EPPM 19.3

June/July 2017 Volume 19 | Issue 03

Your Partner for Healthcare.

IN TOUCH WITH PL ASTICS

THE ‘MEDICAL GRADE’ POLYMER DILEMMA Cover Story | Page 8

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Volume 19 Issue 03

IN THIS ISSUE Pg 6

Pg 24

INDUSTRY NEWS

TPES

The plastics industry has unleashed some pretty significant M&A news in recent weeks, with LANXESS completing its biggest acquisition yet by finalising its buyout of Chemtura, while Huntsman and Clariant are set to merge, forming a materials development superpower.

We explore the wonderful and colourful world of TPEs and find out how these plastics are bringing so much more than a pleasant feel to plastic product manufacturing.

Pg 8 COVER STORY: ALBIS PLASTIC ALBIS PLASTIC scrutinises the term ‘medical grade’ in polymer classification and how change management is not guaranteed when purchasing a “medical grade” plastic.

MEDICAL From 3D printing to clean room injection moulding, we delve into the highaccountability world of plastics processing for the medical sector.

TESTING & INSPECTION Featuring insights from Sikora and Mettler Toledo, we look into what added value testing and inspection systems can bring to the production process.

editorial editor rose brooke rose.brooke@rapidnews.com assistant editor john carlon john.carlon@rapidnews.com

production art & production robert wood

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MACHINERY & MATERIALS Our roundup pages cover some of the most interesting news items in plastics processing machinery and polymer technology to cross the Editor’s desk in recent weeks.

group advertising manager lisa montgomery lisa@rapidnews.com senior sales executive neil bamford neil.bamford@rapidnews.com tel: +44 (0) 1244 680222

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EPPM reflects on a benchmark-setting CHINAPLAS 2017 and we share our report from the second outing of Moulding Expo in Stuttgart.

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EVENTS

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head office Carlton House, Sandpiper Way, Chester Business Park, Chester, CH4 9QE.

Ever wondered if there was another fate for plastic bottles than reprocessing for rPET? A little 3D project called TrussFab believes their structural properties could be put to innovative use.

Each issue is distributed in print and digital format to 17,845 buyers and specifiers in the European plastic processing industry. © June 2017.

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.

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ENGEL automotive

competence is standard

The automobile industry is shaping up for the future with intelligent technology. ENGEL will join your company on this journey: with competence, experience and visionary solutions for injection moulding. Whether your plastic components are to be safe, functional, lightweight or attractive, we at ENGEL will work with you hand in hand, allowing you to make sure your innovations are ready for series production even faster. For example, with our centre for lightweight composite technologies: Here ENGEL optimises new thermoplastic and reactive processes for your pioneering lightweight construction components.

www.engelglobal.com

From The Editor

Fault lines After the political tectonic movement of 2016 with Brexit and the election of President Donald Trump in the US, you would be forgiven for hoping the dust would be allowed to settle in 2017.

The last of the inauguration tickertape had barely been swept away before the election relay began across the pond. In mainland Europe we have seen moderate, pro-EU politics triumph over anti-EU sentiments and protectionism with the re-election of the People’s Party for Freedom and Democracy under Prime Minister Mark Rutte in the Netherlands and Emmanuel Macron and his new République en Marche party storming the French political landscape within a startlingly quick timeframe. Meanwhile, campaigning for the German Federal election in September is already heating up.

A little closer to home for EPPM Towers, British politicians scrambled together their manifestos for the snap General Election earlier this month that was meant to secure Prime Minister Theresa May’s mandate for Britain’s exit from the EU, instead resulting in a hung parliament that will weaken Britain’s position at the negotiating table.

The shifting fault lines of Europe and the changing priorities of leadership all have a bearing on European plastics as foreign exchange rates counterweigh one another, policies of freedom of movement and free trade look set to be amended, and fresh alliances are shaken on. It is my belief that European plastics - after surviving the 2009 economic crisis can weather the current squalls and headwinds, which brings me to this exciting June/July issue.

Medical is put under the spotlight, and we thank ALBIS for being our cover star and for sharing with us the ‘medical grade’ polymer dilemma, which the distributor is working to resolve. We also drop in on Stratasys and its work in producing medical guides to support surgeons. Furthermore, we had the pleasure of putting together a highly technical and exciting

The shifting fault lines of Europe and the changing priorities of leadership all have a bearing on European plastics

Testing and Inspection spotlight which includes an interview with Mettler Toledo about how metal detection innovation can bring so much more than improved inspection to customers.

I hope you enjoy this latest issue of EPPM. Please keep in touch with the team online at www.eppm.com and via @EPPM_magazine on Twitter and let us know your thoughts.

Rose Brooke, Editor

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INDUSTRY

VinylPlus closer to PVC circular economy after Sustainability Forum in Berlin Words | John Carlon

the PVC community, before welcoming Vice-President of IHS Markit, Michael Smith, with his presentation 'Times they are a-changin’.’

Smith identified a future capacity need on a global scale - while construction in China is experiencing further slowdown, Europe and the US are steadily growing.

Following the introductions there were presentations from Michael Kundel, President of the European Plastics Converters; Namsak Choonhajutha, ASEAN Vinyl Council General Manager; Sophi MacMillan, Chief of the Vinyl Council of Australia; Cathy Wang, Vice-President of Yunnan Zhengbang Chemical, speaking on the Chinese PVC industry.

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eaders from the vinyl industry gathered for the VinylPlus Sustainability Forum last month, bringing pressing PVC issues to Berlin, while celebrating advances in sustainability and efficiency.

The forum (May 10th – 11th 2017) hosted 160 delegates from around the world.

With the theme of ‘Towards Circular Economy’, it explored the growing opportunities for the PVC sector to contribute to European industrial and waste management policies.

Welcoming delegates, VinylPlus Chairman Josef Ertl said: "The debate about how Europe can make the transition to a circular economy is high on the political agenda. I’m sure that a sustainable society without a circular economy is difficult to imagine. And the unique characteristics of plastics allow them to make a strong contribution to a more environmentally sustainable and resource efficient Europe.

VinylPlus with its unique co-operation model, bringing together the whole PVC value chain, is the right platform

for sustainability and circularity in the PVC industry."

Panel discussions with leading speakers focused on the role of vinyl in tackling sustainability issues, such as legacy additives in recycled PVC, and contributing to a stronger circular resources flow.

Philip Law, Director General of the British Plastics Federation, commenced proceedings as moderator by highlighting cooperation and unity in

LANXESS completes Chemtura acquisition LANXESS has completed its acquisition of Chemtura, a landmark buyout for the Cologne-based specialty chemicals business.

LANXESS has revealed it will combine its entire additives business within the new Specialty Additives segment at once, giving LANXESS an extra arrow to its bow, with annual sales of approximately €2 billion (£1.7 billion) and some 2,900 employees worldwide. The segment comprises the new Additives and Rhein Chemie business units, within which flame retardants and lubricants are anchored.

The Additives business unit is led by Anno Borkowsky, while Philipp Junge heads up the the Rhein Chemie business unit, which includes LANXESS' existing rubber and colour additives businesses.

In addition to additives, Chemtura’s urethanes and organometallics businesses will be integrated into the LANXESS portfolio, which will absorb some 2,500 Chemtura employees at 20 sites in 11 countries.

The expected annual synergy effects from the Chemtura transaction amount to approximately €100 million with realisation targeted until 2020.

"The new LANXESS is increasingly taking shape," said Matthias Zachert, Chairman of the LANXESS Board. "In its new set-up and with an even more balanced portfolio, the company will be much more stable and profitable. At the same time, Chemtura considerably strengthens our presence in the North American growth region." www.lanxess.com

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After the speeches, and panel discussions, the VinylPlus Sustainability Forum was closed by Josef Ertl and Brigitte Dero. Ertl said: "Please go on with your activities - to further improve our future and everything you do and keep going. We rely on the support of the whole industry. I would like to thank everybody and hopefully we will have the chance to shape the future together."

The forum will convene again next year, in Spain.

Vinylplus.eu

INDUSTRY

Clariant and Huntsman announce $20bn merger Clariant and Huntsman have shaken the global specialty chemicals market by announcing their merger.

This merger of equals will create a specialty chemicals business with an enterprise value of some $20 billion (£15.4 billion, €17.9 billion), with the transaction scheduled to close before the end of the year.

In the announcement made on May 22nd 2017, both companies' Boards of Directors unanimously approved a definitive agreement to combine via an all-stock transaction to form HuntsmanClariant.

"This is the perfect deal at the right time," said Hariolf Kottmann, CEO of Clariant. "Clariant and Huntsman are joining forces to gain much broader global reach, create more sustained innovation power and achieve new growth opportunities."

QUALITY HIGHLIGHTS.

HuntsmanClariant as a combined entity will create a business with sales of some $13.2 billion, an adjusted EBITDA of $2.3 billion and a combined enterprise value of around $20 billion.

HuntsmanClariant will have dual stock exchange direct listing on the SIX Swiss Exchange and the New York Stock Exchange and Clariant shareholders will control 52 per cent of stock, while Huntsman shareholders will control 48 per cent, receiving 1.2196 shares in HuntsmanClariant for each Huntsman share (each existing Clariant share will remain outstanding as a share in HuntsmanClariant).

