EPPM 17.2

March/April 2015 Volume 17 | Issue 02

“SIZE MATTERS: CUSTOMISED LARGE DIAMETER PIPE SYSTEMS FROM A SINGLE SOURCE” Cover Story | Page 10

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IN THIS ISSUE Pg 6 INDUSTRY & EVENTS NEWS

Pg 18 MOULDS & TOOLING

EPPM publisher Rapid News has announced that its leading 3D printing magazine TCT has joined forces with Mesago Messe Frankfurt to launch a new 3D printing and tooling show, while we bring you the latest PLAST 2015 and Fakuma announcements.

Our moulds and tooling special looks in depth at rotational moulding with Midas Pattern Company and Excelsior - who EPPM visited at their headquarters in Bury, UK. While Sumitomo (SHI) Demag’s hydraulic injection moulding system has made big savings for Whale.

Pg 8 COMPOSITES ARRK Europe’s Anthony O’Neill shares his insights into the shifting trends in demand for composites in Europe and the UK and reveals that a drive for quality is bringing manufacturing home to roost.

Pg 10 COVER STORY: BATTENFELDCINCINNATI The engineering involved in producing large diameter plastic pipes is as vast as the products these machines extrude. Leader in the pipe extrusion field battenfeld-cincinnati shares its insights into large diameter pipe extrusion.

Pg 13 PIPE & PROFILE Mammoth pipes for ice age-like conditions.

Asset International shares a few examples of its more extreme large diameter pipe applications, including road culverts in the Arctic Circle.

Volume 17 Issue 2

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

editorial editor rose brooke rose.brooke@rapidnews.com

production

Pg 22 AUTOMATION & ROBOTICS We cast an inquisitive eye over the automation and robotics revolution in plastics in this four-page feature, which includes a detailed thought piece from European Automation.

Pg 27 CHINAPLAS PREVIEW Welcome to our ChinaPlas 2015 Preview, which showcases what some of the biggest exhibitors have planned for the event, while we quizzed NDC Technologies for Exhibitor’s Eye View.

art robert wood production tracey roberts

advertising advertising manager Lisa Montgomery tel: +44 (0) 1244 680222 lisa@rapidnews.com

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Pg 34 EUREKA SERIES Franco-Swedish product design outfit Tomorrow Machine has been making the papers with its wacky food packaging ideas.

We asked the two-woman team about their unconventional creations and the changing face of sustainable packaging.

Pg 16 MATERIALS SPOTLIGHT

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

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

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

Materials expert DSM is spearheading the growing metal replacement trend and its thermally-conductive performance polymers are already making an impact on the lighting and automotive sectors.

BPA Worldwide Membership

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Pipe and Profile_ENG(A4)2013.indd 1

6/12/13 4:04 PM

From The Editor

Pipe dreams Hasn’t March come around in a blink? Perhaps it’s the twin whirlwinds of NPE2015 (see EPPM Jan/Feb 2015 for our extensive preview) and ChinaPlas 2015, where this issue will be on-site, that has made time seem to move in a strange non-linear fashion? It’s a known fact that trade shows have this effect on the space/time continuum, but I always thought that was once you were in the show itself.

If you have picked up this copy of EPPM because you found it on your tour of this year’s ChinaPlas event in Guangzhou, then I am delighted we caught your attention. Please keep reading. If you are a regular reader then welcome back. We have plenty to stretch your grey matter, enlighten and engage, not least with our detailed and colourful Guide to Large Diameter Pipe Extrusion, penned by the experts at battenfeldcincinnati. The mammoth imagery on our front cover should be enough to make anybody with a passing interest in plastics processing stop, look twice and say ‘wow’.

We continue in this theme by delving into the world of producing large diameter pipes for various applications around Scandinavia with Asset International, who have plenty of stories to tell about extruding enormous culverts for harsh Arctic conditions.

And from extruded enormities to the equestrian; we ventured north to Bury to meet Excelsior and learn more about this 120-year-old rotomolding champion’s latest venture into the world of showjumping products with a one-to-one with the Managing Director.

Our Automation and Robotics spotlight homes in on the infrastructure changes realised by the experts at European Automation and their

It’s a known fact that trade shows have this effect on the space/time continuum, but I always thought that was once you were in the show itself.

vision for a Smart Factory that makes the most of automation to improve the efficient running of a plastics processing operation.

Finally, our magazine is full of Eastern promise if the above innovation and inspiration was not enough to kindle your excitement for this protean playing field. Sinophiles needn’t miss a beat in our detailed ChinaPlas 2015 preview, which includes a snapshot of what delegates can expect to see on the sprawling show floor, in addition to a look at what makes this year’s outing stand out for the world’s second-largest plastics and rubber trade event.

Rose Brooke, Editor

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INDUSTRY & EVENTS

formnext powered by TCT:

New additive manufacturing and tool-making event to hit Frankfurt

Copyright Messe Frankfurt

Rapid News Publications and Mesago Messe Frankfurt have joined forces to launch a brand new tool-making and additive manufacturing event.

Words | Rose Brooke

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esago Messe Frankfurt, organiser of formnext, has teamed up with Rapid News Publications to launch 'formnext powered by TCT'.

world. We will bring over 20 years of expertise in the additive technologies sector to bear. We have a deep understanding of the trends and are well connected to the world’s finest speakers."

The organiser of TCT Show + Personalize - the UK's biggest In addition to drawing on TCT's impressive contacts list of worlddedicated 3D printing event - and Mesago Messe Frankfurt will renowned 3D printing leaders and innovators, the conference open wide the doors of the international exhibition centre on programme will also follow the latest insights into tool-making.

November 24th 2015 for the fourThoma commented: "The combination day event which will bring the biggest of a substantial exhibition and an names in European and international expansion of the well-respected TCT additive manufacturing and toolconference series will make formnext making under one roof.

The benefits to the additive powered by TCT the place to be for additive technologies and tool-making.

Indeed, it is the tool-making sector technologies sector are most Knowledge meets expertise, expertise that could capitalise the most from obvious, but the tool-making sector meets customers. A platform that can this new-look event. stands to gain from the innovative be a benefit for everyone involved."

"The benefits to the additive partnership.

"Mesago and Rapid News Publications technologies sector are most obvious, have come together to work with and but the tool-making sector stands to for the wider industry. Our research gain from the innovative partnership," said CEO of Mesago Messe Frankfurt Johann Thoma. "This highlighted the requirement for an annual event, in a global hub, partnership offers additional strength to the formnext concept, with trusted organisers. formnext powered by TCT will deliver this creating a very attractive, international and long-lasting trade and more, giving the industry a stable international platform from which to continue its unprecedented growth," concluded Wood. show concept."

By teaming up, both organisations make use of their industry influence to put together a conference of key international industry figures, which will run in parallel with the show.

COO of Rapid News Duncan Wood stated: "The conference programme organised by TCT’s experienced and well-connected team will be highly attractive for attendees from all over the

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formnext powered by TCT will take place in Hall 3, one of the most modern halls of the Frankfurt exhibition centre. The combination of modern architecture and innovative functionality contributes to the ideal presentation platform for exhibitors and a pleasing tradeshow experience for visitors. The Frankfurt fairground is easily reachable via excellent international and local transportation links.

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PLAST 2015 participation rises along with industry hopes Participation in PLAST 2015 is on the rise with registration soaring to over 1,200, as optimism in the European economy enjoys a period of buoyancy.

The Italian plastics industry is enjoying a period of prosperity - providing the perfect conditions for PLAST 2015 in Milan.

This buoyancy has been reflected in the triennial event’s growing exhibitor registration count, with the number of exhibiting organisations soaring to over 1,200 - a 3.9 per cent increase on the same period ahead of the last show three years ago.

PLAST 2015 has across-the-board representation of all the difference segments and categories in the six PLAST 2015 pavilions, providing yet more evidence that the European plastics market is capable of regenerating and growing. Indeed, Italy’s plastics and rubber machinery, equipment and moulding industry has maintained its reputation as a solid sector, and major contributor to the Italian economy - particularly where exports are concerned.

Analysis by Assocomaplast - the Italian trade association and member of Confindustria, a group

that unites some 170 companies - of ISTAT data on foreign trade between January and September 2014 highlights growth in imports and exports. In the first three quarters of last year, sales abroad reached €1.89 billion (£1.41 billion), compared to €1.82 billion in the corresponding period in 2013, recording yearon-year growth of four per cent. Imports for the same timeframe also rallied by seven percentage points from €423 million in 2013 to more than €454 million last year.

reflected in the number of participating businesses in the triennial PLAST show, which will take place from May 5th-9th 2015.

Recent moves by the European Central Bank are driving optimism for a resurgence in Europe, which is

Do you have PLAST 2015 news?

Email rose.brooke@rapidnews.com.

Managing Director of PLAST organiser Promaplast Mario Maggiani said: “Beyond the numbers it is important to note how foreign exhibitors continue to believe in PLAST. Spaces are almost all reserved, but applications continue to arrive. And of course, we can’t be anything but pleased.”

Additive manufacturing finds a home at Fakuma Additive manufacturing has become an established part of the manufacturing supply chain and is now finding its home at leading plastics machinery and materials event Fakuma.

The appearance of additive manufacturing technologies at Fakuma 2014 as valid systems in the overall plastics processing chain demonstrates how 3D printing has found its niche in big industry.

The 24th edition of the Friedrichshafen-based plastics machinery and materials conference in October 2015 will further reflect the importance of generative processes as a complementary manufacturing technique in the wider segment.

Fakuma organiser PE Schall said how interesting it is to see the relative diversity of 3D technologies available, potentially broadening the horizons of manufacturing with new processes as yet untapped by the more established machinery production sector. Meanwhile, injection moulding has already adopted 3D printing, with metal additive manufactured injection moulds providing prints that are extremely close to contour.

