EPPM 14.8

October/November 2012

Volume 14 | Issue 08

Fakuma 2012: In review on pages 27-28 www.eppm.com

Images used with kind permission of P.E. Schall GmbH

eppm

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eppm head office Unit 2, Chowley Court, Chowley Oak Lane, Tattenhall, Cheshire, CH3 9GA. Tel: +44 (0)1829 770037 Fax: +44 (0)1829 770047 Web: www.eppm.com

editorial

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32

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editor david gray david.g@rapidnews.com

in this issue

publisher mark blezard

production art samantha hamlyn production peter bartley production adrian price

advertising european sales manager tim guest

MACHINERY

pages 5–18

REGULARS: Latest news roundup New installations

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SHOWCASE: AUTOMATION & ROBOTICS

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SPOTLIGHT: EXTRUSION SPOTLIGHT: TESTING & INSPECTION

12–13 14–15

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MATERIALS

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REGULARS: Latest news roundup

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REPORT: COLLOIDS - THE MAKERS OF MASTERBATCH SPOTLIGHT: CLEANING & PURGING

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FAKUMA REVIEW 2012

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THE GREEN ROOM

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REGULARS: Latest news roundup

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SHOWCASE: RECYCLING

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CLASSIFIEDS EPPM 3

EPPM 4

Alex Collins, Director, Vannplastics Ltd.

John Ellis, Segment Manager Polycarbonate, Bayer MaterialScience

Clive Maier, Owner and Director, Econology Ltd.

Nigel Brown, Founding MD, Frontier Aerospace

Dr Martin Kay, Chief Consultant, Pira International

Jan Herring, Strategic Sourcing Leader, Nokia

Charmaine Bowers, Operations Manager, Polymer Training & Innovation Centre

Pipe Extrusion Recycling Micro Manufacturing Home Appliances

Automotives & Compounds

Mark Bonifacio, President, Bonifacio Consulting Services

Andy Bone, Sales Director, Formaplex

Andrew Smith, Head of Manufacturing, Numatic International

Wire & Cable

Aerospace Biopolymers

Andrew McArthur, Engineering Manager, IKO

Jonathon Short, MD, ECO Plastics Ltd.

Jon Herbert, Director, FS Cables

Biopolymers/Materials Science

Simon Chidgey, Director, M&H Plastics

General Industry Insight

Paul Maley, Senior Mechanical Engineer, Selex Elsag

James Goddard, Honorary Lifetime Member, Plastics Pipe Institute

Dr Terence A. Cooper, CEO, ARGO Group International

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

Advisor for the German & Scandinavian Speaking Countries

Film & Sheet Extrusion Recycling Mould Making

Martin Marron, MD, Biffa Polymers

Graeme Diston, Senior Injection Moulding Engineer, Bausch + Lomb

Sourcing & Manufacturing

Construction

Graham Pickwell, Technical Adviser, Polymer Training & Innovation Centre

Medical

Barry Assheton, Sales Director, CRDM

Packaging

John Bunker, Member, Worshipful Company of Horners

Medical

Rapid Prototyping

Omer Kutluoglu, CEO, 2K Manufacturing

Education in the UK & Ireland

David Gray, Editor

John Sturgess, Director, MG Stuma

Andrew Feilden, Principle Consultant, Smithers Rapra

Wood Plastic Composites

The debate over bioplastics as a future material of choice is not a new one, but it still rages on. And evidently Europe is no exception to the rule — even the European Commission seems to be at odds internally over its stance on the subject! This October I received two press releases (just a few days apart) which point to an executive body which can't quite make up its mind.

The first came from EuPR (European Plastics Recyclers) and included a quote from EU Environment Commissioner Janez PotoČnik during the recent PolyTalk conference in Wiesbaden, who was clearly promoting plastics recycling in Europe. In truth, the EuPR release doesn't set out to be especially 'anti-bioplastic'. However, it did prompt me to look for Commissioner PotoČnik's full speech, which clearly does pick a side of the fence on which to sit. He stated: "At first glance, a quick fix solution for plastic litter may be the use of more bioplastics, including biodegradable and compostable plastic. There is certainly a rapidly-expanding market for bioplastics from a production base which is still very low.