"This is in the best interest of all of our stakeholders. Peter Huntsman and I share the same strategic vision and I look forward to working with him," said Kottmann.

Peter R. Huntsman, CEO of Huntsman, added: "I could not be more enthusiastic about this merger and look forward to working closely with Hariolf Kottmann, a man I have admired and trusted for the past decade. Together, we will create a global leader in specialty chemicals with a combined balance sheet providing substantial financial strength and flexibility."

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The new HuntsmanClariant global headquarters will be in Pratteln, Switzerland, while operational headquarters will be in The Woodlands, Texas. www.huntsman.com www.clariant.com

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COVER STORY

The 'medical grade' polymer dilemma The term "medical grade" is difficult to pin down, but ALBIS Plastic is helping customers navigate the market to find the best service package for a polymer suitable for each individual medical application.

WORDS | Mike Freudenstein, Director of Marketing Healthcare, ALBIS Plastic

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n order to be used in medical devices, polymers must fulfill demanding standards. For plastics manufacturers this means a great deal of investment for products with restricted market potential. The product and performance characteristics for "medical grade" polymers are determined at the discretion of the manufacturer, but everybody selling polymers can have their own definition of what a medical grade is, and that can present something of a problem.

There are no valid and

harmonised EU standards that expressly define the term “medical grade” polymer

The selection of materials for medical, pharmaceutical or diagnostic applications can be a difficult task.

Strict legal stipulations demand that plastics comply with standards applicable for these uses, e.g. as regards biocompatibility. Companies that work with such plastics prefer to use "medical grade" polymers because there is an assumption that these are the only materials suitable for use in medical applications. What is necessary to transform a "standard" polymer into a "medical grade" and how this sensitive subject can be dealt with in the market, is a question ALBIS can help answer.

Defining and regulation Requirements for materials used, for example, in the manufacture of medical devices, are specified in various regulatory requirements and directives. One such regulation is the new Medical Device Regulation (EU) 2017/745 for Medical Devices, which came into force on May 25th 2017, replacing the former EU Directive 93/42/EEC. The new regulation stipulates that “all Medical Devices (…) shall be designed and manufactured in such a way that, (…) they shall be safe and effective and shall not compromise (…) the safety of patients…”.

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Annex I further stipulates the requirements for medical devices relating to, among other things, safety, quality and suitability. It is also expressly required that special attention should be paid to the choice of materials being used. This is especially true when considering the toxicity and mutual compatibility with tissues, cells, body fluids and other used materials. The intended use of the medical device must always be considered in this process.

From a legal perspective it is the company that brings the medical device onto the market that is responsible for complying with any applicable regulatory requirements, but medical grade polymers have no strict definition, and very often such plastics are sold on the basis their biocompatibility alone.

Moreover, we must remember the plastics producers are coming from a different perspective. They might have to modify their materials or operational processes slightly to optimise their production.

If you are a producer, you may need to manage and reduce costs to restore operational efficiency. This, however, may lead to changes of processing parameters, processing aids or ingredients. Quite often such changes will not be communicated with customers, as these modifications are not in each and every case resulting in changes of the officially communicated specification of a material. This is normal practice in the plastics world as customers widely accept that the official product specification of a polymer is their reference for changes. However, for customers working in the healthcare field this is often not sufficient as their interest in being made aware of changes is typically going beyond the product specification.

Meeting the requirements In theory, the medical device manufacturer can select any plastic for use, but practical experience has shown that manufacturers of medical products tend to select polymers for their applications for which it can be certified that they were tested for biocompatibility.

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Such certification implies that the medical plastic in question will perform as the batch tested for certification performs. Frequently, polymers that are supplied with such certification are labeled or advertised by the manufacturer as "medical grade" polymers.

The question, however, is if each and every production batch was submitted for biocompatibility testing; in practice this is typically not the case as quite often randomly selected batches are tested and the results of such tests are published as results of a “representative testing� of the material. This means that the value of a biocompatibility certificate for a certain production batch is questionable if the material manufacturer is not committing to a strict notification of change procedure.

Such potential for variation in a polymer, even if the specification is the same every time, may be perilous from a medical point of view, but legally everything is fine.

Serious and informed suppliers will tell you about the service package of their medical grades and explain in detail about their commitment to change management, because they understand it causes a lot of headaches with their customers if a polymer is modified.

The less informed suppliers will just say their polymer is tested for biocompatibility, which does not guarantee each individual batch is tested.

There is a difference between the former and relying on one certificate given to a batch two years ago. So we say a good medical grade plastic is characterised by the service package: the notification of change, biocompatibility, security of supply, backup plants and so on. There is no technical feature that makes a polymer a medical polymer, it’s the service package around it.

The strategy No common standards or norms There are no valid and harmonised EU standards that expressly define the term "medical grade" polymer. In fact, any definition of the product or its performance characteristics which the manufacturer markets for use in medical applications lies at the complete discretion of the polymer manufacturer.

These performance characteristics can be varied in nature and might address the specific needs of production to very different degrees. Services which might be offered specifically for materials used in medical applications include: specific commitments regarding change management as well as notifications of any planned or necessary material changes, such as additivation packages or pre-cursor raw material sources; testing and certification of biocompatibility; clear distinctions between "medical grade" polymers and standard materials; production of polymers in production facilities specifically designed for that purpose; contingency or disaster recovery plans; dedicated quality measures in order to ensure the best possible quality standards; specific cleaning measures to avoid contamination; special packaging materials for medical polymers; and cooperation with certified suppliers and logistics providers.

Three per cent It is estimated that only about three per cent of global plastics production is destined for the healthcare industry.

Considering this, it is clear that not every polymer manufacturer will be willing or even able to meet the healthcare OEM's stringent requirements in the medical and pharmaceutical sectors. When one compares the performance requirements for medical grades with the more commodity-orientated strategies of the plastics industry, an obvious conflict of interest between the two sides is apparent.

As such, the overall supply of plastics for medical technology remains limited so that use of standard polymers is still likely to continue in the future. This represents a potential risk, since change management for standard polymers often insufficiently addresses the high demands of medical applications.

The increasing complexity of medical devices, which are often constructed from a variety of different functionally critical parts and assemblies, also constitutes a potential source of increasing error.

No one who has initiated a (sometimes exhaustive) material qualification for such a complex product would want to be faced with supply shortages, find the material removed from the market or subjected to unannounced changes. It is therefore important to proceed carefully with the selection of materials and only to select those polymers which have been developed specifically for use in medical, pharmaceutical or diagnostic applications. These polymers are generally subject to stringent change management and provide a higher level of confidence and security for the processors of the material.

ALBIS can add value in a way by telling the converter that we understand their rules of engagement and we understand change control, and that avoiding change is of value because it avoids going through the qualification process again which depending on the application can take up to four years.

As a distributor and As a distributor and compounder, ALBIS Plastic is continuously elaborating its strategy for the medical devices, pharmaceutical packaging and diagnostic applications market.

compounder, ALBIS Plastic is continuously elaborating its strategy for the medical devices, pharmaceutical packaging and diagnostic applications market

We go directly to customers and we support our field sales teams by helping to prepare them for certain questions in a meeting or by joining the discussion, this way we reach out to the customer.

ALBIS' broad product portfolio is based on a number of wellknown brands produced by polymer manufacturers. This allows the company to provide a variety of different polymers, all of which have been specially developed for medical applications. In addition, we offer to develop customised compounds based on various polymers. These are then produced under the quality management conditions.

In addition, a broad product portfolio of distribution and proprietary products is of use for complex projects in the medical field. While large polymer producers often consider such projects from the perspective of their own specific product portfolios, for ALBIS it is the technical and regulatory requirements that we focus on with our project work.

In the first step, it is necessary to define a technical Your Part requirement or ner challenge and for Health care. then to select the IN TO UC most suitable H W IT H PL AS TI CS material for solving it. www.albis.com

More informed suppliers can be identified from those who think they understand by asking them how their medical grades are characterised.

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MEDICAL

3D printing and the value proposition for medical Stratasys is at the forefront of exploring the use of additive manufacturing technology in medical. EPPM speaks to Business Manager for Healthcare RenĂŠ Martin about how 3D printing is bringing a real value proposition to medical practitioners and patients.

WORDS | Rose Brooke

A

dditive manufacturing technology can help hospitals, pharmaceutical companies, medical device companies and healthcare providers bring better individual care to their patients.

RenĂŠ Martin, Business Manager for Healthcare EMEA at 3D printing pioneer Stratasys, is passionate about the roadmap additive manufacturing is laying down for the medical industry, both in terms of what is achievable today, and in the future.

"3D printing can connect all of the medical industry stakeholders," he told EPPM. "Everybody needs to reduce costs but at the same time they need to improve patient care somehow. We think this technology can provide different value propositions and help people reduce costs and at the same time improve patient care due to the technology's capabilities."

Martin explained that finding this value proposition in a hospital environment requires looking at additive manufacturing technology in a holistic context. If a patient has an accident, they are brought in an ambulance to the emergency room and the first investigation they have is a CT or MRI scan. If a fracture or a serious injury is discovered based on the scan, a patient-specific printed model of the affected area can be created from the scan data and a surgical guide can be 3D printed for the surgeon to help him or her prepare for the necessary operation. But why would having this 3D model bring value to such a scenario?