Event promoter Paul Schall said: “The hype which is demonstrating nearly hysterical traits regarding the

complex issue of generative production ... has gotten entirely out of control during the last two years and is finally beginning to settle down now that its industrial usefulness is being closely scrutinised.

“In the interest of the exhibitors and expert visitors, we as promoters provide for objectivisation – especially in light of the fact that we’ve been active in the fields of additive, generative and prototyping processes for more than 25 years by creating a platform at a very early stage for exhibitors from research and industry, in order to familiarise the expert visitors with the latest, most highly promising technologies and processes.”

Fakuma is known for having its finger on the pulse and presented MPA technology with combined metal deposition and 5-axis milling processes within the framework of an enormous tooling systems exhibition segment last year. The most up-to-date technologies and applied innovative processes were met with great interest by nearly 1,800 expert visitors from 36 countries (nearly 600 from outside of Germany) and nearly 46,000 expert visitors from 117 countries around the world in 2014 – and thus the criteria for Fakuma 2015 (13th-17th October 2015) has already been set.

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COMPOSITES

Engineering the future of composites

ARRK Europe has a new badge of quality accreditation to help it engineer the future of composites in automotive, aerospace and beyond. EPPM asked General Manager Anthony O'Neill about the trend trajectory of carbon composites in Europe.

Words | Rose Brooke

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In 2014, he continued, the Government announced there would be a 20 per cent growth in the composites market in terms of demand for aerospace, while automotive remains a key force.

hen it comes to the changing face of composites, ARRK Europe is at the coalface, producing truly innovative carbon composite products using its years of expertise and state-ofthe-art technology to bring cutting-edge designs off the page to life. EPPM caught up with ARRK’s General Manager for Nuneaton, Anthony O'Neill, to talk trends in composites in 2015 and beyond.

"We're certainly seeing that from our enquiries.

Automotive will always be one of the largest players for composites purely because of the weight reduction and emission reduction plans they're driving forward, as well as the ability to manufacture lightweight vehicles."

Taking wing "We've recently done a joint collaboration with one of our sister sites in France designing a new lightweight composite seat," O'Neill revealed He continued: "That is certainly a trend in composites that automotive is looking to go down, with weight reduction to reduce emissions and give them a better ecological footprint. In terms of the UK we are looking to grow and expand with the major OEMS JLR, Aston Martin, etc. - and we're introducing composite solutions for them, mainly for the interiors."

In the automotive sector, it is not just the interior components that are lending themselves well to composite materials, but the exteriors, with more OEMs investigating lightweight composites for the external panels of vehicles. In aerospace, however, it could be some time before we see ARRK's composites on the upper wing skin of a Boeing 777.

"We're just doing the parts that are non-critical to the aircraft and flying: casings, coverings etc. This helps us gain a footprint in the aerospace market and then grow from there.

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ARRK Europe has experienced a growth in its aerospace customer base for structural, non-critical flying parts that come into line with the organisation's AS and TS accreditation. The company announced in December 2014 that it achieved - amongst others - the aerospace standard AS 9100 at its composite centre in Nuneaton, UK, while its Petersfield Technical Centre was awarded ISO TS 16949 accreditation. "[The accreditation] allows us to widen our scope and offering of work to the customer," O'Neill stated.

Integrated engineering The growing interest in utilising composites in a wider range of sectors is spurring on ARRK's work and the inner workings of the business itself.

"With our new integrated service offering across Europe we are now able to offer our customers a one stop solution," O'Neill explained. "Our colleagues in Germany can do the full design

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capability. We've got our Basildon site that can do the engineering and FMEA (failure modes and effects analysis) and here in Nuneaton we can build the actual components they've designed, we can manufacture the tooling and make those components.

We've started to really use our depth of expertise to help provide a much better offering.

"Our strapline is a passion to grow and develop together. It's something our clients are really benefiting from."

This integration across the continent, together with a reputation for producing such attractive composites ensures repeat and new custom for ARRK. "The quality of component we make from an aesthetic point of view looks fabulous and we know we are one of the leaders in the area," O'Neill remarked.

"There's a realisation that composites are the future. I think a lot of companies are moving away from the older processes and looking into how composites can benefit them not only from a weight reduction point of view but structurally."

Bringing manufacturing home to roost

"I attended an SMMT meeting recently," O'Neill said, "where they referenced about 60 per cent of the German supply chain is in Germany and the UK-based supply chain into the major OEMs is 30 per cent. That's a massive thing when you think all that additional business leaving the UK." "There's been a push to bring manufacturing back to Europe.

From 2008 onwards, low-cost manufacturing from Asia helped businesses stay afloat but the quality aspects of this are now being realised.

British manufacturing is renowned for being one of the best in the world and from a quality standpoint that is coming back."

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But will Europe be at the sharp end, spearheading the move away from traditional materials such as alumina to composites? ARRK Composites is certainly confident that manufacturing is coming home to roost.

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COVER STORY

The battenfeld-cincinnati guide to large-diameter pipe extrusion Few companies have such depth of knowledge about large-diameter pipe extrusion as battenfeld-cincinnati. This snapshot of the global market is all you'll need concerning the process, industrial and geographic trends pushing and pulling the evolution of these mammoth structures.

Words | Rainer Kottmeier, Managing Director Division Infrastructure. Ralf Mickley, Head of Processing. Heinrich Dohmann, Head of R&D Pipe Heads and Mechanical Engineering Downstream, Mechanical Engineering Pipe Heads/Downstream

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aximum diameters have grown steadily over the years.

While 1,200 mm was the largest diameter worldwide for a long time, the 1,600 mm size took over in 2000. The first 2,000 mm pipe was produced in 2004 and the next line of this size was delivered by battenfeld-cincinnati at the end of 2006. In 2011 the very first pipes with diameters of 2,500 mm became possible. Extra-large pipes require extremely high extruder outputs. Material usage and line lengths are challenges in the process, while wall thickness, sagging and ovality are key parameters to take into consideration.

What does it take to be 'large'?

There is no standard definition where 'large diameter' applications begin. battenfeld-cincinnati defines 'large pipes' as such with diameters of 800 mm and above.

There are two types of large diameter pipe: pressure and nonpressure pipes. The former are solid wall pipes used mainly for drinking water and gas supply, and the most important factor in their production is the pressure rating that impacts the required wall thickness. Non-pressure pipes, used predominantly for waste water transport, must withstand external forces, so ring stiffness is of great importance in production. In this case, by using structured walls and lower wall thicknesses, substantial material savings are possible.

To achieve excellent end product quality and the best possible use of resources, the extrusion process cannot concentrate only on the extruder – the complete extrusion line must be seen as a whole and should be adjusted perfectly.

barrel and the maintenance-free Intracool screw cooling system, all of which enable substantial energy cost savings. Special surface treatment and coatings of the screw and barrel are available for wear protection and a long service life.

In PO pipe extrusion even larger sizes are possible – currently lines with diameters up to 2,500 mm are in production.

For PE and PP pipes, solEX 40 L/D single screw extruders offer a small footprint at a high output range. Extruder sizes are 1-2 times below the market sizes of extruders for the same output rates (for smooth pipe: PE-HD 500 – 2,200 kg/h & PP 300 – 1,300 kg/h; for corrugated pipe: PE-HD 400-1,800 kg/h & PP 240-1,100 kg/h). solEX extruders are robust, with strong drives, a grooved feeding section for increased and constant specific output, high torque gearboxes and highly-energy efficient AC motors. The drives are water-cooled and the motor is air-cooled and maintenance-free.

The 40 L/D processing unit ensures best melt homogeneity and lowest specific energy is needed thanks to optimised screw designs. The efficiency of the solEX series enables cutting of investment costs and the noise level is below 80dB for better production conditions.

Key factor for large diameter pipe production are low melttemperatures. solEX single screw extruders provide excellent melt quality at low melt-temperatures even at highest output rates.

Extrusion leader For PVC pipe extrusion, battenfeld-cincinnati offers twinEX 28D and 34D twin screw extruders. The twinEX series stands for low production costs with best plastification performance and high pipe quality and gives producers a high flexibility in processing a wide variety of formulations and materials. For large diameter pipes, 34D models with a 21 per cent longer L/D section increase effective plastification length. Warranty outputs range from 1502,500 kg/h for U-PVC and 180-1,000 kg/h for C-PVC. The twinEX, has an energy-efficient AC drive, as well as a fully insulated processing unit, the air power cooling system in the

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Melt temperatures for a solEX 90-40 extruder. Constant specific outputs are possible over the entire screw speed range at exteremely low melt temperatures.

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A haul-off for pipes with diameters up to 2,500 mm.

Part assembly of a pipe head helix VSI-T for pipes with diameters up to 2,500 mm

Pipe heads & downstream The Green Pipe concept for pipe extrusion is a modular concept with three different options that can save of up to 45 per cent in downstream length and energy needed within the downstream, compared to regular pipe extrusion lines.

In the past couple of years, the performance of extruders has increased, but higher performance means longer cooling lengths and that can be a problem, but battenfeld-cincinnati has increased cooling performance without increasing the length of the line with its the inner pipe cooling concept.

The helix VSI-T+ and KryoS pipe heads work with inner pipe cooling and have an additional melt cooling concept in the die.

When we registered our patent for inner pipe cooling, we found out that there had already been patents registered by a variety of companies, for example in 1989 by Cincinnati Milacron Austria (now battenfeld-cincinnati Austria) and in 1990 by Battenfeld Extrusionstechnik (now battenfeldcincinnati Germany). As far as we know, however, battenfeldcincinnati is the first company to introduce this patent to the market in an industrial application. Due to the advantages of inner pipe cooling systems, other companies have also begun to market them.