Bioplastics, and in particular biodegradable plastic, certainly have their ideal applications, but at the moment it seems fairly unrealistic to assume that petro-olefin-based plastics could or should be replaced in the mid and long term by bioplastics."

A few days later, my second release came from European Bioplastics - and naturally there was a far more obvious angle in favour of bioplastics in this report.

It cites the European Commission's recent communication on industrial policy, claiming that it "highlights biobased products as a lead market triggering sustainable growth and job creation". And you can see where they got that from — the text does state that "the biobased markets with high demand and favourable legislative framework could make a substantial contribution to the EU’s transformation into a more sustainable economy. The right legislation and framework conditions will, however, be needed to encourage uptake of renewable raw materials for industrial use“. To me, this suggests that biomaterials (plastics specifically weren't referred to in the quote) are on the agenda for the future of European manufacturing - albeit with a degree of trepidation.

My point is that despite the years of arguing over bio technologies, European policy-makers don’t seem to be any closer to making their minds up. Is this because advances in recycling and bioplastic technologies are developing at an equally fast rate? If this is the reason for the indecision, we're not likely to ever see a firm stance — the technology on both sides is just becoming more and more tempting! I'd like to know what you have to say: drop me an email or give me a call — EPPM needs your opinions!

Plastics for the Environment

To bio or not to bio?

Blow Moulding

Recycling

Injection Moulding

from the editor

General Industry Insight

“

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

Dr Gerd Schmaucks, Independent Consultant

MACHINERY

Sumitomo Demag Releases Self-Contained Injection Moulding Cleanroom Cell Sumitomo Demag's new activeCell, a self-contained injection moulding cleanroom, manufactures pharmaceutical and medical, single or multicomponent plastic components to ISO 7 (class 10,0000).

The all-electric compact turnkey system comes complete with platen mounted six-axis robot, laminar airflow cabinets for particle free air in the mould-space area and integral packaging equipment.

It is installed fully compliant meeting GAMP and FDA requirements as well as DQ, IQ and OQ documentation, and offers manufacturers low-investment entry into cleanroom manufacturing.

The system, which is available in 100, 160, 220 and 280 tonne formats, helps manufacturers without a full cleanroom facility to expand into ISO class 7 manufacturing explained Sumitomo (SHI) Demag’s Managing Director Nigel Flowers: “For many medical and pharmaceutical manufacturers a cleanroom facility is often a significant investment, not always essential for their production needs and can be cost prohibitive when looking to expand into niche markets. activeCell is a selfcontained mini cleanroom system designed to address current market requirements for a low investment alternative with complete flexibility at a fraction of the cost of a full cleanroom.”

The compact fully guarded cell, which has been carefully designed to incorporate a platen mounted robot, making the system only 500mm wider than a standard machine, combines technologies from Sumitomo (SHI) Demag’s UK-based technology partners Motoman (robotics), AVT (packaging) and Max Petek (laminar flow hood). The system maintains its ISO 7 class 10,000 cleanroom environment with aid of laminar air flow systems which floods the mould surface and part handling areas with HEPA filtered air. Once parts are moulded, a six-axis robot quickly and accurately transfers product to the conveyor system, chute or packaging system as required. “Over and above its primary purpose, the six-axis robot offers secondary operations including assembly and palletising - a value-add for manufacturers looking for expansion options and fast pay back,” commented Nigel. The final element of the turnkey system is an AVT fully integrated packing system, which bags multiple products in the controlled conditions before they exit the machine.

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

INDUSTRY NEWS Mold-Masters Expands its Direct Sales Network into Turkey Mold-Masters has announced that it has completed the purchase its Turkish distribution agency in order to serve the growing Turkish customer base with a direct Sales and Service office for the full range of melt delivery and process control products and services.

