in sophisticated technologies.

The VDMA’s support and its member firms' presence at ChinaPlas are vital."

Managing Director of the VDMA Thorsten Kühmann added: "We share the same objectives when it comes to sustainability. We recognise the need for saving energy and other resources as well, because their supplies are not unlimited. At the same time, we see sustainable technologies as a model for economic success both for machinery manufacturers and for their customers, the plastics converters. Energy efficiency is an important driving force of economic success."

Green packaging, automation to improve on fuel and time efficiency, and lightweight metal replacement solutions are just some of the trends that were prevalent at the event, proving that China is willing to gallop alongside Europe in terms of being green and keeping a lid on waste of any kind.

EPPM’s top three launches at ChinaPlas 2015 KraussMaffei debuts CX series KraussMaffei has debuted the CX series at ChinaPlas 2015, where the new system - which has a clamping force range of 350-1600 kN - was on show to allow delegates to see it up close as it demonstrated economical solutions for multi-component injection moulding made possible with its two-platen construction. The new CX takes advantage of every opportunity to increase efficiency, offering customers energy, space, time and materials savings.

30

ICL-IP chooses ChinaPlas as tool launch platform Leading producer of flame retardants and the world’s largest producer of elemental bromine ICL-IP chose ChinaPlas 2015 as the platform to launch its new assessment tool for flame retardants, which assesses the sustainability profile of individual flame retardants according to their application. Christened SAFR (systematic assessment for flame retardants), the tool was designed for a range of stakeholders with the help of ICLIP’s customers.

WWW.EPPM.COM

Coperion Nanjing launches CTE PLUS twin screw extruder series Coperion Nanjing has combined the best of German quality and Chinese innovation in its ChinaPlas 2015 showcase, with the launch of the CTE PLUS twin screw extruder series launch. The CTE PLUS is equipped with a new gearbox engineered by Coperion Stuttgart that can bear a specific torque of 7.2 Nm/cm3 and is exchangeable with the old generation of CTE gearboxes.

The rotating parts and bearings of the new gearboxes have been redesigned so tooth width has been enlarged and tooth flank and profile have been optimised to ensure a perfect intermeshing surface.

Fakuma floats Thermoforming Island

EVENTS NEWS

Fakuma will be launching a Thermoforming Island in Friedrichshafen this October, while this year’s plastics processing outing also introduces additive manufacturing into the value chain.

Fakuma organisers have announced the addition of a new and exciting feature, a Thermoforming Island concept, which will showcase the thermoforming industry in a compact exhibition.

Taking place in the West Foyer of Messe Friedrichshafen, the Thermoforming Island aims to provide potential users of the technology with in-depth insights into the thermoforming process, highlighting the fact that modern thermoforming is now approaching accuracy levels once deemed impossible.

In addition to this exciting new feature, Fakuma 2015 will bring the first ever generative manufacturing segment to

the international plastics processing event.

Additive manufacturing technologies will be present in the tool and mould-making exhibitions, and in the wider manufacturing showcase.

Due to the fact tool- and mouldmaking are essential constituent parts of the Fakuma line-up, industrial additive manufacturing is considered a complementary manufacturing process, allowing users to produce complex shapes and to build sophisticated parts with cooling channels close to contour - geometries that would not have been possible without additive manufacturing technology.

New and alternative materials are now offering previously unknown substitution options in the production of prototype parts, in addition to short-series manufacturing using 3D printing, which in many cases can now do more than supplement injection moulding, thermoforming and extrusion processes.

Floor space is already booked up for the major industry event, with even the West and East Entrance foyers snapped up. The East foyer will once again accommodate a popular and coveted exhibitor forum where numerous experts are already signed up to deliver presentations.

Visitors to the event, which will take place this year from October 13th - 17th from the new opening hours of 9am5pm, will be able to view all of this together with a cross-section of the entire plastics processing supply chain on the shores of Lake Constance.

EXHIB IT EXCITI ING SOMETH NG AT FAKUM ING Make s ure you A? subm for

one of our two it your previe w p

by Sep tember rinted previe ws feature . Email to ensure the y articles words of m rose.br and an image ax 150 ooke@ rapdine to ws.com .

AIMPLAS hosts first-of-its-kind compounding workshop AIMPLAS is hosting a unique independent compounding workshop designed for technical staff wishing to gain a broader understanding of the practice and theory behind the compounding process.

A pioneering compounding event that promises to be the first of its kind in Europe is being hosted by AIMPLAS, the Spanish Plastics Technology Centre in Valencia.