Inner pipe cooling systems are most useful when strong cooling performance is needed, for example for large diameter pipes, pipes with big wall thicknesses or high line outputs. The pipe heads can be used for producing smooth mono- and multilayer PE and PP pipes with wall thicknesses up to 150 mm. helix VSI-T+ are suitable for pipe diameters from 63 to 2,600 mm and helix KryoS for diameters from 110 to 1,200 mm. Inner pipe cooling is best suited for new high output extrusion lines, but may also be retrofitted in existing lines that meet certain criteria.

Product quality can be improved with inner pipe cooling, too as there is less stress within the pipe wall due to equal cooling and sagging is greatly reduced. Additionally, there is equalised temperature distribution inside and outside within the pipe wall at the cutter and less difference in the OIT-value between the inside and outside pipe surface.

The Green Pipe downstream provides savings by reducing energy consumption as well as reducing pump capacity and cooling losses. Instead of cooling each tank separately, in the Green Pipe downstream the last tank is supplied with cooling water, which is then led from tank to tank against the direction of extrusion. From the first tank, the heated water is led back to the chiller. On the way, waste heat is used and free cooling helps to reduce the needed cooling capacity in the chiller. This results in substantial savings of water and energy.

In full production field tests at the facility of one of our industrial cooperation partners, volume flow was reduced by up to 88per cent, the temperature difference (in-out) was increased from 3 °C to 20 °C, while free cooling was increased from 45 per cent to 97 per cent (outside air temperature 15°C). The pipes produced during the tests were of excellent quality and released for sale. more overleaf >>

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battenfeld-cincinnati offers complete large diameter pipe extrusion lines (from extruder to tooling and downstream) with diameters of up to 2,500 mm (PO) and up to 1,600 mm (PVC).

A spider 1200 pipe die for PVC pipe with diameters of up to 1,200 mm.

Where next?

Pipes sizes will increase further.

At the moment, the largest PE pipes produced on our production lines have a diameter of 2,500 mm. A line for diameters up to 2,600 mm is currently being manufactured by battenfeldcincinnati. First studies on pipe sizes above 3 m are on the way.

The largest PVC pipes currently in production are for diameters up to 1,300 mm. For PVC lines, battenfeld-cincinnati has all technical specifications ready to offer lines up to 1,600 mm.

The highest demand for large diameter plastic pipes is for water transport, particularly in Europe, and North America, while we see a growing number of enquiries from Asia, where we expect the highest overall growth rates.

View of the inside of a large diameter pipe produced on a battenfeld-cincinnati line.

Due to the inner pipe cooling concept, excellent surface qualities and minimal ovality can be achieved.

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PIPE & PROFILE

Weholite takes large diameter plastic pipes around the world Asset International claims to produce the biggest large diameter plastic pipes in the world, with demand coming from as far north as the Arctic Circle, to as far south as the Falklands.

EPPM quizzed MD Simon Thomas as to where in the world these vast pipes are being laid.

Words | Rose Brooke

Simon Thomas Weholite MD

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sset International's prowess in manufacturing Weholite large diameter polyethylene pipes takes it all over Europe and beyond, utilising the product's sturdiness and size in a surprisingly broad range of applications.

Moving away from steel and concrete

EPPM spoke to Managing Director Simon Thomas, who is based at Asset's headquarters in Newport, South Wales, to learn a bit more about the exciting projects Weholite has played a crucial role in.

"The world's largest totally plastic pipe"

"Every country has its own view on plastic pipes," explained Thomas. "In the Nordic countries they've always been fairly innovative about using plastic in civil engineering one of the reasons for this is temperature. Polyethylene pipes are very easy to use in extreme weather conditions whereas concrete is difficult to use, especially in wintertime when pouring concrete becomes an issue.

Finnish business Uponor Infra, formerly KWH Pipe, has been licensing the Weholite technology to Asset for 20 years now and as demand for the product has grown, so have the pipes.

"In the UK we've been at it now for 20 years and large diameter plastic pipes are still regarded as a new product. It is a hard battle to convince people of the benefits."

"We started life in the 1990s producing pipes of up to 2.2 m internal diameter and at the end of the 20th century we procured a third production line allowing us to go up to 3 m internal diameter. By the middle of the last decade, Uponor developed the technology to allow us to make up to 3.5 m internal diameter pipes, which at that stage was - and may still be - the world's largest totally plastic pipe without any sort of composite reinforcement. We made the investment in the production line to make up to 3.5 m internal diameter pipes in 2008," Thomas explained.

In central and southern Europe, concrete and corrugated steel culverts are still accepted over large diameter plastic pipes and while traditional materials have their place in many instances where plastic is unsuitable. Thomas admitted that if a road authority is going to change material, that is down to how receptive the senior civil engineer is to the advantages of large diameter plastic pipes.

Asset was approached to produce road culverts in northern Norway in 2011 by the local roads authority, who were upgrading the road network and required plastic piping.

"The roads authority up there in northern Norway approved the use of the large diameter pipe after we showed them our designs. The first culvert went over at the back end of 2011 and we've supplied one a year ever since," Thomas said. "We only have a small window of time to get it over to Norway and for it to be installed before the winter started when you can't do anything for half the year."

Some authorities are yet to be convinced to make the switch from metal to plastic like the north Norwegian roads authority.

"Engineers need to be taught the benefits of newer materials and what they can bring. Using Weholite we've offered major benefits in terms of cost, the environment, health and safety – the benefits are there to be had," stated Thomas.

Weholite developer Uponor has utilised large diameter plastic pipes in two significant projects recently: for piping sea water into a data centre to keep the computer systems cool in Hamina, Finland, and in a scheme to upgrade the drinking water supply to the 850,000 inhabitants of SkĂĽne, Sweden.

"The data centre was right on the sea, so the water was brought in from the sea to cool the equipment and then sent back out again," Thomas explained.

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PIPE & PROFILE Land, sea, land While shipping large diameter plastic pipes around the world from the UK can be incredibly expensive due to the fact they are produced on an island - requiring at least three legs to their journey via land, sea and land - international success is helped by the fact there are now around 35 Weholite production lines spread over four continents.

"A 3.5m diameter x 12 m long pipe is going to be the only thing you get on a lorry," Thomas said. "We cover the UK and Ireland and we supply pipes into Norway because we're the only ones who make 3.5 m-diameter pipes - and that's what Norway wants for its large culverts. Believe it or not, shipping from the UK to the Arctic Circle can be more cost effective than bringing pipe across Europe simply because Norway is full of fjords and islands, so once we get it onto a boat it's quite a cost effective process to get them reasonably close to their final destination."

"We also have a very good business in the Falklands for road culverts," Thomas added. "We've been supplying the Falkland Island Government once or twice a year for around 10 years."

That sinking feeling Usually plastic pipes would have concrete jackets fixed around the outside to give extra weight when submerging them, but because Weholite is extruded from a hollow box section, the team simply fills the voids with concrete, saving on cost and the logistical headache of managing submersion with concrete jackets bolted around the pipe.

Uponor developed the technology to allow us to make up to 3.5 m internal diameter pipes, which at that stage was - and may still be - the world’s largest totally plastic pipe without any sort of composite reinforcement.

"We're able to weld pipes together in long strings of 50-100 m in length together so they're homogenous. Those strings of pipes are then floated out to sea, submerged and we use divers to bolt the strings together with flange joints," Thomas explained. "We use inflatable bags along the length of the pipe and then seal off each end of the string of pipes. Because it's polyethylene, it still floats even with the concrete, so we then use inflatable bags for stability during the submersion process and as we let the air out of the pipeline, we let the water in to sink it.

"We deflate the bags in order from one end to the other slowly to do what they call an 'S bend' submersion. Then you have a nice smooth submersion onto the seabed because when Weholite pipe is submerged in strings, it can stand a sharp bending radius without damaging the pipe. You can bend the pipe to 50 times its radius easily without any issues at all. That methodology is used for Weholite around the world."

Weholite truly is being used around the world with demand in the power industry in Vietnam and Thailand continuing to grow, while there are more enquiries coming from the Middle East, where British engineering consultants have relocated bringing British standards with them.

Rafts for rhinos Luckily for Asset, Weholite does not just take the team to frozen Nordic lands. Thomas revealed one unusual application for large diameter plastic pipes was at a game reserve in South Africa, where during the winter, a river would flood preventing a migrating herd of rhino from getting to fresh grazing land.

"We supplied pipes to a local company down there to be made into a raft to transport the rhinos back over so they wouldn't run out of food and starve."

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PIPE & PROFILE

Pipes buck low plastics confidence plateau trend The construction industry's demand for pipes is giving the UK plastics sector hope during a period of long-running flat confidence according to a fresh report from the BPF.

The British Plastics Federation (BPF) has reported an ongoing confidence plateau for the UK plastics industry, with pipe production proving to be the exception to the rule In its latest survey of Business Conditions - which has revealed further flat-lining of business confidence effecting expectations of sales turnover, profitability and investment intensions over the next 12 months - the BPF revealed that optimism is still thin on the ground within the British marketplace this election year.

The survey was conducted in January and February 2015 and attracted responses from 93 Members from the BPF's 400-strong member base.

BPF Director General Philip Law was buoyant. "Overall performance remains robust," he said, "but the world is currently a very uncertain place and it's hardly surprising that manufacturers are exercising cautious judgement and to some extent sitting on their hands. The international political situation is volatile, potentially impacting the supply of raw materials and energy sources and the outcome of the general election only adds to the haze."

While two-thirds of the firms surveyed were predicting an increase in UK sales turnover, only 37 per cent predicted an increase in profitability, which is significantly down from 46 per cent only one year ago and is the lowest the BPF has recorded in more than two years.