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Beyond the CT scan "Surgeons will always tell you the only truth is when you see the patient open on the table, because then you can identify [the problem] with your fingers and your eyes. A CT scan is good but you can't hold it in your hand. At the end of the day there's no room for interpretation or room for mistakes, whereas if you have a patient-specific model in your hand, you can achieve 100 per cent visibility and plan the surgical intervention. Maybe it's not so dangerous and you can avoid unnecessary surgical intervention," Martin stated.

In the case of maxillofacial surgery where a patient has an orbital fracture requiring an implant, for example, a patient-specific 3D printed model can serve as a template for the implant, which saves time in the operating theatre, reducing hospital costs while increasing diagnostic visibility. And one day the implant itself will be 3D printed as standard.

"In future we will be talking about [3D printing] plastic implants such as hip or knee replacements. We as an industry are on a very good track to find new materials for usage inside the body so we can replace titanium implants," Martin explained.

Titanium or steel will always be treated as foreign when in the body, which makes these operations especially complicated. With polymers, however, practitioners can create implants to a specific accuracy in an inert material that is less likely to be rejected by the body.

Model behaviour Until the 3D printing technology is implantable, surgeons can rely on 3D-printed models and the good news is the more models a hospital prints, the more economical the technology is and Martin believes most hospital departments will be able to benefit from 3D printed guides and models in-house.

For example, a maxillofacial department at a hospital in Sweden orders 100 3D printed models from external service providers a year and regardless of the body part, this costs between â‚Ź1,500 and â‚Ź2,000 annually.

Far cheaper to have a 3D printer in-house that can print 200,000 patient-specific models a year.

"This is definitely the future because with this we will improve patient care, improve the clinical outcome and we will massively reduce the operational costs," said Martin.

This technology can provide different value propositions and help people reduce costs and at the same time improve patient care

But who manages the 3D printing of surgical models? Martin believes the technicians who carry our CT and MRI scans and X-rays have the technical understanding of the imagery and are best suited for the job of managing the additive manufacturing side, which reduces model turnaround from four days to six hours using machinery that is reliable enough and capable of producing models 24 hours a day, seven days a week for 10 years.

"Reliability for the healthcare sector is what Stratasys provides," Martin stated. "Reliability for stakeholders that we have great biocompatible materials technology and two different printing solutions (FDM and PolyJet) allowing you to create patient-specific surgical guides or anatomical models for training, plus our service partners and resellers. That's a very good bundle to offer the healthcare sector." www.stratasys.com

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MEDICAL

Amies Innovation makes the most of modular cleanroom Medical moulding company Amies has won extra business for injectionmoulded components after buying a modular cleanroom from Connect 2 Cleanrooms.

A 90-year-old moulding company based in the UK has expanded into medical products after building a cleanroom.

Amies Innovation installed an ISO Class 7 Modular Cleanroom in 2013, to manufacture injection moulded components for use in non-invasive detection, measurement and monitoring tests. Typical applications include parts and assemblies for point of care testing (POCT), screening for MRSA, drug abuse and monitoring blood coagulation for anticoagulant users.

IMI Norgren, an engineering company based in Birmingham, contacted Amies for a new project in 2013, with the pre-requisite that Amies Innovation achieve the accreditation ISO 13485 and it use a cleanroom.

At the time Amies agreed it would install a cleanroom at its plant in Chesterfield, Derbyshire. Following a recommendation from its moulding machinery supplier, Connect 2 Cleanrooms were chosen to design, make and install a modular hardwall panel system with a softwall entrance, covering 25.5 m sq.

The cleanroom, which achieves 96 air changes per hour, includes the ECO 1 System allowing the operators to constantly monitor the cleanroom by recording the temperature, humidity, filter pressure and particle counts.

The modular cleanroom option was the ideal choice for Amies Innovation, due to IMI Norgren being a new project and their first requirement for cleanroom operations, as it allows them to expand or relocate their cleanroom at a later date based on capacity requirements.

Bob Ball, Managing Director at Amies Innovation, said: “The installation of our cleanroom has not only increased our sales but has also improved our credibility in the medical sector. It has been fully operational for three years and we are now looking to expand the room to house additional machinery due to the manufacturing demand.�

www.amiesplastics.co.uk

Medical certification for BIEGLO PEEK powders PEEK powder and granules (CoPEEK) supplied by German polymers distributor BIEGLO will be used for medical applications after ISO 10993 certification success.

John Biesterfeld, BIEGLO CEO, said: "CoPEEK has always been convincing for our customers with its quality and price competitiveness. With our ISO 10993 certification, all PEEK material processors in the European medical market have gained a new firstclass supplier."

Founded in 2011, BIEGLO is the exclusive agent for the CoPEEK of Panjin Zhongrun High Performance Polymer Company. www.bieglo.com

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MEDICAL

Contact lens moulders set sights on global growth Sumitomo Demag is seeing results for injection moulding for contact lenses using advanced cleanroom technology.

A

s medical and optical plastics applications have diversified, the popularity of contact lenses has grown. The optometry community estimates 125 million people wear contact lenses daily.

As contact lens manufacture is a process requiring the highest standards of hygiene and precision, Sumitomo (SHI) Demag has developed advanced moulding methods.

Every contact lens that is produced requires a bespoke mould, an application of Sumitomo (SHI) Demag’s injection moulding expertise.

Knowing that each lens must meet the highest levels of quality and cleanliness, it is essential that the moulds are consistently perfect. The process starts with the injection moulding of a front and base curve mould.

This mould is then filled with a monomer (a molecule that can be bonded to other identical molecules to form a polymer) and is then closed and cured before the lens is hydrated and packed.

Nigel Flowers, Managing Director of Sumitomo (SHI) Demag UK, said: “Every single mould used to make a contact lens is produced to a very high level of precision and cannot be reused.”

Discarded moulds will still be recycled – only not for lenses.

“Because the final lenses are moulded against a surface that has already been injection moulded, any imperfection within the mould will find its way into the lens.”

Flowers is confident that Sumitomo’s moulding innovation will pay off, as demand for lenses increases in Latin America and Eastern Europe: “Much contact lenses demand is driven by people who no longer want to wear glasses, as well as improvements in lens technology.

To make lens moulds, both all-electric and hydraulic injection moulding machines are used – though over 90 per cent are allelectric.

place to allow the mould to fill naturally.

This intervention reduces the cavity pressure and stress in the material. Once one cavity fills it moves on to another one.”

Repeatability is the main rationale, as well as meeting ISO Class 8 clean room standards. Direct drive machines offer major improvements in efficiency, including a reduction of up to 75 per cent in energy usage during operation and improved repeatability and cycle times.

While contact lens moulds are not technically classed as medical devices, any airborne contaminants, such as dust and particles from the raw materials, as well as bacteria, could affect the lens function.

Because no two eyes are the same, there is a broad spectrum of styles and parameters to meet when it comes to the production of lenses.

To accomplish quality and accuracy, Sumitomo (SHI) Demag installs its awardwinning Active FlowBalance technology in machines that produce the contact lens moulds. This helps to combat uneven filling of multi-cavity moulds.

Flowers said: “When we’ve got to a certain part of the fill and the materials are moving under their own inertia, we stop pushing and let the mould fill naturally. We are not forcing it in at high pressures and forces.

“The key is to ensure that the manufacturers that specialise in making contact lens moulds can do it repeatedly and with the highest precision in order to mass-produce the moulds cost efficiently. For this reason, production using Active FlowBalance only really works on all-electric machines, such as the IntElect. That’s because we can repeatedly stop the screw in the right

“When you have to wear glasses, it is a bit of a compromise, yet today it is easier to not accept the shortfalls.”

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A variety of moulds are used in the production of contact lenses, representing the different magnification levels (graded in quarter dioptres) that are prescribed for each lens. The differences are in the variation in the space thickness between the front and rear of the mould, which dictates the thickness of the lens. There are a finite number of combinations and a standard number of magnifications and variations on the curve. Nevertheless, production still should be carefully planned and controlled, to ensure the machines maintain the highest efficiency levels possible.

Flowers said: “If you’ve got a stigmatism, the lens rotates and always ends up in the right place. All of this places greater challenges of the machines to meet the specific needs of the customer, but breakthroughs are happening all the time. We’ve not quite reached the point where we are 3D printing the lens according to someone’s eye, however this might be possible in the future.”

With contact lens demand continuing to increase, machine manufacturers are constantly facing challenges of how ensure their hardware can stay one step ahead, and Nigel Flowers believes there is a bright future: “The preference of disposable lenses – and relatively lower cost – makes them a much more appealing solution to resolving short or long sightedness than glasses.” uk.sumitomo-shidemag.eu

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“Herco” (2007); chilling compressor “GEA” (2014); air-conditioning system “GEA” (2004); cooling compressor /heat recovery unit “York” (2010); cooling tower “Karlsruhe” K3, dim.