“We are excited by the future opportunity to establish even closer direct ties to our customers in Turkey and to providing even stronger technical and commercial collaboration and better utilizing our global structure” said Armin Traby, Director MasterCARE and Sales and Branch Manager East Europe at MoldMasters.

Taking over leadership of the region from the agency will be Semih Aytar. Semih is an experienced industry expert with ambitious plans to grow the business in Turkey. Mustafa Gevrek, the former agent will continue to support the transition and act as a Snr. Hot Runner consultant in the new Mold-Masters office.

Mold-Masters is now offering the complete range of hot runner and temperature controller technology in Turkey, including its Master-Series and TempMaster-Series brands. With the SPRINT systems for high cavity closure applications and its latest innovation called IRIS for single-step barrier moulding for i.e. caps and thin-wall packing applications, the company offers solutions across all market segments including packaging, medical, automotive, white goods as well as technical applications. Mold-Masters also recently added the MasterPET preform technology to the product and service portfolio in Turkey. This fully dedicated PET product series adds new tools and refurbishing offerings and includes the patented iCool and iFlow technologies. Additional products include the E-MULTI fully electric auxiliary injection units, a unique fast delivery program for standard systems called VELOCITY and a specialty

solutions program called MasterSOLUTION. The new office in Istanbul will further continue to explore the market and continuously strengthen Mold-Masters’ position in Turkey.

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Mold-Masters Tel: +1 800 387 2483 Email: info@moldmasters.com Web: www.moldmasters.com

MACHINERY ROUNDUP Engel’s ‘inject2blow’ Process Reduces Time and Costs Engel Austria, in partnership with Italian group Cantoni, says it has set a new standard for process integration. The inject2blow method, which the two companies developed together, combines the injection moulding and blow moulding processes in one mould on one injection moulding machine and significantly reduces time and costs in the manufacture of cosmetic, drug, and food containers by doing so.

The process reportedly has a cycle time of under 14 seconds for the manufacture of wide-necked jars on a 90-tonne clamping force Engel victory injection moulding machine in a 2+2cavity mould produced by Cantoni.

Preforms normally have to be made using injection moulding first and then subjected to a second process on a blow moulding machine before they become a final product, but the new method allows small, ready-to-use containers to be manufactured in one process. This combination method is the first of its kind available on the market.

Other benefits of integrating the processes include lower system investment costs, a smaller system footprint, higher system availability, simpler quality control, and no maximum clamping force. The inject2blow method can be used to process a wide range of thermoplastics from polyethylene, polypropylene and polycarbonates to PET. Engel and Cantoni supply the integrated production systems from one source. In

addition to the Engel injection moulding machine, they include a Cantoni sliding table mould and an Engel viper linear robot which removes finished parts from the mould. Both the injection moulding and blow moulding processes are visualised, monitored, and controlled via the Engel injection moulding machine CC 200 control unit. This means that injection moulding machine operators don't have to learn how to use new technology; they will instead be guided through the integrated injection and blow moulding process by the Engel control unit which they are already familiar with.

Injection moulding machines from the Engel victory and Engel e-victory series, which are adapted to the individual requirements of the application, can be used in the manufacturing cells. These machines offer plenty of free space for the sliding table mould because their clamping unit does not have a tie bar.

As the mould clamping platens of tiebar-less machines can be used up to their edges or even beyond, large moulds can fit on comparatively small injection moulding machines. Machine size can therefore now be decided according to the required clamping force instead of the size and movement radius of the mould, which keeps investment and operating costs low. The barrier-free mould area also simplifies the automation process, because the robot can access the mould from the side without being hindered.