The survey showed the construction sector is performing extremely well with all pipes and windows firms surveyed predicting an increase in sales turnover over the next 12 months.

Polymer distributors were, however, more pessimistic with only one in four predicting an increase.

"Despite conservative predictions of future profitability, the survey showed that 52 per cent of firms were planning to increase staffing levels over the next 12 months; the highest ever recorded in our survey," Law stated.

"The issue, however, is that firms simply cannot attract the right staff and once again nearly half of those surveyed stated they were having difficulty recruiting. This is something we are looking at tackling head on via our newly established Skills and Education Committee."

The full report can be found here: http://www.bpf.co.uk/about_ the_bpf/Business_Conditions_Survey.aspx

The international political situation is volatile, potentially impacting the supply of raw materials and energy sources and the outcome of the general election only adds to the haze.

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MATERIALS SPOTLIGHT

Turning up the heat on thermoconductivity Global materials leader DSM is spearheading the development of thermally-conductive plastics for cars. EPPM grilled Engineering Plastics' Business Development Manager for Automotive Electronics BEVs Richard Frissen and Automotive Sales Manager Joost D'Hooghe on the burning issue.

Words | Rose Brooke

Osram LED downlights keep cool with thermally conductive Stanyl TC polyamide 46 from DSM.

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and traditionally for automotive only metals are used for high-power LEDs."

etal replacement performance polymers are already superseding their traditional counterparts in a wide variety of applications, and international material development giant DSM has taken the next step with its advanced thermally conductive polymers.

EPPM spoke to DSM Engineering Plastics' Business Development Manager for Automotive Electronics BEVs Richard Frissen and DSM's Automotive Sales Manager Joost D'Hooghe to learn more about how this advancement could change the face of the lighting and automotive industries.

Lightweighting lighting "We see advantages in domestic appliances and the industrial arena. We have replaced aluminium with plastics for lighting manufacturer Osram recently," said D'Hooghe.

The Osram project saw DSM develop LED downlights utilising Stanyl TC thermally conductive polyamide 46 in the fixtures' heat sinks. The quick-to-mould material enables the lights to be formed into complicated geometries, effectively removing heat from around the LED light source, ensuring longevity.

Frissen noted that as LEDs become more efficient, not only are there more design opportunities to be had in the domestic lighting sphere, but in automotive too.

"We all know the automotive market is booming for LED technology, especially with premium OEMs. By 2025 it is expected that in Europe 50 per cent of headlights will be LED based on what we are seeing now, but it's a clear sign there's this move [towards performance polymers]. "[In automotive] the thermal environment is a little different. In the engine, we're talking about temperatures of 100-120 degrees

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Lighting has become a brand statement, with OEMs working to forge a brand identity by using the design of the lighting itself - an opportunity for thermoconductive polymers which are capable of being designed in more sophisticated geometries - to become as much a part of a vehicle's individuality as its body or dashboard.

"Freedom to design parts with a signature face is a trend," D'Hooghe acknowledged. "Audi was revolutionary with the first headlights to be made into a signature design amongst its peers."

"The possibilities of plastics include design freedom on the one hand and weight reduction on the other," Frissen added. "We all know that in 2020 there will be CO2 penalties forcing us to reduce the weight of cars - [that's] where this new lighting system will be a strong feature."

Metal replacement performance materials have to be able to cope with the demands of an automotive environment, where the materials have to withstand vibration and be durable to meteorological attrition. Aluminium holds up well in an automotive environment, but as design freedom and lightweighting place a greater bearing on what OEMs produce, performance plastics will provide the alternative.

Frissen explained: "We see a lot of alumina but that trend is clearly changing because of the weight requirements, so with heavy units like LED lighting systems I can see thermoplastics being used."

A place for metal Frissen and D'Hooghe do not envision a future where metal is replaced by performance plastics completely - at least not in the automotive or lighting sectors, and at least not in the foreseeable future.

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"For some areas it's just not possible to replace metal - especially with high-power LED solutions where the local power hotspot on an LED is too high," Frissen explained. "LEDs are becoming more efficient, but on the other hand the drive to reduce the weight in automotive lighting is stronger because modern LED lights have a high weight. That's a key challenge for this industry. And the fact is the best thermoconductive materials cannot reach the level of thermoconductivity of an alumina."

Frissen acknowledged the added challenge of introducing a new material into an established supply chain, particularly as the automotive industry is historically extremely conservative, where cost and reliability remain important push-pull factors.

However, the ability for thermally-conductive polymers to increase performance by reducing thermal loads should open some doors where others remain tightly shut.

D'Hooghe said: "Now we can put more performance plastics in a high thermal load environment. It's almost a no-brainer to find extensive chemical solutions to ensure parts withstand certain temperatures."

Stanyl and Stanyl ForTii utilised in a memory connector for a server.

Stanyl ForTii used in breakthrough LED array holder.

Healthy competition, healthy marketplace Developing thermally-conductive plastics to address mechanical needs is being spearheaded by DSM. Frissen believes the thermoplastic polyester PET XL-T offers good mechanics and moderate conductivity, but this is by no means the only product on the market, as growing interest in thermoconductivity has led to increased competition.

"I think this is not too bad," D'Hooghe noted. "We always say it's difficult if you're the only one in the market. Having some peers means this is a solution that has a market and that customers are interested."

But despite welcoming the competition as a positive indicator, D'Hooghe said this does not diminish DSM's drive to lead the development of thermoconductive polymers for certain applications, namely automotive.

Both experts agreed that moving more thermally-conductive "A nice example of that," added Frissen, "is we have one grade plastics under the bonnet is an on-going challenge for DSM. that is fully developed which we will be launching soon that gives Developing polymers that can survive the harsh environment us the possibility to make materials of an engine is not simple, but which show better mechanics than the benefits are there to be had. competing materials, while also being Nevertheless, the team is hard at thermoconductive. That's a huge work and is positive that once these challenge - especially for us in the The best thermoconductive performance plastics are approved, market of PPAs and PPSs. the company's global reach will do

materials cannot reach the level of thermoconductivity of an alumina.

"Making a material thermoconductive uses mechanics and toughness but if you use the material with an extremely high toughness as Stanyl does, it allows you to make materials that are tough enough for the job and tougher than the competition."

Electric revolution Frissen revealed that Stanyl can even retain its thermoconductive properties and robustness in thin-wall designs, which could be a huge breakthrough once the true benefits of the development begin to percolate into the supply chain, particularly as the design of the standard road vehicle alters with the rise and rise of electric cars.

the rest.

"An advantage we have is we're a global company and we are emphasising our global footprint with backwards integration into base chemicals in all our regions. In addition to our facilities in Europe, we have Shanghai offices and US offices as well, so we have a global understanding of trends," D'Hooghe stated.

"Thermoconductivity is a highly competitive market - we need to stay on our toes."

"It's not a big volume market yet - sales in e-cars are still low but that's one of the key markets for a strong interest for thermallyconductive plastics.

"When there is an electrical current flowing, you generate heat.

Of course with high-power systems like electrical cars, if you talk 1,000 watt heat losses you can do nothing with thermoconductive materials, but when it comes to the connection systems overheating there will be areas where temperature is critical.

This is how heat management is influencing the performance of these systems much more than it is now because we have the combustion engine which is completely metal. The future design for e-cars sets a new challenge."

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MOULDS & TOOLING

Midas tooling breaks the mould… and the waves Midas Pattern Company’s rotational mould tooling knowledge has played a crucial role in bringing an exciting new body board to market.

Midas Pattern Company's rotational mould tooling innovations have been making waves in the body board market.

The British company's expertise played a pivotal role in the new Fatyak Hönö, a multi-purpose leisure board designed for fun both in the sea and on snow.

Midas' tooling, which is manufactured in two halves, is now producing some 600 of the 1200 x 590 x 100 mm Hönö boards a year at the Williton, Somerset, facility of Kingspan Environmental Ltd, of which Fatyak Kayaks is a trading name.

Fatyak Kayaks have been on the scene for a quarter of a century and the name is a familiar leisure brand and rotational moulding specialist. The company’s products are designed to offer easy and affordable entry into the world of outdoor activities, and the Hönö is no exception.

General Manager Nick Hawkins said: "We wanted a quality, dual purpose product, which is when we had the idea for the Hönö.

The Hönö is a multipurpose fun board that allows users to body board and knee board in the waves, and jump on and have fun in the snow.

"As always we wanted to create the best possible product with no expense spared in design and execution."

Rotationally moulded plastic parts are perfectly suited to larger, more rugged applications where strength and size are key factors.

Made from tough polyethylene, the Hönö is corrosion resistant and features the latest UV stabilisation packages to reduce colour fade and maintain strength. The 4kg Hönö also offers a number of

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other design innovations that would require careful consideration by the selected tooling manufacturer, such as deep channels on the bottom for good tracking, a batwing profile on the tail for stable turning, a moulded-in feature to secure the board-saving leash and a drain plug location.

Although Hawkins cross-checked the market by approaching other suppliers of rotational mould tooling, he said Midas has become the company’s "go-to" mould tool maker.

"Midas always do a fantastic job with superb quality," he said. "In addition, the tools are priced competitively and always delivered on time. I’m not just saying these things to boost their ego, these are the facts."

The design challenge of the Hönö was to find the perfect ratio between strength, weight and performance for a moulded board with no seams or joints, while staying within budget. According to Hawkins, Midas "made important suggestions about how to bestproduce certain features".

Midas specialises in complex, multi-part rotational tools that include complex thread forms, loose pieces and sliding actions, for example. The company can manufacture both cast aluminium and billet machined aluminium rotational mould tools, while surface finishes can include polished, commercially smooth, blasted and peened.

According to Hawkins, the Midas tooling was delivered "right first time" to Fatyak and the Fatyak Hönö is now on the market and "selling well" with typical annual sales anticipated at 600.