10.000 x 5.000 x 3.750 mm; TRAFOSTATION “ABB”, power 800 kVA; transformers “Transformer” and “AEG”; battery power supply system;

TANKS: 15 adsorbent tanks incl. “Ansyco”, VA tanks incl. “Grill u Grossmann”, VA storage tanks incl. “Hausach GmbH”, tanks with agitator incl. “Nowak”, FT-IR MICROSCOPE “Thermo Fisher”; PUMPS & E-MOTORS, wrapping machine; CLOSING: Tuesday 27

and Wednesday

Simplicity through extensive standardisation Ultra-rapid delivery Variable, flexible, maintenance-friendly Worldwide service included

www.hasco.com

28 JUNE

Viewing: Thursday 22 June from 10.00 till 18.00 hs and Friday 23 June from 8.00 till 14.00 hrs

www.TroostwijkAuctions.com

326 Vetaphone EPPM mag.qxp_326 Vetaphone EPPM mag 11/01/2017 12:41 Page 1

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The world’s largest online plastics encyclopedia

The world’s largest online plastics encyclopedia

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TESTING & INSPECTION

Kistler shows sensor integration at Moulding Expo

Hammer-IMS boosts measuring capabilities at ANL Plastics

The Kistler G ro u p chose Moulding Expo as the platform for showcasing simple methods of installing measurement technology for quality assurance in injection moulds.

Kistler focused on sensors that are insensitive to their installation position and multichannel connectors, as well as solutions and tools designed specifically for mould-makers to meet requirements for integrated quality testing in the injection moulding process. With Type 1722 multi-channel connectors, up to eight sensors can easily be linked up through single-wire plug connections – so there’s no need for screwed joints, and the connector is more robust. Kistler also unveiled its new Type 6185 sensor, which is insensitive to its installation position. This product has been systematically adapted to confined installation conditions – its frontal diameter is 2mm – and its design ensures that measurement results cannot be falsified by lateral forces (such as those caused by difficult installation conditions).

ANL Plastics, a plastic packaging maker, is using equipment from HammerIMS in its production facilities in Wellen, Belgium.

Hammer-IMS provided its Marveloc 602-CURTAIN measurement system to ANL. The system contains four M-Ray sensors, continuously measuring the plastic thickness on an ANL Plastics production machine. Stefan Tielen, CEO of ANL Plastics, said: “The disruptive technology of Hammer-IMS fits our strategy to play a leading role in downscaling the widespread use of X-ray and nuclear measuring systems in our sector. It is great to see these kinds of innovations coming from local start-ups. We are always looking for innovation and we are happy to cooperate with Hammer-IMS as it has provided a win-win situation. In addition to innovation, Hammer-IMS being located in our backyard is practical in terms of service and language.”

Noel Deferm, General Manager at HammerIMS, added: “We can be proud to have realised a unique and successful cooperation between two Flemish companies with pioneering visions on technology.” www.hammer-ims.com

www.kistler.com

Inspection to star at Interplas

Lex Machinery offers Rommelag leak detectors Lex Machinery will offer a specialist line of Rommelag Leak Detector machines to complement its extensive range of pro du c t i o n machinery and ancillaries. The Rommelag HVLD high voltage leak detector operates based on the high voltage test method and the electrical conductivity of the fill product packaged in a non-conductive plastic ampoule. The system is designed for fully automatic in-line leak testing of ampoule blocks. If any leak is present, the discharge current will flow through the pinhole into the container and the detection of this current will automatically cause the container to be rejected. Jim Angel, Managing Director, said: “Current FDA guidelines require validation for container closure integrity tests. EU GMP guidelines stipulate that all plastic ampoules should be subject to 100 per cent integrity testing. We are pleased to offer a high specification machine at low cost that meets FDA requirements.”

The Rommelag HVLD 924 Leak Detector is fully guarded with clear layout and accessibility. Operation pressure is 6 bar and depending on ampoule width, the machine can test up to 6,000 ampoules per hour, based on 15mm width. Up to 6,000 ampoule blocks per hour can be achieved based on a block width of 65mm or less.

Interplas, the leading plastics processing show in the UK, will be giving inspection technology a special platform with its Inspex feature, which will focus on measurement and quality assurance. The exhibition brand hopes to further accelerate awareness of the challenges and opportunities for metrology and inspection within the plastics industry. At Interplas and sister event TCT Show, which run concurrently from September 26th – 28th at the National Exhibition Centre in Birmingham, UK, providers of metrology and inspection hardware, software and services will be highly visible on the show floor in locators and show maps, making it easier for visitors to navigate and find solutions in this area more easily. www.interplasuk.com

www.lex-machinery.co.uk

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1915

Solar Determinator®

1927

Original Weather-Ometer®

1954

Xenotest® 150

1977

Ci65 Weather-Ometer®

1995

Ci4000 Weather-Ometer®

2017

The New Ci4400 Weather-Ometer®

Our Latest Milestone.

The Atlas Ci4400.

For over 100 years, Atlas instruments have revolutionized the science of weather durability testing. The new Atlas Ci4400 WeatherOmeter® is our most advanced instrument yet - providing easy and effortless operation, unmatched uniformity, increased capacity and a sleeker design, delivering unparalleled value and performance. With its user-friendly touch screen interface and ergonomic features, the best-in-class just got even better. Learn more about the new Ci4400 Weather-Ometer at atlas-mts.com.

TESTING & INSPECTION

Testing machines maker Tinius Olsen wins online award in China T inius Olsen’s metals and plastics pendulum impact testing machine IT503 has been ranked top of the most popular scientific instruments by users of the scientific instrument information website instrument.co.cn.

Martin Wheeler, Director of Sales and Business Development, said: “We are delighted with the award which is indicative of the way our testing machines have been received within the Chinese marketplace. China has the second largest economy in the world, so interest such as this from within the industry sector is very pleasing.

“The IT 503 is one of the best machines available within its sector. Obviously, this reputation has reached the Chinese market which can only help establish the Tinius Olsen brand.”

Despite a recent slowdown in economic growth, China is outpacing other world economies, importing an estimated $1.53 trillion (€1.36 trillion, £1.2 trillion) in products and services every year.

Industries across all sectors export more than $2.37 trillion, creating a ready-made market for the testing machine industry.

clamp or anvils in the base of the unit, to test plastics in accordance with ASTM D256 (Izod impact), ISO 179 (Charpy impact), ISO 180 (Izod impact), ASTM D6110 (Charpy Impact), ASTM D4812 (Unnotched Cantilever Beam Impact),

ASTM D4508 (Chip Impact) and the ASTM D950 (Adhesive Bond Impact). www.tiniusolsen.com

The model IT 503 plastics impact tester, together with the model IT 504, continues to set the industry standard for versatility, ease of operation, and display of information with high resolution.

These machines can determine an impact resistance using either a Charpy or Izod configuration, without changing the entire pendulum. The operator attaches the appropriate striking tup on the pendulum and the specimen

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TESTING & INSPECTION

Inspection and analysis of XLPE and HPTE material in highvoltage cable production WORDS | Harry Prunk, Executive Board SIKORA AG

C

ross-linked polyethylene (XLPE) is a popular insulation material for medium- and high-voltage (MV and HV) cable production for its low dielectric loss and excellent electrical and physical properties for power transmission.

Prysmian pioneered using HPTE (High Performance Thermoplastic Elastomer) instead of XLPE. HPTE has no cross-linking and no byproducts, while it is re-usable, has a shorter production time and is compatible with existing network components. Today, both XLPE and HPTE are used in MV and HV cable production.

In such cases, joints sometimes have to be used. Because of this, some standards for HV cables demand the exclusion of contamination from 75μm in the processed materials. Moreover, there are guidelines from the Association of Edison Illuminating Companies stating cables have to be designed for at least 40 years' use. Accordingly, it is necessary to inspect the material for purity to 100 per cent before it enters the end product and sample tests are not sufficient to exclude all contamination reliably.

Catching impurities via screen The need for clean plastic material for HV and EHV cables

Today cable manufacturers use screens positioned in the melt flow, after the extruder and before the crosshead to catch impurities in the XLPE and HPTE melt before they get to the cable. These screens are subject to clogging and scorching, and production has to be stopped in order to change these screens, which means a joint is required at that position later on. Joints, where the cables are welded together, are produced manually and are a critical component, which is why cable manufacturers try to deliver large cable lengths with minimal joints, as they contain a potential risk for breakdowns.

The purity of the plastic material that is used for the insulation of HV and extra HV (EHV) cables is important.

The purer the compound, the lower the risk of breakdown.

Metal impurities of just 50µm can cause damage to the end product with high follow-up costs. The repair of a defective subsea cable for example, can lead to weeks of downtime, which is why EHV cables are tested at above nominal voltage in-plant as standard.

Pellet inspection systems are used either in laboratories or for online monitoring during the granule production process.

The majority of systems are based on optical technology to detect pellet contamination, however such systems cannot detect internal pellet contamination.

On average, five-to-six breakdowns a year are registered by each production site causing tremendous losses, with a single breakdown costing up to €150,000 (£129,000) even before the cable is delivered to its dedicated position, leading to a loss in time and missed delivery dates.

Combined X-ray and optical inspection Sikora's inspection and sorting system provides 100 per cent online quality assurance by using X-ray technology and optical technology, which identifies impurities as miniscule as 50μm with image processing software.

XLPE comprises of carbon, which has six protons in its core. A typical contamination of iron particles - which have 26 protons at their core - from the extruder or granulator, are picked up due to their much higher X-ray attenuation, resulting in a perfect contrast between the two materials in the X-ray image.

In order to allow precise recordings of material flows at industrial speed, modern camera technologies (eg. optical and infrared) are used. A powerful image processing software similar to the one used for the X-ray inspection is used to detect contamination with an optical system.