The training activity days will take place at AIMPLAS’s headquarters on October 14th and 15th, giving attendees the chance to gain a better understanding of the various concepts for the successful incorporation of fillers, pigments, additives and reinforcements in plastics for optimising the properties of the material.

a new material, while the practical content will look into the processes of control and optimisation of performance with mineral changes and fibres.

Professionals can register to attend until September 11th 2015 and cost to enrol is €500 including attendance, refreshments and supporting literature.

Enrolment to the workshop and dinner is €550 and for every attendee a company sends, the second will receive a 50 per cent discount. Email formacion@ aimplas.es for more information.

The workshop has been designed for technical staff wishing to strengthen their expertise in plastics mixtures. It will consist of around 65 per cent theory and 35 per cent practice and include work with a twin screw extruder.

During the sessions, attendees will learn how to obtain an optimum mixture in each compound, understand the most appropriate machinery for each mixing process and grasp the concept of designing a new mixing process and controlling the compound production process. The theoretical element will be dedicated to the characteristics of the machinery and how to design tests to develop

WWW.EPPM.COM

31

EPPM Classifieds 45 Years in New & Used Machinery to the Plastics Industry Worldwide.

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

Download our full stock lists online

New Machines, including Granulators, Shredders, Blow Moulding & Injection Moulding Machines

Weima NZ4S 310-600 Granulator. Throat: 310x600mm, 12 mm screen, Drive: 22Kw motor, Rotor Blades 10 new, Stator Blades 2 new, Solid staggered, rotor

Large Granulators & Shredders: Used for all types of plastic, material, carpets, window frames & wood.

• Rapid GK1000 55Kw Granulator 55Kw Drive, Throat 1000x600mm.

• Remcaw RPC80200 Granulator • Remcaw 65-35 Shredder (Red) Brand New, 55Kw Drive, Throat 650x350mm.

• Vecoplan VAZ 800/40 Shredder 11Kw Drive, Throat 800x1000mm • Tria 60-35 Granulator 25Kw Drive • Bano 630 Shredder 15Kw Drive, Throat 600x750mm.

• Gross Gaz 62 Single Shaft Shredder Tools: 14 knives, Feed (mm): 600 x 800 • Cumberland 38-60 Granulator 75Kw Drive • Blackfriars 40-40 Granulator 22Kw Drive • SG-3660 Sound-Proof Central Granulator 11Kw Drive • Remcaw RPC3280 Granulator • Getecha 440 400 Granulator 18.5Kw Drive Medium Granulators & Shredders: Used for all types of plastic, bottles, PVC frames & foam.

• UPM Model 12-16 Granulator 11Kw Drive.

• Cumberland 40-50 Granulator 15Kw Drive.

• Tria Model 45-35 Granulator 15Kw Drive.

• Cumberland 40-30 Granulator 11Kw Drive.

• Cumberland 40-70 Granulator 30Kw Drive.

• Moditec G95 Shredder Twin Shaft Shredder.

• Zerma GSC 30-30 Granulator Throat size 300 x 300mm, 7.5Kw Drive, 8mm screen • Getecha GE 1000 Granulator 15Kw Drive • Lanceline 300 300 Granulator 11Kw Drive • USI Cumberland 30-40 Granulator 11Kw Drive Small Granulators & Shredders: Used for all types of plastic, bottles, top & tails from moulding & CD/DVD cases.

• UPM Model 10-10 Granulator Blower & Cyclone.

• Polymer 9-12 Granulator 7.5 Kw Drive • Moditec G45 Shredder 230 x 455mm throat.

• CMB MS20 Granulator 4Kw Drive.

• CMB ML220 Granulator 4Kw Drive.

• Cumberland 30-23 Granulator 4Kw Drive

Gross Gaz 62 Single Shaft Shredder. Feed opening (mm): 600 x 800, Rotor (mm): 252, Power required (kW): 11/15/18,5, Tools: 14 knives

New & Exclusive Granulators Bano Mac 630 Shredder. 600 Rotor, Throat: 600x750mm, 15Kw Drive, 2001 model, 18 teeth, 2001 (new model), Screen 20mm, Hydraulic Ram, Heavy duty solid rotor

• • • • •

Remcaw RPC 2640 Granulator Remcaw RPC 2660 Granulator Remcaw RPC 3260 Granulator Remcaw RPC 3280 Granulator Remcaw RPC 4280 Granulator

• • • • •

Remcaw RPC 42100 Granulator Remcaw RPC 52100 Granulator Remcaw RPC 52120 Granulator Remcaw RPC 66120 Granulator Remcaw RPC 80160 Granulator