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MOULDS & TOOLING

Sumitomo (SHI) Demag moulding systems leads to mammoth efficiency gains for Whale Sumitomo (SHI) Demag's hyrdraulic Systec range has upped efficiency for Northern Irish manufacturer Whale at a time when the company needed to upgrade its moulding technology with minimal disruption.

An innovative pump faucet and plumbing systems manufacturer has benefited from Sumitomo (SHI) Demag's hydraulic Systec range's ability to up capacity and increase efficiency.

Northern Ireland firm Whale's manufacturing facility in Bangor is at the epicentre of a recent boom in business. Whale - which is approaching 75 years in the business - is experiencing significant growth of late, placing huge demands on its injection moulding machines.

Whale manufactures pump faucets, space and water heaters and plumbing systems for niche markets such as leisure marine, caravans and domestic shower drainage at its Bangor site which is home to a Technology and Polymer Centre, including an advanced polymer injection moulding facility with 11 injection moulding machines ranging from 30 to 200 tonne models.

Michael Crosbie, Technical Moulding Manager at Whale, commented: "Previously manufactured from traditional materials, like metals, parts can now be reliably produced to very high tolerances with plastics. The added benefit is this significantly reduces the weight of components, which is vital for manufacturers of leisure vehicles and vessels. Our new products are predominantly manufactured from high quality polymers."

The wide range of component parts in 30 different polymer materials means more than 50 tool changes a week for Whale.

“With all this in mind, efficiency is vital for us and we needed machines that offered best in class efficiency," said Crosbie.

Within a decade of being established in 1998, many of the facility's machines were reaching the end of their lifespan and Whale was tasked with replacing the hardware with minimal disruption.

In 2010, Whale approached Sumitomo (SHI) Demag and purchased a Systec 120 hydraulic injection moulding machine. It was to prove a successful acquisition with immediate improvements in quality, reliability and time management. The improvement in efficiency led to the installation of two further Systec models – with an additional Systec 120 being delivered in August 2014.

"We chose Sumitomo (SHI) Demag initially based on recommendations from other local companies. The firm’s injection moulding equipment has a great reputation for reliability, ease of maintenance and service back up. That is certainly our experience. At our plant we run them 24 hours a day, five days a week and with so many tool changes required, their ease of maintenance and reliability is certainly thoroughly tested by our daily requirements," Crosbie remarked.

Since the installations, all of Sumitomo (SHI) Demag’s Systec machines have run like clockwork and in terms of downtime, efficiency on machine breakdown has already improved by 20 per cent.

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MOULDS & TOOLING

From horse carts to horse jumps Excelsior may be very different from when it was founded 120 years ago, but the Bury-headquartered rotomoulding business has come full circle, from selling cotton spinning cans off the back of a horse-drawn cart to producing its own range of equestrian equipment.

Words | Rose Brooke

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xcelsior has been in business for longer than one might think.

Founded in 1896 when Excelsior sold spinning cans for the cotton trade off the back of a horse and cart, the Lancashirebased company has been making its name as a leading rotational moulder for more than 40 years thanks to the hard work and perseverance of the Fielding family, who have been at the Excelsior helm since 1946.

big in in the past have declined over the years. This company had a few products and a small customer list and we thought 'why not'.

We already offered some products such as the mounting blocks, but now we have our own products because we realised there were no other rotomoulders who were directly supplying the trade."

EPPM went to Bury to meet Managing Director Giles Fielding and to explore the site - a traditional red-brick factory building that has found itself incongruously located amid a residential area as new homes have sprung up about it - to learn more about Excelsior's position in the wider European and International rotational moulding sector.

Fielding revealed that at present demand for its equestrian products is strongest in Germany, France, the low countries and Scandinavia, with orders and enquiries coming in from as far afield as the Middle East and Australia, where there is high demand but limited availability.

A little bit of history repeating

"The UK is a fairly saturated market, so the growth is really going to be in Europe and beyond, but we're looking at it in the same way as we do the materials handling products that we supply through the trade to end users. It's an interesting market and is completely different to anything else we've done," Fielding said.

The historical aspect of the business remains a novelty for Fielding, who has seen the Excelsior-branded cans on family days out to local points of interest and yet no records indicate how the company came by its mythical name. But there is little time for a busy organisation to delve into its past, with the company continuing its evolution since establishing Excelsior's rotational moulding operations in the mid-1970s.

"Back then it was pretty basic," said Fielding. "Everything was blue and grey and dreary, but now we offer more products and up to 12 colours and ironically for a business that sold its product off a horse and cart, we've come full circle to horses all these years later with our equestrian range."

Excelsior has utilised its rotational moulding expertise and knowledge of the marketplace to tap the equestrian market, after a business it had been supplying asked if they would be interested in a buyout.

Fielding explained: "When this came along, we had been looking for other markets to get into as some of the markets we've been

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Flying the flag for quality

"There is competition, but whenever we do trade events we fly the flag and people like that and come back to us for the quality. So we're affected by competition but not to a huge degree."

Family-run Excelsior is based across two sites in Lancashire, employing a staff of 44 including some who have been at the company for as long as 40 years. In addition to the head office in Bury, there is the tool-making and sheet steel tool-making division that is joined to the company's materials handling division, while the company has an additional facility for making fabricated cases from extruded plastics.

Fielding's father John is company Chairman, while his wife Karen manages equestrian product sales and his brother Jonny is a Director looking after sales of materials handling products. "We still have the family feel," said Fielding. "We rely on the family flavour and customers like that. Despite being an established company, we are quite a young team and try to stand out from the other moulders."

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"We want to focus on our strengths and that's what's taken us back to focus on contract moulding (which accounts for 40-50 per cent of Excelsior’s turnover). We've decided to really push that we're rotomoulders first and foremost. That's the future. Marketing this is something we work hard at and some of our products are quite eye-catching, but the thing with rotomoulding is there aren't new products coming through all the time like with injection moulding.

We have several prospects in the pipeline but they can take a year to come to fruition by the time the design is finished. Then obviously there's tooling and once the tool is here, it takes time to sample and sign off. It's quite a long process," he explained.

And it seems Fielding is not satisfied until there is a finished product.

"Seeing the finished product is the most exciting part of the process for me," he stated. "Seeing the finished thing when it's hot off the tool and it's still warm is a great feeling. After the excitement of getting the order that's the most satisfying thing for me."

Plenty of business for everyone

Excelsior receives demand from many sectors, including the education sector (for lockers) and the leisure sector (for children's play equipment), while its growing equestrian operations account for 10 per cent of growth. By focusing on its contract moulding customers, Excelsior's business is safe, because if one market experiences a decline, there are at least two safety nets allowing the business to evolve again, like it has so many times in the past.

In addition to keeping its eyes open to where markets are showing growth and where there is decline, Excelsior is investing in modernisation, such as developing a custom-made computerised system that indicates what the company's margins are, how long it takes for products to be moulded and how production time can be used more effectively.

Fieldng explained: "It's now generating data and shows us instantly what's working well, what's not doing so well, scrap levels and such. It's brilliant. If we didn't have it, our hands would be tied behind our backs and to some degree we'd carry on as we were, assuming things were working, and having to check data manually.

Ultimately we want a full stock system but we're not quite there yet, but this investment is a huge step in the right direction."

Now is a good time for Excelsior's rotomoulding operations, with the company outsourcing to other moulders as and when required.

In the team's conversations with these other organisations, Excelsior has ascertained that the market is fairly buoyant, with the price of raw materials improving margins - albeit temporarily and enough demand to ensure a rosy 12 months.

"We're also investing in a new machine - and we're bringing that in in May or June to increase our capacity and make us more competitive, and we're also looking to move premises in the next 12 months. We've been here since 1997 and we've outgrown it," Fielding revealed.

"We have a relatively new Production Manager and Quality Manager and they're getting out there. Talking to other moulders we've met doing our outsource work, you learn a lot and working together is the way forward. There's plenty of business for everyone and everybody's very friendly and helpful."

The company wants to stay in Bury, but there is a shortage of premises large enough to accommodate the growing business, which is currently "bursting at the seams". Nevertheless, the search continues within a "10-mile radius" of Bury for where the next chapter in the company's history will be set.

“Ironically for a business that sold its product off a horse and cart, we’ve come full circle to horses all these years later with our equestrian range.”

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AUTOMATION & ROBOTICS

Plastics and the smart factory The appetite for innovation shines through every aspect of our lives, with more than two million patents registered every year. So why is it that between 2003 and 2012 the European plastics industry was only responsible for 25 of those patents?

Darren Halford, Sales Manager of industrial automation parts supplier European Automation, explains how intelligent automated solutions can make the plastics sector more innovative and sustainable.

Words | Darren Halford, Sales Manager, European Automation

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he versatile character of plastics has made them the material of choice for most industries, from packaging to food and beverage, construction, building, automotive, electrical, electronics and agriculture. Despite increasing global demand, the plastics industry is facing significant challenges from rising energy costs and restricted access to raw materials. To remain productive and competitive, plastics processors need to find creative ways of saving energy, conserving resources, improving recycling levels and developing new generations of materials.

In recent years, European plastics companies have been facing additional pressures from their international competitors. The US, for example, has gone down the route of non-conventional fuels like shale gas, while Latin America is taking the lead in bioplastics production. India is constantly increasing its plastics conversion sector to respond to a growing population and rapid industry developments.

To remain competitive, European plastics and packaging manufacturers need a fundamental shift towards more sustainable processes and materials. In other words, they need to innovate.

Make more with less energy Efficient manufacturing means lower production costs, as well as sustainable processes and products. Industrial automation is a good way of increasing productivity and reducing energy usage in a manufacturing plant.