Unlike traditional two-stage methods,

preforms do not have to be heated up again before the blow moulding part of the process. Ecodrive – the energy saving option for hydraulic Engel machines, which is offered by the Engel victory and e-victory machines – matches consumption levels achieved by fully electric machines. Hydraulic injection moulding machines equipped with the servohydraulic system ecodrive consume between 30 and 70% less energy than comparable machines which don't have this energy saving option, depending on the specific machine and use according to Engel.

Despite the high degree of process integration and automation, manufacturing cells are very flexible when they are in operation. Cavity inserts make it easier to change from

one product to another, and the production of small batches more economical. As the inject2blow process is based on standard injection moulding machines, the system can be used with moulds for classic injection moulding products too.

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

Specialist in Molecular Orientation Provides New Business Opportunities Spanish company Molecor is involved in the development of the technology for applying molecular orientation to pipeline solutions. Molecular orientation is a physical process which modifies the molecular structure of the plastic, whereby amorphous PVC-U structure is re-organised into a layered structure, improving the physical and mechanical properties of this material. When applied to high-pressure water pipelines these become very resistant and have an extremely long life expectancy.

Molecor has developed a technology to manufacture PVC-O pipes ranging from DN 90mm to 800mm and up to PN 25 bar. This new system is air–based which results in a safer, cleaner and more costefficient manufacturing process. The technology can be adapted to any specific need, technical requirement and market standard. For that purpose, Molecor builds long term relationships with its clients to back up every phase of the project, before, during and after the

industrial implementation of its technology.

Molecor not only provides the machinery, but also support to its clients.

This assistance includes among other aspects: studies of PVC-O standards applied in the market, support with PVC-

O certification, technical studies of the installation requirements and full technical advice, start up at Molecor facilities including full training of the client’s staff, start up at the client’s factory to ensure the full success of the industrial implementation, and after sale

Molecor Tel: +34 902 566 577 Email: info@molecor.com Web: www.molecor.com

APPOINTMENTS

Technical Growth for Summit Systems UK–based Summit Systems has announced the arrival of 4 new employees.

Within the company’s Technical Department, Graham Wooldridge has been promoted to Technical Manager and will oversee all technical planning and design across both plastics processing equipment and recycling machinery.

Experienced Project Engineer Richard Dean, has been recruited and Summit says he will be very “hands on” within

services incorporating Molecor’s remote surveillance.

the plastics processing machinery sphere.

Also joining the squad is Chris McCormack; an experienced recycling professional, whose expertise will benefit the technical team in relation to the provision of their increasing recycling installations.

Further growing the Summit family, a Production Manager has been appointed for Boomerang Plastics; Summit’s own recycling line. Richard Last is being kept very busy as the

single line plastics recycling plant continues to develop.

The fourth new addition; necessitated by the increasing amount of business being won, is a Management Accountant to assist the Financial Director.

Summit’s Managing Director, Mike Jordan, said “It has been essential for us to create these new jobs at this time.

Particularly within our Technical Team, who along with our Service and Installation Engineers is our front line.

Summit Systems remains dedicated to

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providing excellent design, project management and support to its customers and we have therefore invested to ensure this happens. We are working closely with our suppliers, developing innovations that will make a significant contribution to cost savings for our customers” Summit Systems Tel: +44 1827 265800 Email: info@summitsystems.co.uk Web: www.summitsystems.co.uk

MACHINERY ROUNDUP INDUSTRY NEWS Renmar Joins Forces with European Groups for Storage and Recycling Solutions Renmar Ltd, based in the UK has recently expanded its product range by entering into an agreement with German company A.B.S. Silound Förderanlagen GmbH. The partnership will allow Renmar to expand in the field of flexible silo systems.

The move means that the group can offer its customers a product that complements the existing Flexible silos from A.B.S. product range of drying equipment, blenders and companies, Renmar’s customers will in conveying systems. Flexible silos offer the future benefit from a strong team an easy, simple and reliable means of with technical know-how and top service storage of different bulk goods. in the area of storing bulk goodssays The Flex-Silos are made from a very Horne. strong and durable “exclusive” fabric Both companies say they are looking which has had to pass many stringent forward to a long and successful tests of quality. With over 50,000 Flexpartnership.