Rawmec EEC Ltd, Rawmec Industrial Estate, Plumpton Rd, Hoddesdon, Herts. EN11 0EE More info, machines & photos visit: www.rawmec.com or email: info@rawmec.com

Rapid GK1000 55Kw Granulator. Throat: 1000 x 600 mm, Motor 55Kw Drive, Rotor Blades 10, Stator Blades 2

See our machines in action on our YouTube account

EPPM_210x143_06-15.indd 1

09/06/2015 20:06

Over 40 Years of Service

120+100+45mm Omv 3 extruder Coextrusion unit, Gear pumps, coex block, 850mm die, Panels, 1000mm Omv 5 roll packaging film sheet unit PP, PS ABS packaging.

2950mm wide Welex Davis Standard sheet extrusion line with 150mm DS extruder, 33D, Flex lip die, 2950mm x 500mm 3 roll stack, pump group, haul off, guillotine.

Tel: +44 (0) 1793 827666 Email: sales@transxl.co.uk Web: www.transxl.co.uk

2000mm wide Omipa/Union coextrusion sheet line. 120mm and 90mm Omipa extruders, 2000mm wide Union 3 roll stack 500mm rolls, haul off guillotine. 2002.

1800mm wide Reifenhauser sheet extrusion line. 120mm Reifenhauser extruder, melt pump, 1800mm die, 3 roll stack, pump group, haul off, cross cut saw.

2950mm Sheet line for HDPE 2290mm Sheet line for ABS 2000mm Omipa/Union Sheet line.

1800mm Reifenhauser sheet extrusion line 1700mm Kuhne Sheet extrusion line 1500mm Bandera stack 1350mm Welex/union sheet line 1300mm Kuhne Sheet line

115mm Davis Standard Thermatic extruder model 45IN45T . 30:1 L/D with barrier PP/ HDPE screw, 305kw motor, Fan cooled electrically heated 6 zone barrel 2008!!

SUBSCRIBE TO OUR

CHANNEL

1000mm wide Omv coextrusion sheet line.

120mm and 70mm extruders, melt pump, .

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

EXTRUDERS

SHEET LINES

1300mm wide Kuhne sheet extrusion line with K701E - 30D vented extruder, melt pump, 1200mm die head, 1300mm x 300mm chrome rolls, pump group, winder.

OVER 300 VIDEOS TO VIEW

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

1350mm Welex 3 Roll Stack. 300mm Dia Rolls. Silent Chain. Dc drive. 3 zone pump group. 2 roll haul off 1986.

1100mm SML Coextrusion 1000mm Omv sheet line

50mm Welex extruder 90mm Egan extruder 90mm Kaufman extruder 100mm Union Extruder 100mm Omv P.P extruder 115mm Davis standard extruder 120mm Omv Extruder 150mm Egan extruder

4 Component Piovan gravimetric blender model MDW1000/41 with hopper loaders 1999.

1000mm Esde 3 rollstack

MATERIAL HANDLING

PIPE EQUIPMENT

Piovan gravimetric blender 1000kg/hr Colourtronic Gravimetric Blender Plasmec 1000 litre batch gravimetric 4 component blender.

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

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

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

760mm (30”) wide Lyle 130FM48 SPD form trim thermoforming machine. Unwind, servo platens, servo plug, 30” x 48” tool. 132PV vertical trim press. 2006.

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

150ltr Motan Luxor 50 Dryer With Twin Desiccant Beds dehumidifing dryer. Hopper loader and material blower.

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

110kw dc motor and drive. Temperature panel 1987.

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

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

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

1100mm wide SML coextrusion sheet line for 150micron to 800micron PP. model SMLSC90,45/1100/. 90mm extruder 45mm coex, calender, haul off winder. 2003.

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

32

WWW.EPPM.COM

Uniloy M 64 point co Coros OP 2

Whitelands Mill, Whitelands Road, Ashton-under-Lyne, OL6 6UG, UK

To advertise here please contact Graham Voss: E: graham@rapidnews.com

Tel: (44) 0161 308 2550 T: +44 680222 (44) (0)1244 0161 343 2026 Fax: Email: aml@abbeymb.com Web: www.abbeymb.com

Tweet All About It! MATERIALS HANDLING

Extruder and Extru

Follow EPPM & MEP On Twitter

Tel: +49-2244-830 email : pmh.gmbh@t-o www.pmh-extruder

@EPPM_Magazine

RE-PROCESSING EQUIPMENT Follow the official Twitter feed for European Plastic Product Manufacturer magazine if you want to be alerted to the latest news and the latest opinions to hit the European plastics market. Keep up to date with what's happening at the biggest shows around the world from our reporters on the ground and join in the debate.