However, you can’t just throw technology at a process and expect it to improve. The first step towards reducing production costs is an in-depth analysis of existing systems and processes. An objective evaluation of what savings can be achieved by modernising existing systems is crucial, before deciding on what investments should be made.

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Clearly, not every plastics manufacturer will be able to completely redesign their production lines and immediately replace existing equipment for state of the art industrial robots or ‘done-in-one’ manufacturing cells. However, they should be able to take the first steps towards more energy efficient operations.

Intelligent measurement technology, smart sensors, process automation and electric drives technology are just some of the industrial automation solutions that can help plastics manufacturers reduce the amount of energy they use and implicitly reduce their operating expenses.

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Induction motors, for example, are at the very heart of industry, but are also responsible for using 30 per cent of the total amount of electricity generated in the world. By replacing all of the obsolete motors in a plant with IE3 (Premium Efficiency) ones, or by retrofitting variable speed drives on older, inefficient motors, companies can reduce motor energy consumption by 60 per cent.

In addition to energy savings, variable speed drives also allow an additional level of communication between the motor and the control system. This results in valuable production and maintenance data that can be used to identify where further energy savings can be made.

The smart plastics factory If the shift to industrial automation continues, machine-tomachine communication will become a common feature of plastics manufacturing and converting facilities in the next decade.

Concepts like industry 4.0, the Internet of Things and big data explore the potential of connecting equipment on the factory floor to a central control system and using production data analysis to make processes more efficient by reducing energy usage, costs and waste.

In a smart factory, intelligent sensors and encoders collect and transmit data from equipment on the factory floor. Advanced systems like SCADA and DCS monitor, diagnose and control equipment remotely and can react in real-time to any problems that might arise in the system. With the help of user-friendly human machine interfaces (HMI) and remote data access, operators can identify any potential threats, minimise downtime and optimise processes, thus reducing costs and increasing efficiency. The large amount of data generated can also be archived, stored and analysed to make further improvements to the system.

In the future, cutting-edge industrial automation solutions like robotics, big data and additive manufacturing will play an even bigger role in the plastics and packaging industry, allowing manufacturers to design flexible production and conversion lines and even simplifying the recycling process.

In the short term, the most likely solution for industry players is to upgrade existing production lines and retrofit industrial automation equipment like variable speed drives and human machine interfaces to increase the control function. This, along with sourcing obsolete industrial automation components, can help reduce costs significantly. By repurposing existing equipment, capital expenditure can be kept under control and operation costs can be significantly reduced.

The plastics industry is a very fertile sector for innovation in terms of new materials like bioplastics or anti-counterfeit polymers.

To keep ahead of the game, European plastic manufacturers and converters should apply the same creative lens to their production facilities and see how they can take advantage of innovative industrial automation technologies and concepts like the smart factory.

Intelligent measurement technology, smart sensors, process automation and electric drives technology are just some of the industrial automation solutions that can help plastics manufacturers reduce the amount of energy they use.

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AUTOMATION & ROBOTICS

SolutionsPT systems up efficiency for APPE SolutionsPT has helped a Wrexham-based rigid plastic packaging manufacturer up its efficiency and manage its production, saving the company time and money.

Words | Mike Charles, Operational Intelligence Product Manager, SolutionsPT

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ndustrial IT solutions and services provider for the manufacturing industry SolutionsPT has reported the successful integration of one of its systems at leading rigid plastic packaging producer APPE in the UK. APPE produces packaging for some UK and Europe's best-known brands. Prior to the global recession, APPE began to focus heavily on improving its operational strategy. The Wrexham-based business needed to increase its competitive edge and quickly realised the best way to do this was to invest in a SCADA-based IT system which would create the backbone for an Operational Intelligence capability, allowing the company to improve the overall visibility of its production processes and enhance operational efficiency.

The challenge When APPE approached SolutionsPT, they had a number of operational issues to resolve. Manual reporting meant that effectively measuring KPIs was a time-consuming and complicated process, while APPE also needed to analyse the true cause of incidents, costs and losses, and create a wellsupported, robust system with minimal downtime.

Furthermore, the business needed to be able to ensure product quality through process control.

SolutionsPT put forward a solution comprising of Wonderware InTouch (SCADA HMI software) to visualise APPE's production processes; Wonderware Historian, a high-performance realtime database designed for real-time manufacturing data; and Wonderware Information Server, a web-based reporting and dashboard portal to share and display the information.

Operational intelligence Following its partnership with SolutionsPT, APPE implemented a high-speed data acquisition and storage system with a traditional database management system; giving the business full visibility of its production process and allowing it to monitor, collect and evaluate data points.

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APPE has also benefitted from advanced KPI reporting tools.

Wonderware Historian constantly tracks machine temperatures, pressures, set points, and statistics on machinery downtime and spoilage, helping the company monitor KPIs such as Manufacturing Effectiveness, Unplanned Downtime and Cycle Loss.

Operators and managers now have actionable and meaningful information to enable APPE to make informed business decisions in a more efficient way, enabling fast and effective data capture and KPI reporting. The added intelligence obtained has also enabled APPE to track how its production compares to its sister plants.

Tim Manuel, Continuous Improvement Champion at APPE, said: "Prior to this project, we were 'running blind' with no way of recording how we were performing. We struggled to carry out rootcause analysis of issues but we can now get a snapshot of what is happening across the shop floor every 10 seconds, providing the information we need, when we need it."

Streamlined quality management Since the IT overhaul, APPE now has access to advanced levels of intelligence in its production process. Accurate root-cause analysis can now be carried out, and fact-based decisions can be made, as opposed to taking educated guesses.

Manuel added: "The increased quality of our products has played a crucial role in helping us to win new business. In recent years we have landed several new accounts, including a number of highend clients who previously worked with our competitors. We’ve achieved significant time savings since installation, because we have reduced the number of manual inspections from two per 12 hour shift, to just one. As a result of the Historian installation the one check we do, is a much more efficient, thorough and based on all the data from that shift."

"SolutionsPT have helped us achieve a 30 per cent increase in volume, as well as enabling APPE to ensure product quality, reliability and a reduction in losses. This has been a major contributing factor to the continued success of our plant," Manuel concluded.

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AUTOMATION & ROBOTICS

KraussMaffei pioneers injection moulding with Multisubmit integration Integrating Multisubmit function control into injection moulding systems will benefit customers by giving them a control system that can carry out many peripheral processes at the same time.

KraussMaffei has a reputation for being a vanguard of injection moulding technology and the company has used its expertise once more to integrate Multisubmit function control into the MC6 operating concept of its industrial robots.

From January 2015, this new programme function - in conjunction with the KUKA KR C4 Version 8.3 (Win 7), is available in the KraussMaffei control system. Customers will benefit from a central control system that can carry out multiple peripheral processes simultaneously.

This new Multisubmit programming function has allowed KraussMaffei to increase its own ProgTechX command library.

The diagnostic and pneumatic functions, as well as variable monitoring, are displayed via the KraussMaffei MC6 VisuX visualisation.

Thomas Marufke, Managing Director of KraussMaffei Automation, said: "The new Multisubmit programming function complements our proven MC6 operating concept perfectly. Central system control, programming and operation can be carried out via the handheld terminal of the robot. In addition, the complex integration of an additional PLC (programmable logic controller) is omitted in a wide range of applications. Basically, system operation is being centralised and, in turn, simplified."

Moreover, acquisition costs are coming down as the amount of training effort required for machine operators is decreasing, while expertise for programming an additional PLC is no longer needed.

The handheld terminal of the robot with KraussMaffei MC6 VisuX visualisation, combined with the ProgTechX command library, form the central programming and operating element here. A product change or system expansion can be carried out with ease.

What is Multisubmit?

A submit interpreter is a KRL program (KUKA Robot Language) that runs parallel to the robot program. Until now, there was just one submit interpreter (Singlesubmit) in the robot control system.

With the release of the new KUKA KR C4 Version 8.3 (Win7), seven independently operating subinterpreters were added to this function

(Multisubmit). The main application of Multisubmit is the activation of external, peripheral components operating simultaneously, such as conveyor belts with separators, assembly stations and drawer systems and magazines.

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CHINAPLAS PREVIEW

ChinaPlas 2015: A platform for global plastic trends

Asia's Number One and the World's Number Two plastics and rubber event is coming to Guangzhou and promises buyers not only a return on their investment, but the best possible insight into the Chinese manufacturing industry.

Leveraging nearly 30 years of experience and expertise, ChinaPlas - the International Exhibition of Plastics and Rubber Industries - is at the forefront in driving the development of the plastics industry in China and around the world.

This May in Guangzhou, China, ChinaPlas will add four new high-tech theme zones to its original 11 theme zones to address the emerging demands of the Chinese market.

Industrial Automation Zone China's labour-intensive industrialisation has a negative impact on the environment and in recent years, Chinese enterprises have faced issues such as a shortage of labour, leading many to consider introducing automated production lines to reduce production costs and enhance quality.

Ada Leung, General Manager of Adsale Exhibition Services Ltd, the organiser of CHINAPLAS, said: "In the past, various automation technologies were scattered over different theme zones. This new theme zone will serve as a onestop destination for visitors to learn about the latest automation technologies from all over the world and can watch live demonstrations of robotic systems as well."

Composite & High-Performance Materials Zone The recent rapid development of high-added-value products have brought about the development of many high-performance materials, composites and specialty plastics. Thanks to these innovative materials, many downstream industries have experienced revolutionary transformation. The Composite and High-performance Materials Zone will be officially debuted at CHINAPLAS 2015 for visitors to witness the latest achievements in this field.

Colour Pigment & Masterbatch Zone and Additives Zone With a gradual growth in the pigments, masterbatch and additives industries, the Colour Pigment & Masterbatch Zone and Additives Zone will be set up as two individual main theme zones in a bid to provide more targeted and efficient exhibition platforms of related products and technologies to visitors.