The combination of both X-ray and optical technologies enables the detection of contamination in the pellet itself and on its surface.

X-ray inspects transparent and coloured pellets as well as semi-

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conductive XLPE material for impurities, and the optical system detects black specs on the pellet, foreign objects and foreign pellets as well as other organic or metallic contamination.

The system is installed between the hopper that is fed from the XLPE and HPTE supply and the hopper of the extruder, and the compound is fed by gravity.

In addition to online inspection and sorting devices, there are modular designed systems available for on- and offline inspection and the analysis of pellets, flakes and tapes/films. These are used for smaller throughputs as well as production lines where sample testing is sufficient, or for the control of incoming goods. Depending on application, the systems are equipped with X-ray technology, infrared technology or optical sensors to be used during production or for sample testing, detecting contamination from 50 Îźm.

For example a laboratory inspection and analysis device with X-ray technology inspects up to 3,000 pellets (200 ml) that are placed on a tray. Within seconds, these pellets are inspected and contaminated pellets are optically highlighted, easing their extraction.

For comprehensive process optimisation for cable production, manufacturers combine an online inspection and sorting system with an offline inspection and analysis device. Once contaminated pellets have been detected and sorted out, the laboratory system inspects these pellets again and marks contamination optically, easing separation. This interaction of online and offline inspection and analysis ensures material purity and builds a database that prevents future contamination.

The need for high purity in XLPE and HPTE materials in MV, HV and EHV cables is vital, and on- and offline quality control inspection technology can protect the value chain even before materials processing.

By using X-ray and optical technologies, contaminants inside the pellet and on its surface are detected, guaranteeing total quality control. With the use of an offline inspection and analysis system for contaminated pellets separated by the online inspection system, production processes can be improved further using the data gathered.

Introducing these quality control technologies for XLPE and HPTE materials is essential to assure high-quality MV and EHV cables, ensuring the efficiency of the cable production line to a great extent. sikora.net

What a new ASTM standard for thickness & variability means for plastic film WORDS | Rob Lawrence, SolveTech

F

ilm variability has real implications for performance and the new “Standard Test Method for Determining Plastic Film Thickness and Thickness Variability using a Non-Contact Capacitance Thickness Gauge� will help improve quality, customer/supplier relations and innovation.

The new ASTM standard coupled with innovative technology seeks to change the status quo and is currently going to vote in subcommittee. It defines film thickness using a NIST traceable calibration, and a device with a precision of +/- 0.1 micrometres. In practice, the SolveTech PR2000 Precision Profiler will exceed this performance level.

Film thickness and variability are key parameters for film, but as films get thinner, they are harder to measure. For example, many producers use micrometers that are precise to +/- 1 micron, but this is +/- eight per cent of the thickness of a 12 micron film.

The new approach eliminates the problems of film deformation, dust and dirt affecting the reading.

Users can profile a strip characterising their entire extrusion in 30-to-60 seconds, measuring every area along the strip. If a 3mm wide measurement area is used, the film will be measured every 3 mm, providing complete coverage.

The film industry trades billions of euros in film annually without a standard in place. Many buyers are therefore forced into making price-based decisions.

Now buyers can compare the variability of film and before it is shipped to a converter, the film can be checked using this new standard to verify it will perform as intended.

Since it is not practical to measure every spot on a film sample, most decide to measure several points and call that their variability; this is not standardised.

So when someone says they have a material that is +/- five per cent in variability, what does that mean?

SolveTech is distributed in the UK and Europe by Quantum Opus.

With dozens of different on-line gauge suppliers using different techniques, there is no way to standardise variability from these varied systems.

gauging.com

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TESTING & INSPECTION

Much more than metal detection Mettler-Toledo brought a very convincing case to Interpack 2017: that the best inspection technology on the market can offer a manufacturer increased capacity and operator safety as well as top-specification quality control.

WORDS | Rose Brooke

L

eading inspection technology on the market in Europe today improves a customer's quality control, but the best inspection technology on the market in Europe today does much more.

Mettler-Toledo made a statement at Interpack 2017 in May when it presented its innovative solutions for the food and pharmaceutical markets that bring improved efficiency and operator safety to the factory floor.

Mike Bradley, Head of Sales at Mettler-Toledo, was kind enough to give EPPM a tour of the market-leading array of inspection units, singling out the technology that is so effective, he wishes it had been his idea.

"A lot of our customers from an inspection point of view are looking for more than product inspection - in this case metal detection. They are looking at how the device can help them drive their productivity and overall equipment effectiveness," he explained.

Mettler-Toledo's research and development for metal detection draws on the conversations people like Bradley have with the company’s customers, focusing as much on its own targets to detect even the tiniest specs of metal as it does on the customer's constant drive to improve efficiency. The modern factory floor has to be able to process products - regardless of what they are - quickly, cost-efficiently, safely and effectively and a Mettler-Toledo system such as its Profile Advantage Metal Detection systems do much to support these competitive targets.

Quicker, faster and more efficient "Although we have a metal detector which is probably the number one inspection device out there," said Bradley, "our R&D focus over the last three-to-five years has been on two main areas, one is on the core sensor technology to detect smaller and smaller pieces, and the second is to look at ways to help our customers do that quicker, faster and more efficiently."

Metal detector clustering allows Mettler-Toledo customers to inspect multiple products on a single setting, the idea being when the operator is doing product changeovers they do not have to change the metal detector settings or system as well. Not only does this make product changeover quicker, but it significantly reduces instances of human error.

"These inspection units are a critical point in the production line," stated Bradley. "So with our metal detection systems, the only time you have to touch them is to test them and you don't need to changeover recipes thanks to clustering technology which finds a common setting automatically and is operator-free running."

This too reduces cost for the business, as by taking away operators, a line is less expensive to run, saving money and improving factory floor safety in one hit.

Super sensitive, super safe Mettler-Toledo's Profile Throat Metal Detectors with Virtual Network Client (VNC) technology made its debut at Interpack and once again, brings customers so much more value than just efficient metal detection.

The inspiration for the system came from a customer, who had hundreds of metal detectors who calculated how much time it takes to test these devices, which involves climbing a ladder to drop a piece of metal through the system, which then prevents the alien item from being bagged. Of course, if the bagger stops, the production line stops, which means production is paused every time the system is tested, which in this case was every two hours.

Mettler-Toledo's Reduced Test Mode function operates on a slightly increased level of sensitivity than the customer's specifications, and monitors its actual operating sensitivity level, sounding an alarm should the sensitivity reduce. The alarms sound before the metal detector reaches the customer's specification so the metal detector is always working to or better than specification, enabling the customer to test the Safeline metal detectors less often, which means productivity is vastly improved, allowing the customer to produce millions more products a year with a return on investment of less than 12 months.

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Bradley added that in addition to the attractive return on investment, there is another incentive for the customer, one of operator safety.

bottom line. These metal detectors have the technology inside them to drive their capability to another level, we start by offering a food safety solution and end by helping drive OEE and bottom line profit".

"These metal detectors are often installed high up and to test them somebody has to climb a ladder, drop some test pieces in and climb back down again. Now they're only going up and down the ladder four times a day so there's a big benefit for the operator in terms of health and safety."

www.mt.com/pi

Production payback

This by-product of managing productivity is where the customers are really benefitting

The final part of the story, Bradley said, is that to complement the reduced requirement for testing the metal detecting systems, Mettler-Toledo's Automatic Test System (ATS) can automatically fire a test piece of metal through the system, in a process that takes 30 seconds.

"Now it's only stopping for 30 seconds twice a day when it was stopping for three minutes 12 times a day," Bradley said. "These machines typically produce products at about 100 packs a minute, so the payback is phenomenal."

He explained that approximately 3,600 packs per machine do not get made every day if a customer is using traditional metal detector testing methods and undertakes 12 tests a day, which equates to close to one million packs a year not being made. If a customer has 24 machines, which is the case of one of Mettler-Toledo's clients, the numbers get more serious, with some 24 million products not being made due to inefficient metal detection inspection.

"This by-product of managing productivity is where the customers are really benefitting," said Bradley. "I always ask, what's in it for the customer? The answer is: increased productivity - that's profit and

International trade fair for plastics processing 17. – 21. OCTOBE R 2017 . FRIE DRICHSH A FE N

The Entire World of Plastics 25 th Fakuma ! More than 1700 exhibitors from all over the world will present global offerings for technologies, processes and products made of plastic, as well as equipment and tooling for plastics processing, in 12 exhibition halls. You’ll be awaited by flexible, individualised solutions for current and future challenges faced by the automated, globalised economy.