@MEP_Magazine USED. TESTED. ALL RIGHT.

Purchase and sale: Injection moulding machines accessories and spare parts

The Middle East has an emerging plastics industry and Middle Eastern Plastics is there for when the news breaks. With a growing following, count yourself among those in the know about this exciting region and track the goings-on at some of the most influential plastics events in the Middle East.

JOIN THE DISCUSSION WWW.EPPM.COM | WWW.MIDEASTPLAST.COM

eppm

Phone: +49 2173 8 950 790 www.mhborowski.de

FOR SALE

QUALITY MODERN 485 Tonne MOULDERS • 2 x Sandretto S9 HP485-2650 c/w Robot – Year 2007 • 1 x Sandretto Mega TES 700 Tonne (2005)

To advertise To here, or advertise place here, display or place adverts displayin print or adverts in print online

To Contact list a directory Graham Vossentry on

visit Tel: +44www.plastrep.co (0)1244 68022

or online

Contact Lucinda Nicholls Tel: +44 (0) 1244 680222 Email: lucinda.nicholls@rapidnews.com

Email: graham@rapidnews.com and join the world’s

fastest-growing plastics community for free!

New and used Granulators, Shredders, Pulverisers, Wash Plants Blades and Screens Blade Sharpening Ancillary Items Service – Repair - Spares UK & Ireland Agents for

Contact David: +44(0)7540 633552 info@plasticinvestments.co.uk www.plasticinvestments.co.uk

Tel: 01827 838840 BG Advert EPPM.indd 1

WWW.EPPM.COM

Email: info@granulators.org

www.granulators.org 21/01/2015 16:43

33

EUREKA SERIES

Knock on wood Star of the NPE 2015 Startup Garage, cycleWood’s innovative bio-thermoplastic made using a papermaking by-product could be the green future the plastic bag-making market has been looking for.

Words | Rose Brooke

N

PE 2015’s Startup Garage was an exciting hub for meeting interesting new companies, which is where EPPM got talking to cycleWood solutions.

“Most people don’t realise how much lignin there is in the world,” said Darrouzet. “Lignin is the second-most abundant naturally occurring polymer on the planet, second only to cellulose.

Approximately 30 per cent of all non-petroleum carbon on earth is in the form of lignin. For the last 100-plus years, this material has been dumped or burned in paper mills.”

cycleWood Solutions is confidently stating its Xylomer pellets a proprietary blend of polymers and additives - can not only be processed using existing converting equipment, but they can be used to produce plastic bags, refuse sacks and packaging for meat using commercial blown extrusion hardware, while Xylomer pellets can We have been able to create also be used in injection moulding Xylomer containing grades for blown and vacuum forming.

So far, so normal - but what if cycleWood Solutions claimed Xylomer is 100 per cent biodegradable and compostable and made using one of the world’s most prevalent polymers that is naturallyoccurring in nature?

films, injection-moulded parts, thermoformed parts and filaments.

Vice-President of Business Development Louis Darrouzet told EPPM: “cycleWood Solutions has built its business on repurposing an enormous waste stream into value-added materials. We take the unused parts of trees and turn them into thermoplastics for use in various plastic applications.”

The secret to cycleWood’s success is in harnessing the lignin byproduct of papermaking, which is left behind while the cellulose is processed into paper.

34

However, a number of paper companies around the world have begun extracting lignin and cycleWood has been procuring this purified lignin, transforming it into the surprisingly versatile thermoplastic Xylomer.

“One of our blends is certified compostable under the ASTM-D6400 standard which we currently convert into certified compostable trash liners for sale in select retailers. Additionally, cycleWood is working with major companies to develop the next generation of sustainable products by substituting Xylomer for a major portion of petroleum-based plastics,” Darrouzet explained. “Reducing a products’ petroleum dependency by 30-60 per cent is no easy feat, but we have been able to achieve this by using our modified lignins. We have been able to create Xylomer containing grades for blown films, injectionmoulded parts, thermoformed parts and filaments.

“We are continuing to discover new partners who are interested in integrating our innovative lignin-based materials into their products. With the large lignin supply around the world, it is time to tap into this sustainable, yet underutilised, resource.”

WWW.EPPM.COM

Intelligent Solutions

B1-1106