Leung stated: "ChinaPlas is a one-stop platform converging high-end technologies and solutions from around the world, giving visitors an opportunity to gain access to various products and technical information at one place. The continuous growth of the exhibition scale also proves that ChinaPlas maintains a high level of ROI for both exhibitors and visitors."

An exhibitor's eye view: NDC Technologies at ChinaPlas 2015

M

easurement and control systems leader NDC Technologies will once again be making the pilgrimage to China for the world's second-largest and Asia's 'number one' plastics and rubber show.

NDC Technologies' Worldwide Marketing Manager Jay Luis revealed that Asia is a crucial market for the company, which is why ChinaPlas plays such a key role in the business's events calendar.

"Because of its size and recognition, this show draws a huge attendance and we get to see a wide range of plastics manufacturers, from small to the largest companies in Asia. This offers us the opportunity to learn about what is happening the Asian marketplace," Luis stated.

"Last year, NDC Infrared Engineering and Beta LaserMike merged to form NDC Technologies. Both

of these companies have been attending ChinaPlas for years. This year is special because we'll be under one roof as NDC Technologies to display our broad portfolio of measurement and control solutions."

This joining of forces means a larger booth for NDC Technologies, which Luis revealed will be "striking and inviting".

"We have some great demonstrations planned so attendees can get a close-up look at some of our latest non-contact measurement and controls technology for plastic film, sheet, pipe and tube extrusion applications."

"The team is extremely excited," Luis remarked. "With each year, we strive to make a greater impact at this event. We invite ChinaPlas attendees to stop by our booth to see what all the excitement will be about."

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ChinaPlas 2015 visitors can find NDC Technologies on booth 9.2K31.

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CHINAPLAS PREVIEW

AMUT

ARBURG

AMUT will give a live demonstration of the VPK-C84 automatic thermoforming machine, which is ideal for producing rigid packaging such as trays, punnets and containers.

Arburg will present high-end injection moulding machines and the Freeformer for additive manufacturing to cover the entire production spectrum from oneoff parts to mass-produced items at ChinaPlas 2015.

The AMUT Group range of thermoforming machines stands out due to their sturdy structure, an innovative design criteria and high running performances at low energy consumption. Both off-line and in-line solutions are provided. The machines boast a proven strength and durability even under the heavy conditions of cutting tougher materials, such as PET and PP at high cycles rate.

AMUT GROUP is also a reliable manufacturer of tailor-made extrusion lines to produce foils, sheets, films, membranes, pipes and profiles. Its Recycling Division is highly specialised in washing plants to recover PET bottles and HDPE containers and offers a wide range of machinery for the waste handling and sorting, while AMUT DOLCI and BIELLONI offers printing machines, blown and cast lines for different multilayer films, coating and laminating lines.

AMUT GROUP shares the booth together with COMI, Italian partner leader in manufacturing customised thermoforming machinery, cutting systems, moulds and presses for several types of applications.

In addition to demonstrating an industry first by combining an elastic standard TPU material with a special supporting material, the company will present the cost-effective injection moulding of massproduced items for the medical and packaging industries with two Allrounder exhibits. Two Freeformers will demonstrate the potential of Arburg Plastic Freeforming for the industrial additive manufacturing of functional parts as one-off items or in multi-variant small-volume batches. The Asian sales launch of this innovative system for industrial additive manufacturing will coincide with the start of the trade fair.

The pioneering Freeformer is not only suitable for the additive manufacture of one-off parts and small batches, mass-produced parts can also be customised in conjunction with injection moulding and Industry 4.0 technologies.

Arburg will also present the ‘Packaging’ version of a hybrid Allrounder designed especially for thin-walled applications in the packaging industry.

The high-performance injection-moulding machine from the Hidrive series offers high productivity and reduced energy consumption.

A 2+2-cavity stack mould is used for the IML application.

BASF

Brückner Maschinenbau

BASF, the world’s leading chemical company, will sponsor the “Design x Innovation” event at ChinaPlas 2015. The event will focus on the power of plastics technology in empowering designs that boost product innovations. Plastic technology helps customers respond to fast-changing market needs, such as sustainability demands, intense competition and the requirement for faster time to market.

Brückner Maschinenbau will mainly focus on two areas of a modern plastics film production at ChinaPlas 2015: reduced energy consumption and raw material usage, and the manufacture of special functional plastic films.

The “Design x Innovation” event consists of a gallery showcasing plastics innovations, open forums for industry experts, and interactive programmes. Through these platforms, “Design x Innovation” will illustrate how plastics technology opens up design possibilities to inspire new product experiences - showing how lighter weight, new looks, new materials, and new functionalities can address the needs of daily life for energy efficiency, lifestyle and performance.

Brückner Maschinenbau’s Chinaplast 2015 highlight will be Intelligent Line Management (ILM) including an energy monitor for measuring and analysing the energy consumption of the film production process.

Additionally Brückner will be presenting more solutions for a sustainable film production of bio-based resin, either as new investment or as modification of existing lines for bio-plastics processing.

Visitors at the joint Brückner Group booth will also meet: Brückner Servtec with their solutions for the profitable operation of film stretching lines; Kiefel, who will showcase the latest developments for the packaging, automotive, medical and appliance industry; and PackSys Global, which will present advanced packaging equipment.

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ENGEL

EREMA

With four innovative applications for the automotive, teletronics, medical and packaging industries, ENGEL will again be giving an impressive demonstration of its great industry and system solution expertise at ChinaPlas 2015.

EREMA will be shining the spotlight on its new INTAREMA generation of systems featuring the core technology Counter Current at ChinaPlas.

EREMA will present an INTAREMA 1007 TVEplus system with an EREMA melt filter SW4/104 RTF. The system - which has a throughput of 300-350 kg/h - will demonstrate the efficient recycling of heavily printed LDPE materials.

The new ENGEL e-pic pick-and-place robot is celebrating its first outing in Asia at ChinaPlas 2015 in the “Robot Parade” in Hall 4.2, directly one floor above the ENGEL main stand. The e-pic combines linear motion with a swivel arm. Robots are increasingly becoming fixed components in injection moulding machines in China and automation, as an integrated part of the process, supports new processes, component functions and product qualities, thus substantially improving the plastics processor’s competitiveness.

The all-electric and tie-bar-less ENGEL e-motion 30 TL will be put through its paces at ChinaPlas with an application from the electronics industry. The machine will be producing 60x board-to-board plug-in connectors to exacting precision standards. ENGEL’s automation range includes ENGEL viper linear robots and ENGEL easix multi-axis robots among other products.

ENGEL will be presenting the entire spectrum at ChinaPlas.

With over 30 years of success, more than 4,000 systems in operation throughout the world and a notable list of references, EREMA has been regarded as the global market and innovation leader in plastic recycling systems for years. EREMA technologies are regarded as the leading global standard for a wide variety of recycling jobs and with the patented Counter Current system EREMA sets another milestone in plastic recycling system engineering. The Counter Current system is that the material spout in the cutter/compactor is reversed, moving against the direction of the extruder. The result is increased process stability and higher throughput. With this new innovation EREMA confirms once again its position as global market leader in plastic recycling systems.

ILLIG

motan-colortronic

At ChinaPlas 2015, ILLIG will be presenting the current state-of-the-art in thermoforming with automatic roll fed machines of the RDK and RV series.

motan-colortronic will exhibit its range of solutions for plastics processing applications at ChinaPlas. The focus will be on four major product areas; drying with compressed-air dryers and dry-air dryers; conveying systems such as the the new METRO G material loaders, which can be integrated into automatic central conveying systems; dosing and mixing systems such as the new MINIBLEND V; and control systems for supervising material processing to ensure quality products.

Technically, hinged food packs will be manufactured on an IC-RDK 80 thermoformer out of polyethylene terephthalate (APET) with a maximum forming area of 756 mm x 565 mm. Equipped with a 10-up mould the line reaches a speed of up to 50 cycles per minute. The user benefits from the new ILLIG IC (Intelligent Control Concept) since thanks to this concept the high efficiency of these servo- driven thermoformers can be utilised to the full extent, like RDK machines which reach a speed up to 55 cycles per minute. These machines work in the forming-punching method.

Machine model RV 53d is the second machine ILLIG will be presenting at the stand, featuring a forming area of 500 mm x 350 mm. The broad application range of these thermoformers is supported by the use of cost-effective moulds. At a speed of up to 50 cycles per minute the benefits of RV machines become especially obvious in the production of food and non-food packaging.

Developed by motan engineers, METRO G combines the latest technologies from colortronic and motan and enhances those systems with a number of new features. The METRO G is the most comprehensive and flexible material loader on the market today. Its modular building block system allows users to create and configure the optimal material loader for their specific application.

The volumetric MINIBLEND V dosing and mixing unit offers excellent mixing quality and consistently accurate dosing. Mounted between the machine hopper and the feed throat of the plastics processing machine, the unit requires very little space. Disc dosing with the MINIBLEND V gives you real volume dosing which guarantees a very high dosing accuracy.

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CHINAPLAS PREVIEW

NDC Technologies NDC Technologies will present its wide range of solutions for the sheet and film industries for on-line measurement and control of thickness, weight and co-extrusion layers.

In response to demand for higher quality products, NDC has developed a number of unique infrared sensor technologies for non-contacting, non-nuclear measurement of film and sheet products.

Its FG710S sensor applications include single- or multi-layer composition measurement for most polymeric film and sheet products ranging from 5 microns to 5 mm, while the OptiMike OM190 optical micrometer provides direct, single-sided, non-contacting thickness measurement for extruded sheet and non-metallic thick film products.