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

www.fakuma-messe.com

Organizer:

P. E. SCHALL GmbH & Co. KG

+49 (0) 7025 9206-0

WWW.EPPM.COM

fakuma@schall-messen.de

23

TPEs

Sumitomo Chemical expands in Chinese car industry

FKuR updates portfolio with biobased TPE FKuR brought an updated portfolio of biobased thermoplastic compounds to Interpack 2017, extending the window of application of biobased raw materials into the TPE product group with Terraprene. Depending on the grade, the share of renewable resources can be as high as 80 per cent with Terraprene, which offers performance features and resistance equivalent to petrochemical TPEs. Terraprene is suitable for both injection and extrusion moulding and the currently available standard types of Terraprene cover a wide Shore hardness range from A 20 to D 40. In addition, individual adjustments based on the customer’s requirements are possible. Typical applications include soft touch handles, toys, tools, and sports equipment. Terraprene is also a sustainable substitute for PVC. www.fkur.com

Sumitomo Chemical will strengthen its automotive materials business in China, by establishing a new manufacturing base for polypropylene in Chengdu, Sichuan, as well as providing manufacturing capabilities for thermoplastic elastomers at its facility in Dalian, Liaoning. China’s automobile market is the world’s largest, and continues to expand with improved safety features like more airbags using TPE. Chengdu is a major Chinese manufacturing centre and Sumitomo hopes to grow the plant in years to come. www.sumitomo-chem.co.jp

Natvar launches tight-tolerance tubing for vein surgery

Teknor Apex makes TPE gels more adhesive

Natvar has launched a tight-tolerance microextrusion medical tubing product line. The microextrusion tubing will be used in surgery on nerves and blood vessels. Bob Donohue, Manager of Natvar, said: “Natvar’s considerable investment in manufacturing enables us to microextrude monolayer, coextruded, multi-lumen tubing or profiles in a variety of thermoplastic (PVC, urethanes, TPEs) materials at CPK1 values above 2.0.

The ability to run thermoplastics means that medical device companies can realise desired performance attributes at a fraction of the cost associated with fluoropolymers and glass.” www.tekni-plex.com/natvar

Teknor Apex has released two new series of Medalist medical elastomers to overcome problems of tackiness and poor adhesion to PP substrates.

Medalist MD-16100 low-tack gels exhibit less surface friction than standard TPE gels, providing smooth surfaces and improved haptics. Grades are available with hardness levels from an exceedingly low 20 Shore OO to 65 Shore OO, or 10 Shore A. The compounds can provide padding, support, or cushioning in applications like orthopaedic devices and prosthetic liners and can serve in diabetes therapy as insoles, heel cushions, and toe spacers. The new compounds are safe for skin contact, process and demould easily, and are available in clear and translucent grades that are ideal for custom colours. Ross van Royen, Senior Market Manager of regulated products, said: “New Medalist 16100 and 10100 Series compounds are unique among TPEs. Their outstanding properties as cushions and liners make them cost-effective replacements for silicones.” www.teknorapex.com

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TPEs

From the dosing valve to leakage protection: TPEs for advanced product packages KRAIBURG TPE is responding to trends in the packaging industry with a broad spectrum of materials and services. Simone Hammerl reports on the many advantages of using TPEs in product packaging with increased functionality and reliable sealing.

WORDS | Simone Hammerl, Public Relations Manager, KRAIBURG TPE

D

ue to their good elastic properties and ease of processing, TPEs are ideal for highcontrast two-component injection moulding applications in hard/soft combination with other thermoplastics.

Manufacturers of consumer products are striving to use their packaging to provide unique selling propositions. At the same time, the increase in shipments of single liquid products as a result of e-commerce, as opposed to conventional large-scale distribution on pallets, increases the requirements for packaging with a reliable seal.

Intelligent and functional packaging “A classic soft-touch surface that conveys a high-quality product character to the consumer is no longer enough,” said Josef Neuer, Product Management EMEA, KRAIBURG TPE. “That is why we insist on market- and customeroriented formulations in the development of our materials that pave the way for innovative packaging solutions.”

An innovative application for TPEs is the use of dosing valves. MENSHEN of Finnentrop in the Sauerland region, a worldwide leading manufacturer of highquality closures, developed the one2serve dosing valve, which opens only when pressure is applied to the bottle or tube. As soon as the pressure decreases, the opening slots seal again.

The dosing valve is manufactured as a one-piece finished product using the two-component injection moulding process. The outstanding adhesion of the TPE to the hard component ensures a cost-effective and reliable manufacturing process

Custom engineered compounds The TPE formulations for use as dosing valves feature elasticity throughout the entire life cycle that is comparable to typical silicones. The hysteresis or elastic-plastic deformation behaviour of these compounds shows a significant decrease in deformation compared to standard TPEs, in which the stress and relief curves are further apart. To ensure that higher dosing pressure is not needed when the valve is opened for the first time, the TPE materials are also specially designed to prevent clogging.

is more difficult in applications with a high surface/ volume ratio. However, each single application must be analysed on an individual basis. KRAIBURG TPE provides in-depth customer support in this respect.

The KRAIBURG TPE portfolio includes numerous compounds for fatty food applications for which the formulation can be adapted to the specific surface/ volume ratio.

Outstanding resiliency Packaging in the growing e commerce sector benefits from the cost-effective two-component injection moulding process.

We support our customers with a comprehensive service package from the product idea through to series production

Compatibility with foodstuffs The new THERMOLAST K materials fulfil the stringent requirements of the Code of Federal Regulations, the US Food and Drug Administration and of the EU Directive for plastic materials that are intended for contact with foods.

The EU Directive contains an extensive positive list of monomers and additives. It applies to materials and objects made of plastic that are intended for use in contact with foods and defines an overall migration limit (OML) of 10 mg/dm sq. The migration test is conducted for different foodstuff classes by means of food simulants. In general, compliance with the limits

“The increase in single shipments by post or parcel service necessitates packaging solutions with very good sealing properties,” Neuer explained. “For these applications we have developed special materials that ensure an optimal and permanent seal.”

KRAIBURG TPE’s tests confirm that seals made of these materials retain their outstanding resiliency even after the repeated application of pressure over a period of several weeks.

The specially-developed series for these applications are easy-flowing, which allows even filling of cavities in the injection mould and prevents problems with weld lines. The specific formulation can be adjusted to individual requirements. Due to their good cold elasticity the materials also retain their sealing function during transport and storage at low temperatures.

New applications from the THERMOLAST K portfolio illustrate the diversity of this TPE for increased functionality and performance in view of new trends and challenges in the packaging market. www.kraiburg-tpe.com

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27 – 29 June 2017

MOC Munich, Germany

Organisers: Mack Brooks Exhibitions Ltd

International Exhibition for Polyurethane Solutions

Discover the innovative capabilities of PU solutions – Applications for new markets!

• •

Live presentations of machines and solutions Feature areas for networking and knowledge exchange

• Raw materials • Materials/semi-finished products • PU products/systems • Processing machinery, systems & equipment • Services

   

• • • •

APPLICATIONS Blown Film Cast Film Ceramics Converting Medical/Specialty Films Nonwovens Paper Glass Coatings

Business Solutions Ltd.

26

Tension Compression Flexure Shear

• • • •

Puncture Peel Tear COF

• Melt index • Impact • Vicat /HDT • Hardness

All tests can be performed in accordance with the following standards…

Film variability has real implications for film performance including strength, permeability, print speed, consistency in converting processes and much more. Take advantage of the new ASTM Standard for thickness measurements with SolveTech On-Line and At-Line Gauges and ask for free sample analysis at www.info@QOBusinessSolutions.co.uk.

Quantum Opus

www.pse-europe.com

The first name in materials testing

World Leader in On-lie and At-Line Film Thickness Gauging Technology offer Free Sample Analysis.

    

For various industries

Info@QOBusinessSolutions.co.uk

ISO, BS, EN, ASTM, JIS and more www.tiniusolsen.com sales@tiniusolsen.co.uk

+44(0)1295 68 81 37

WWW.EPPM.COM

01737 765001

MACHINERY ROUNDUP

Hooked to the silver screen

Do the robot

KraussMaffei Berstoff has custom built a twin-screw extruder for Zhejiang Xinli New Material, an LCD screen-maker in China, leading to excellent results and a happy customer. The compounder is a twin-screw extruder of the new ZE Performance series from KraussMaffei Berstorff. Its performance profile is adapted precisely to the needs of the mid- to highrange market.

FANUC’s total production of its acclaimed Robocut range has reached 30,000 units. The portfolio of wire-cut electronic discharge machines, which FANUC has manufactured since 1975, now comes with enhanced speed and precision for mould-making and parts machining. Capable of being integrated with FANUC robots, Robocut machines are helping manufacturers to optimise their efficiency by enabling continuous, unmanned operation.

FANUC is now continuing to develop its Robocut range in line with the needs of global manufacturing industry, based on more than 40 years of development and expertise.

www.kraussmaffei.com

www.fanuc.eu

Booster pack

Extra time

Global injection moulding machinery giant the Wittmann Group is giving the Wittmann Battenfeld plant in Kottingbrunn, Austria, a €15 million (£12.8 million) boost.

The cash injection - which has come about as a result of recent years of growth across the PowerSeries lines - will extend and remodel both the manufacturing facility and the administrative offices. Plans have been made to extend the assembly area by an additional 2,200 m sq. This area will house the assembly lines for medium and large machines from the EcoPower and SmartPower series to complement the assembly line for small machines already in operation since 2015.

Milacron has extended the production period for its Ferromatik injection moulding machines in Malterdigen, BadenWürttemburg, Germany. In March 2016, Milacron announced it would move injection moulding machine assembly and machining from Malterdigen to a factory in the Czech Republic by the end of 2017. 130 workers were to lose jobs, though some of them will now return to the factory to complete the orders. The company will continue production at Malterdingen until the end of 2019, due to higher orders for machines across Europe. It still plans to transfer manufacturing operations to its new facilities in the Czech Republic but will use both German and Czech facilities for a period.

www.wittmann-group.com

www.milacron.com

Getting hybrid

Hip Hop Hooray

Broanmain Plastics has added to its roster by investing in an energy-efficient hybrid injection moulding machine from Sumitomo (SHI) Demag.