Silos installed worldwide, A.B.S. is said More recently Renmar has also added to be one of the most experienced and to its range of recycling equipment by successful specialists in this area. entering into an agreement with Austrian “With A.B.S. Silo- und Förderanlagen group ARTEC machinery GmbH. ARTEC GmbH we have found a partner who is manufactures recycling machinery for already successfully established in thermoplastic waste. These plastic Europe and who has almost 30 years of recycling plants have been installed experience in the area of silo storage”, worldwide for: said Kevin Horne, Managing Director of • Inline recycling Renmar.

• In-house recycling Thanks to the co-operation of these two • Post-consumer recycling ARTEC develops and builds plants and The ARTEC 125 V with single degassing supplies tailor-made solutions for all system recyclable thermoplastics. The addition of the range will complement Renmar’s existing portfolio of recycling machinery from Amut and shredder/granulators from Cumberland.

Renmar Tel: +44 844 6933225 Email: info@renmarltd.com Web: www.renmarltd.com

B&B MAF Launches Bag-Making Line for PE Film

Packaging equipment specialist B&B has released a bag/sack maker dedicated to the conversion of PE materials.

The unit is able to process materials including: • PE/PE laminates (4-6.5 mm, respective 90–180 microns) • Mono PE, PE/CPP • Coex PE, PE/PET/PE The SFS is designed for the production of edge seam or quad seal bags, as well as flat bags. The bag forming takes place on one flat film roll.

Precise cross bottom sealings and bottom corner (mitred) sealings can be done on the SFS. As another benefit a professional stacking device is installed at the machine which allows the customer to have proper bag stacks for easy tacking over to the packaging process.

B&B MAF Tel: +49 5458 7930 Email: mail@bub-maf.de Web: www.bub-maf.de

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MACHINERY ROUNDUP New Mould Heater Controls Temperature and Cost A new water temperature control unit from process cooling specialist, IsoCool, is said to boost cycle times, productivity and product rate.

The new EWTC thermoregulator boasts a range of features, such as solid state relays and PID control for temperature accuracy, designed to optimise manufacturing efficiency. The EWTC is reportedly offered at a highly competitive rate, making upgrading more achievable and maximising return on investment.

Ensuring precise temperature control for injection moulding machines, cylinders and extrusion barrels is key to improving product success rates. In the EWTC this is said to be achieved via intelligent PID control, which regulates process temperature to better than +/1°C during heating and cooling phases.

This constant monitoring of process

temperature makes the EWTC particularly beneficial to systems with variable loads, as it automatically helps the unit to compensate for any changes.

In addition to advanced microprocessor technology, the EWTC comprises an indirect heat exchanger for process cooling, and solid-state relay controlled immersion heaters for quiet, reliable and fast operation. The solid-state heater switching – combined with the PID controller – is also said to offer fast ramp-up time with minimal overshoot. A submersible centrifugal pump ensures that the process fluid circulates at a constant pressure and flow rate.

The EWTC also features an audible alarm, which sounds if the temperature falls outside of the desired range.

Furthermore, in the event of a leak a mould leak stopper is included to act as a failsafe mechanism. The controller has

an easy to read LED display, a mould drain system, which saves time during mould changes, and automatic water make up for ease of use.

Isocool Tel: +44 1376 328455 Email: info@isocool.ltd.uk Web: www.isocool.ltd.uk

Packaging Producers Can See Clearly with IML Film

Kiefel Gets Back to Basics with New Forming Machine

Printing specialist Verstraete has developed a super-transparent film that makes it possible to leave sections of an in-mould label transparent, creating a see-through packaging effect.

By leaving sections of the label without lacquer, ‘SuperClear IML’ allows for transparent areas, creating the illusion of no IML label at all in certain parts of the packaging.