NDC will also display its complete plastic pipe and tube extrusion line measurement and control system with Beta LaserMike gauges in place from the extruder through the puller station, in addition to the Beta LaserMike LaserSpeed non-contact gauge for measuring the length and speed of products. NDC will show how the Beta LaserMike DataPro process controller and data management system ties all the gauges together to continuously monitor product dimensions and automatically control the line to keep production processes and product quality under control.

ChinaPlas sun shines down on whole of manufacturing C

hinaPlas 2015 is set to shine the spotlight on the entire manufacturing spectrum - every sector and every stage - with a series of complimentary, concurrent events.

designers to share their award-winning works and experiences. Design x Innovation will be held at booth A21 in Hall 13.2 and the Viewing Deck outside Hall 9.3 in Zone B.

The global manufacturing arena is growing apace and ChinaPlas 2015 will represent every facet of this burgeoning industry with three concurrent events to help plastics processors keep up-to-date with trends.

Industrial Automation – Robot Parade & Smart Production

Design x Innovation ChinaPlas organiser Adsale Exhibition Services Ltd and BASF join forces to demonstrate how plastics combined with creative design can provide sustainable and innovative solutions. The event will showcase well-designed industrial products made of BASF advanced materials including auto parts, building materials, consumer goods, apparels and housewares. An Open Forum on the topic of 'Design & Innovation' will be chaired by internationally revered engineering and product

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The Industrial Automation Zone will be set up at Hall 4.2 to feature a legion of tools and technologies such as robotics, automation systems and peripherals, remote control systems, drives, sensors, arm tooling and software that help make production lines more automated, more intelligent and more efficient. The Zone rallies market leaders from all over the world such as ABB, Wittmann Battenfeld, Honeywell, Rockwell, Siemens, Mitsubishi Electrics and Shini. 'Robots Parade & Smart Production' - a fascinating live demonstration - will illustrate the manufacturing advantages brought by clever automation technologies

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Medical Plastics Conference This two-day conference will be held during ChinaPlas on May 21st-22nd. It will present hot topics in the medical plastics field such as the latest developments in the global and regional markets, the special requirements for polymer production, additives use, moulding technologies, post-processing and medicine packaging, with a view to unlocking future business potential for market players.

In addition to the concurrent events highlighted above, there will also be over 50 technical seminars being held during the exhibition period.

CHINAPLAS 2015 opens up a new dimension of green packaging ChinaPlas 2015 is going to broaden delegates’ horizons in the field of sustainable packaging across the entire market spectrum, as corporate and domestic responsibility to the environment becomes increasingly important in China and around the world.

Plastic packaging, heralded as green, eco-friendly and low-carbon, is growing rapidly in recent years, in the midst of growing concerns surrounding food safety and the environment.

after. New sealing methods also improve consumers’ experience, for example, plastic zippers and screw cap pouches allow users to open the packet without needing to tear the bag.

Intelligent, multi-functional, lightweight and eco-friendly packaging remains the mainstay of packaging trends, where plastics are widely, occupying over 30 per cent of market share in the industry.

At Chinaplas 2015, over 3,100 companies from over 39 countries and regions will showcase solutions that cover all aspects of plastics and rubber processing, with the spotlight being shone on packaging technologies.

China - despite being the world’s largest producer and consumer of agricultural products - has wasted some 30 per cent of its consumer and agricultural stock as products have been damaged in storage, transportation and retailing, partly due to poor packaging.

Certain new packaging technologies that greatly improve food safety and extend shelflife such as high gas barrier films, heat resistant additives, temperature resistant additives and antimicrobials are highly sought-after and have a strong future in the Chinese market.

For the beverage market, PET bottles predominate carbonated drinks sector at 57.4 per cent. As China’s tea market is booming, heat resistant PET bottles are among the fastest growing arms of plastics with annual growth rates of over 50 per cent among polyester bottles. It is estimated that the need for shrinkable film will reach a 20 percentage point growth rate in the coming five years, particularly in the application of PET shrinkable film on PET beer bottles. With the increased disposable income, consumers are more willing to spend more on high-end household chemical products and set a higher bar for their appearances. Thus, novel and aesthetic packaging are highly sought

What to expect?

TOTANI’s Three-Side-Seal pouch making machine - The attraction of Totani's 3-servo system lies in separate control of film feed and vertical heat-sealer drives. Using the "Sealing Time setting function" and "Sealing Waiting Time function", allows for a quicker setup at low speed and a ramp to high speed, without changing acceleration, to give high-speed bag making at up to 240 CPM. Capabilities of up to 4-lane pouch making for Three-Side-Seal pouches can produce up to 960 pouches/minute. The machine has three different lengths to suite different factory space requirements.

BRÜCKNER’s production lines for high-barrier BOPP films can achieve the outputs above 6,000 kg/hour, production speeds up to 525 m/min: BOPET lines for the various optical applications up to 400 microns; LISIM simultaneous technology provides the contact free stretching in both directions at the same time for BOPP, BOPET, as well as BOPA films, serving critical markets and applications such as laminations for aroma and flavour retention.

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31

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

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

Download our full stock lists online

Excessive Reduction For End of Tax Year.

Delivered before 31/03/2015

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• UPM Model 12-16 Granulator 11Kw Drive.

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• Cumberland 40-70 Granulator 30Kw Getecha 440 400 Granulator. Throat: 400×440mm, Drive.

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• Carpet, Clothing, Cardboard, Foam, Paper Shredder Bailer • Getecha GE 1000 Granulator 15Kw Drive • Lanceline 300 300 Granulator 11Kw Drive • USI Cumberland 30-40 Granulator 11Kw Drive Small Granulators & Shredders: Used for all types of plastic, bottles, top & tails from moulding & CD/DVD cases.

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Vecoplan VAZ 800/40 Shredder. Throat: 800 x 1000mm, 11Kw Drive, Single Shaft Shredder, 20mm Screen

New & Exclusive Granulators USI Cumberland 300-400 Granulator. Open Rotor Throat: 300x400mm, 11Kw Drive, Rotor Blades 3 new Stator Blades 2 new, Open Rotor, 12 mm Screen

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

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Uniloy MSA/95D Twin Head Blow Moulder. Moog 64 point control, Continuous extrusion series, Siemens Coros OP 25 control, Clamp force 28KN

Rawmec EEC Ltd, Rawmec Industrial Estate, Plumpton Rd, Hoddesdon, Herts. EN11 0EE See our machines in action More info, machines & photos visit: www.rawmec.com or email: info@rawmec.com on our YouTube account EPPM_210x143_03-15.indd 1

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

Over 40 Years of Service

1800mm wide Reifenhauser sheet extrusion line. 120mm Reifenhauser extruder, melt pump, 1700mm die, 3 roll stack, pump group, haul off, cross cut saw.

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

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

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2950mm Sheet line for HDPE

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

100mm Omv P.P extruder 115mm Davis Standard Thermatic extruder model 45IN45T . 30:1 L/D with barrier PP/ HDPE screw, 305kw motor, Fan cooled electrically heated 6 zone barrel 2008!!

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125mm Speedex vacuum unit 1650mm Wide Casplast Horizontal 3 Roll Stack . 500mm Dia Rolls Independently Driven Via 5.5kw Ac Motors. 2 roll haul off 2005.

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

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To advertise here please contact Lisa Montgomery: (44) 0161 308 2550 T: +44 (44) 0161 (0)1244 343 2026 680222 E: lisa@rapidnews.com

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33

EUREKA SERIES

We believe in looking at science from a creative point of view to shape the innovations of tomorrow.

Tomorrow Machine: Food packaging unwrapped Food packaging is in need of an environmental makeover as the industry tackles the thorny issues of litter and landfill - and one product design business has been working hard to innovate how we unwrap our food.

Words | Rose Brooke

T

he world of food packaging is changing and the aptlynamed Tomorrow Machine is one company that is not afraid to be at the pointy end of the action.

Founded in 2012 and based jointly in Sweden and Paris, Tomorrow Machine has enjoyed international publicity thanks to its innovative wrappers and egg-like breakable shells for products such as oil, which make use bioplastics in a series called This Too Shall Pass.

Product Designer Anna Glansén - who co-founded Tomorrow Machine with Hanna Billqvist - told EPPM that the company’s mission is to develop specialised packaging concepts.

“Our vision as designers is to build a better world through research, new technologies and intelligent material. We believe in looking at science from a creative point of view to shape the innovations of tomorrow,” Glansén explained.

This Too Shall Pass, she added, is a series of packaging innovations where the wrapper or carton has a short lifespan like the food it contains, with the package and the food therein “working in symbiosis”.

Tomorrow Machine’s packaging solution for oil-based products is a bioplastic formed of sugars with a wax coating, the idea being that individual portions of oil or other sauces and lubricants can be dispensed by cracking the package like an egg, leaving behind waste material that will degrade in its final environment.

Another prototype is the rice package that is made from a paper-like material and coated in wax, that can be peeled like an orange, dispensing a single portion of the product inside.

Finally, Tomorrow Machine’s smoothie packaging makes use of a bioplastic comprising of agar-agar seaweed which degrades at the same rate as its contents and is ideal for drinks that have a short lifespan and have to stay refrigerated such as milkshakes.

Of course, the advances being made by these busy product designers are a small piston in the wider sustainability engine as far as the environmental impact of spent food packaging is concerned and Glansén believes that the development of biodegradable materials and a better recycling system are necessary to progress both the work the Tomorrow Machine does, and how we dispose of packaging in general.

Glansén said: “We do not believe that there is only one way to solve this issue, we need to look at each product and each problem individually and find the right solution.”

“We started this project by asking ourselves the question, ‘Is it reasonable that it takes several years for a milk carton to decompose naturally, when the milk goes sour after a week?’”

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