The Surrey-based technical moulding company took delivery of a Systec Hydraulic 160 tonne machine in December 2016, the company’s eighth Demag unit to date. The installation of the machine comes after significant investment in Broanmain’s premises. Thanks to its reputation as a socially conscious organisation, machine energy efficiency was a key consideration during the selection process of a new machine. Jo Davis, Operations Director at Broanmain Plastics, said: “The new generation of hybrid injection moulding machines are much more energy efficient and quieter than before and both of these factors were a major driver in investment.”

Motan Colortronic has released a new line of mobile single hopper units, building on the success of the proven ETA Plus technology that Motan uses on drying systems with multiple hoppers. The EMA dryers are specifically designed to offer consistently low dewpoint air to a drying bin of 60, 100, and 150L, while reducing energy consumption to a minimum. The dryers are available with fully automatic air-flow control, which saves further energy and automatically creating an anti-stress system for the material. All the units can be supplied with single conveying units or a mini central system built into the dryer, which ensures a very flexible unit.

uk.sumitomo-shi-demag.eu

WWW.EPPM.COM

www.motan-colortronic.com

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MATERIALS ROUNDUP

Short circuit

Ruffling feathers

A thermoplastic polyester for use in protection layers of surface mount circuit boards has been revealed by A. Schulman.

With high heat distortion resistance, Schuladur HT GF30 is suitable for use in circuit boards, as it will not be melted by soldering irons. It is an economical alternative to other high-performance polymers including PPA, LCP, and PPS. Compared to these, low mould temperatures are required, which allows standard processing equipment to be used, as water cooling systems are suitable with temperatures of 90°C. In addition, Schuladur offers shorter injecting moulding cycles, which further lowers costs.

AIMPLAS is participating in the European project KARMA 2020, to develop a keratin extraction process to prevent waste and create biodegradable plastic for packaging. Coordinated by CIDETEC, 16 partners from 10 different countries have begun research into designing a valorisation process to make bioplastic packaging. Over three million tonnes of poultry feathers are thrown away by the European poultry industry every year, but the keratin making up the feathers can be used in fertilisers, biocomposites, and bioplastics. Once the feathers are d e co n ta m i n a te d and treated at nano- and microscale, the extracted keratin can be used with biopolymers to form recyclable packaging. www.aimplas.net

www.aschulman.com

Sit down next to me

Brace for impact

Covestro’s Cardyon Polyurethane foam, which is made using around 20 per cent carbon dioxide, was on show at the Cologne Interzum 2017 furniture fair, forming part of Thomas Schnurs Factory of Ideas display. The Cardyon material has been used in a chair design along with other Covestro materials representing ‘the transformation of a cloud structure into a seat’. By incorporating carbon dioxide to synthesise plastics, Covestro is helping to preserve increasingly scarce fossil resources while closing the carbon loop.

SABIC is introducing two high flow injection-moulding grades, PP 513MK46 (MFR70) and 512MK46 (MFR50). They are impact copolymers based on a phthalate-free catalyst, which enable efficient production, shorter cycle times, and lightweighting through thin wall manufacturing. The products are stiff, and have a high top-load strength for stackability, which contributes to faster production cycle times and lower transport and storage costs.

513MK46 and 512MK46 are to be used in packaging for frozen, chilled, and dairy products, as well as for applications in appliances, toys, and caps and closures.

www.covestro.com

www.sabic.com

Stiff competition TechnoCompound has created a new carbon fibre compound product line called Techoforce, for highly attractive lightweight construction solutions both in the automotive and non-automotive i n d u st r i es.

Th e TechnoForce carbon fibre compounds offer a number of beneficial properties, including extremely high stiffness and mechanical strength at low weight, and exceptional cost performance balance. The carbon fibre compound has been developed using various raw materials and polymers, and in addition to virgin carbon fibre material, TechnoCompound has a long experience with secondary carbon fibre qualities.

Leavin’ on a jet plane A new passenger plane design, featuring plastic reinforced wings, has taken flight across Siberia. United Aircraft Corporation (UAC), the Russian state aeroplane manufacturer, completed a project to build the Irkut MC-21, a single aisle twin jet passenger aeroplane, which flew from the Irkutsk Irkut airfield, in central Siberia.

The MC-21 has wings made from carbon fibre polymer, built by Sukhoi, using Solvay’s resin infusion technology with its Prism toughened resin.

The plane’s empennage was built from HexPly carbon fibre and epoxy prepreg composite, supplied by Hexcel for the tail structure. UAC will use the MC-21 to target the regional to medium haul flights sector, and the aircraft is expected to begin commercial operations in 2019 pending approval from the European Aviation Safety Authority.

www.technocompound.com

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Only one magazine covers ALL European regions Fakuma is a very important event for EPPM both as a hotbed for industry news and as a meeting place for our advertising partners and readers, providing perhaps the most accurate cross-section of the EPPM community in one place. September will feature our Fakuma preview, October’s issue will be our on-site edition with hall plan centrefold and the biggest Fakuma announcements will be rounded up in our November/December review edition.

Online, EPPM will cover Fakuma via a dedicated newsfeed via eppm. com, with major news appearing in our newsletter and ‘show dailies’.

FAKUMA MARKETING OPPORTUNITIES If it’s the Fakuma audience you are targeting, let EPPM be your platform. We have a number of marketing devices you can take advantage of to accommodate any budget across print and online.

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visitors know that you are there.

We here at EPPM are keen to ensure attendees know that you are exhibiting. In October’s issue, which will be distributed at the event, we will be featuring a double page Hall Plan for Fakuma which provides an affordable way of marketing yourself, letting

For only £250 you can be a part of the Fakuma Hall Plan, ensuring you are seen by attendees on-site.

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NEC BIRMINGHAM, UK | 26-28 SEPTEMBER 2017 INJECTION MOULDING

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29

CHINAPLAS 2017 The Review EPPM looks back at CHINAPLAS 2017, how major product launches made the show a record-breaking edition.

Words | John Carlon

C

HINAPLAS 2017 has broken all its records for the highest total visitors, the highest number of visitors in one day and its largest exhibition area.

As East Asia’s largest plastics trade fair ended, organisers celebrated an expanded show breaking all totals from previous years – a sign of growing demand and interest in the East Asian plastics industries.

All the world’s major plastic processors gathered in Guangzhou (Canton), in Southern China, the expansive metropolis at the mouth of the Pearl River, to take part in the plastics conference second only to K in numbers and impact. With China’s role as the engine-room of global plastics, decisions and announcements made at CHINAPLAS will be felt around the world.

A total of 155,258 trade visitors from 159 countries attended over CHINAPLAS' four days, a growth in attendees of over a fifth since the last Southern CHINAPLAS in 2015. The show alternates between Guangzhou and a Northern venue, in Shanghai, each year. Another 5,000 extra visitors flew in from overseas to take part in the show compared to 2015.

Organisers expect CHINAPLAS 2018, in Shanghai, to be its biggest and best yet, to break even the exceptional records set this year for visitor numbers and engagement.

Machinery at CHINAPLAS Hundreds of processing machines were on display, as global plastics machinery manufacturers demonstrated their latest injection moulders and extruders around the China Import and Export Fair Complex.

KraussMaffei Berstorff brought along its KMD 63 K/R conical twin-screw extruder from its Performance series, on show at CHINAPLAS for the first time.

Advances towards smart manufacturing, particularly looking at Industry 4.0, were a focus for the fair, with seminars on the application of connected digitisation for the automotive, electronics and packaging industries.

CHINAPLAS has evolved from a former sourcing and trading platform for materials and machinery into an international, technologyoriented platform

Stratasys, a leader in 3D printing, discussed case studies that can lower packaging costs by 90 per cent through 3D printing. Other speakers included Industry 4.0 pioneers Arburg, KraussMaffei, Engel and Wittmann Battenfeld, who showcased their latest smart technologies.

China’s materials industries are becoming more dynamic, partly due to its Government seeking a high-tech diversification of industry, and rising wage costs leading to companies favouring automated production in the long-term - Chinese industries are hoping to prepare production facilities as smart factories of the future.

Ada Leung, Manager of the CHINAPLAS organising team, said: “We are impressed by the increasing importance attached to the Chinese market by the leading overseas technology suppliers. Meanwhile, we are also witnessing strong interest in Chinese machinery by overseas buyers.

CHINAPLAS has evolved from a former sourcing and trading platform for materials and machinery into an international, technology-oriented platform.”

Since it came to an end, both domestic and foreign companies have reported successful deals struck at CHINAPLAS, with a consequent upturn in orders. Such huge trade fairs advance the sector by encouraging the sharing of ideas and experience - as CHINAPLAS has run since 1983, it has coincided with the transformation in China’s polymer processing industries.

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Kaijun Fan, KrausMaffei’s Vice-President of Extrusion in China, said: "With the introduction of the conical model, we will be able to professionally handle the requirements of pipe producers for a robust machine with small diameter ranges of up to 63mm as well as for twin-strand systems.”

As well as a space-saving design, the conical extruder features an outstanding high-performance gearbox and a high level of flexibility and process stability from a process technology standpoint. The C6 control system with its many monitoring and control functions is the key to an optimal production process.

Reifenhäuser Cast Sheet Coating had its REIcofeed 2.2 Feedblock on show, with a layer structure that can be controlled and influenced while production is running.

The coextrusion feedblock enables film structures of up to 11 or more layers to be optimally adjusted with the line in operation. In addition, its efficiency

can be significantly improved by the integration of a new small element: It allows the encapsulation of a multi-layer film inside the feedblock to avoid the need for an additional encapsulation device in the flat die and the use of an additional extruder – a space-conserving solution and a plus point in terms of efficiency. Film producers can use less energy and raw materials.

More machinery was on show from Battenfeld Cincinnati, with its SolEX 60-40-C extruder for high-performance PO pipe production.

SolEX extruders offer 15-25 per cent energy savings compared to conventional extruders, and they are ideal for large diameter pipe extrusion thanks to excellent melt homogeneity and low melt temperature. These help to reduce sagging, saving material, which is a large cost factor in pipe production.

and corrosion issues caused by high loadings of traditional flame-retardant additives, such as organic phosphorous, in polyamide compounds.

Meanwhile, Addivant, a leading polymer additives supplier, greeted visitors with a comprehensive range of materials innovations that exceed the performance requirements of the most demanding applications, while addressing future environmental concerns. It had a range of ideas for the Chinese car industry, the world’s largest, such as next generation ultra-low emissive anti-scorch antioxidants for polyurethane foams. It was also pleased to report on the progress of its polyethylene stabiliser Weston 705, which has received approval from Chinese authorities for use in food packaging.

battenfeld-cincinnati also had a LeanEX C1-60-30 extruder at CHINAPLAS. Since its introduction eight years ago, around 110 LeanEX extruders and 140 LeanEX turnkey pipe extrusion lines have been sold. There are four extruder sizes for outputs up to 540 kg/h (PP-R) and up to 720 kg/h (HDPE) and pipe diameter ranges from 63 - 630mm.

Milacron also showcased technologies from its injection moulding machine portfolio - Tom Goeke, Milacron CEO, said: “Milacron was proud to participate in this year’s edition of CHINAPLAS. We place great value and importance on the Chinese market and our Chinese customers, with the tremendous growth and evolution of the CHINAPLAS show.”

Milacron’s focus was on its injection moulding machines, with numerous representatives in attendance from their industry leading brands MouldMasters, Uniloy and DME to answer questions regarding hot runners, control systems, mould components, blow moulding and extrusion. It showed the Ferromatik 160 Injection Moulding Machine, for packaging with fast cycle times and high injection speeds; its Magna Toggle 150630 Injection Moulding Machine, with a servo design to increase energy efficiency while providing outstanding repeatability, accuracy and precision, and its Elektron EVO 275 Injection Moulding machine, designed for a full range of applications while setting a high standard for movement repeatability, it features a Mould-Masters TempMaster controller, enabling thin-wall moulding of a disposable food container in one cavity with a seven-seconds cycle time.

Materials at CHINAPLAS In addition to whirring cogs and humming machinery, CHINAPLAS was the location for some major materials announcements. At the trade fair, Dow Corning introduced the first grade from its advanced Flame Retardant Synergist family, designed to resolve mechanical performance degradation

Eastman Chemicals also saved a big product announcement for CHINAPLAS, with the release of a cellulose-based thermoplastic, ‘TRĒVA’, that brings together high-level performance and sustainability.

Burt Capel, Vice-President of Eastman Speciality Plastics, said: “Eastman leveraged nearly 100 years of cellulosic expertise in the design and testing of TRĒVA to meet the improved sustainability profile and performance needs of brands, fabricators, moulders, and other companies across the value chain.”

TRĒVA is about half cellulose, sourced from trees derived exclusively from sustainably managed forests that are certified by the Forest Stewardship Council (FSC). The new material is BPA-free and phthalate-free.

Eastman hopes to apply the TRĒVA thermoplastic to glasses frames, wearable electronics, headphones, car interiors and electronic display covers. www.chinaplasonline.com

We place great value and importance on the Chinese market and our Chinese customers

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Moulding Expo 2017 pitches up for pitch-perfect second outing Having found the sweet spot as a tool and mould making meeting place for the German and wider European industry, Moulding Expo hit perfect pitch at its second outing at the end of May 2017.

WORDS | Rose Brooke

M

esse Stuttgart is celebrating the much-anticipated second outing of Moulding Expo (May 30th-June 2nd 2017), after its 2015 debut concluded enthusiastically, marking the event out as the key European show for tool and mould-making, together with the industry's very broad church of associated technologies from scanning to 3D printing.

The show is positioned well in the industry calendar and on the map.

This region of Germany is a tool and mould making industry cluster and being in the first half of the year, it does not compete with the big autumn plastics processing events such as Fakuma or K. Its next outing in 2019 will be a test when it lands on a K year, but even so, making itself a first-half-of-the-year event ensures momentum before the summer shutdown period.

EPPM caught Florian Niethammer, Senior Project Manager, at Moulding Expo organiser Messe Stuttgart on Day Two of the event in the VDWF pavilion to find out how he was feeling once the second edition of the show was in full swing.

"We're just pleased we can get on with the fun part and finally get round to meeting our exhibitors and visitors - especially those who

are new this year," he said. "What's amazing is when we look at the stands ... it's very impressive because you see how seriously these companies are taking their stand construction. It really makes us proud and our exhibitors and visitors are what makes us kind of unique."

The Messe Stuttgart team has great plans for Moulding Expo, with Niethammer planning to expand its influence further throughout Europe, recognising its potential as "a big meeting point for European industry" as well as for what is currently a predominantly German industry audience.

Without jumping ahead to 2019, Niethammer was happy to take in the great atmosphere of the show at that moment - and there is a good feeling when you walk the halls that this is a place for high quality conversations and cementing relationships. This is tool and mould making, the pace of this industry is historically steady, which is probably why it's been around for such a long time.

Moulding Expo is what it is today because of Messe Stuttgart's ongoing partnership with its exhibitors and Niethammer was keen to state that this collaboration is key to the event's success in the future.

“In the last three years, it’s the customers who have become our friends in the industry and we develop the show together.”

What are the exhibitors saying?

“We like Moulding Expo because the companies that present here are partners and customers and the visitors are partners and customers, and that’s very important for us.”

“We were at the very first Moulding Expo two years ago and both years have been good.

At the end of the day we have to be here for the mould making industry.”

Frank Barlog, Bahsys.

“Moulding Expo is still new and it has specialist customers, exhibitors and visitors.

We focus on this topic here in Stuttgart which is a very strong location for the tool and mould making industry.”

“[We are getting] high quality leads thanks to interested customers and new companies.

Being here was a good decision.”

Burkhard Werner, Sigma Soft.

“This is a good show - it’s new but it is becoming the leading show for tool and mould making and the team behind the show really want to push it forward and I love their enthusiasm. And that attitude is in the exhibitors and visitors.

It’s a great atmosphere.”

Thomas Wunsiedler, Knarr.

Lia Klimmer, Meusburger.

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Peter Ottillinger, Deckerform.

Andreas Kiehl, Heitec.

Spokeswoman, HASCO.

“It’s been perfect for the quality and quantity of visitors and business we have seen - this is a show where everything is as it should be and it’s exciting meeting customers and getting to know them a bit better.”

“This is our second Moulding Expo ... it’s more than business and sales and it’s more than engineering.

Being here is about supporting customers.”

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EUREKA SERIES

Bottling it A new 3D software builds large-scale structures using waste PET bottles and 3D printing, making the most of 3D technologies and bottle architecture to realise designs that are strong and stable WORDS | Rose Brooke

P

lastic bottles are one of the most visible types of disposable packaging out there, and with PET bottle production on the increase as the bottled water market booms, end markets for used plastic bottles are in demand.

While PET is widely recycled, there could be another end market for this type of plastic packaging, as a new 3D software has been designed to capitalise on the strength and shape of PET bottles to form strong structures.

TrussFab is a new program that creates large-scale structures that can support human body weight. Developed by researchers at the Hasso Plattner Institute in Germany, the software utilises PET bottles as beams, forming sturdy structures from triangular supports. By making these honeycomb structures using triangular frameworks, the bottles are far less likely to break or become

34

deformed under pressure as “they are very strong when pushed or pulled along their main axis�.

The software converts a 3D model of for instance - a dinghy into a tetrahedral

the software utilises PET bottles as beams, forming sturdy structures from triangular supports

modelling software SketchUp - then allows the designer to tweak shapes and add more support to the overall structure while calculating the internal forces of the structure, warning if a particular design is liable to break.

Once the structure has been designed, TrussFab then generates 3D-printable hubs to join the bottle beams together to form the honeycomb, while it generates laser-cuttable 2D hubs for facades.

Once these hub joints have been printed, the user can assemble their structure by following the markers embossed on each hub.

The TrussFab team has tested the system successfully by building tables, chairs, a 2.5m bridge, a two-seater boat and a 5m dome, which took 512 bottles to construct.

honeycomb structure using the TrussFab converter. The TrussFab editor - which is an extension pack to the popular 3D

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