Verstraete states SuperClear IML provides the injection moulder and the brand owner with great flexibility. The technique is said to allow an infinite number of different IML looks to be created with the same keyline. If the brand owner wants to switch to a label that has a different shape, the company states there are no further costs required for reprogramming the IML robot.

With this technique Verstraete says it is also capable of creating the illusion of a floating label. This label is only printed on the upper part of the packaging, something which would be a huge challenge - or even impossible - with a standard white IML label.

By only printing the upper portion of the SuperClear label, the label appears to be floating. However, the label is actually injected underneath the IML base layer so that it can be processed easily.

The KMD 78 BASIC automatic pressure forming machine is the latest addition from thermoforming expert Kiefel to its KMD series.

According to Kiefel, it is a particularly costefficient variant, which supplies “just the right amount” of forming technology to cover a wide range of components.

Equipped with HTS ceramic heaters for the consistent distribution of heat-output, with toggle drive and motorised upper-yoke adjustment for both the forming and cutting stations, KMD BASIC has been designed to meet the essential requirements for cost-efficient production of formed components.

Tension bars help ensure play-free movement of the drive components and accurate repeatability of cutting procedures. A newly-developed, twostage cutting system provides a particularly accurate cut. The fullyadjustable stacking unit operates from bottom to top, while the formed components are placed onto a conveyor belt.

Fast reconfiguration to cope with different product formats has been

Verstraete Tel: +32 50 301 301 Email: info@verstraete.be Web: www.verstraete.be

Kiefel Tel: +49 8654 78 182 Email: kiefel@kiefel.de Web: www.kiefel.de

INDUSTRY NEWS

Coperion Acquired by US-based Industrial Firm Hillenbrand, Inc. has agreed to acquire the Coperion Group, Stuttgart, Germany.

The transaction is anticipated to close by December 31, 2012, subject to regulatory approvals. Hillenbrand, Inc., is a US-based, strategic global diversified industrial company, publicly listed on the New York Stock Exchange and will acquire Coperion from Deutsche Beteiligungs AG, a leading German private equity company.

Coperion will be part of Hillenbrand’s Process Equipment Group (PEG). The PEG is a recognised leader in the design, production, marketing and servicing of equipment and systems used in processing applications for a

designed for fast tool-changeovers in the forming and cutting stations. Horizontal adjustment of the spindle drive permits efficient length-adaptation of the corresponding formats.

The KMD 78 BASIC is equipped with a touch-screen Siemens Simotion control system.

The unit can handle a maximum formsize of 760 x 540 mm, with a negative/positive formed-component height of up to 150 mm and a maximum film-width of 810 mm.

wide range of industrial markets. Its three operating companies are K-Tron, which focuses primarily on feeding and pneumatic conveying equipment; Rotex, a manufacturer of separation equipment, including gyratory and vibratory screeners and sifters; and TerraSource Global, which makes size reduction equipment, conveying systems and screening equipment, operating under the three brands Pennsylvania Crusher, Gundlach and Jeffrey Rader.

“Coperion is an international market and technology leader with a remarkable global network – in manufacturing and engineering as well as sales and services. This acquisition will enhance

Hillenbrand’s growth strategy and strengthens our position in key markets such as the plastics, chemicals, food and minerals industries. Both companies share a common vision of the future for the process equipment industry.” said Joe Raver, President of Hillenbrand’s Process Equipment Group.

“For Coperion this change of ownership opens up new opportunities in markets beyond the plastics industry. It will also strengthen our business in the areas where we have been engaged in strategic execution over the past years: to reduce our dependency on the polymer industry business, expand our

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global sales and service network and product offerings, develop turnkey process solutions with our own system and process competence, and to improve earnings resilience. We look forward to this new partnership with the Process Equipment Group and their companies, because our companies are so closely aligned from a strategic pointof-view. We believe that we have a perfect strategic match.” said Guenter Bachmann, CEO of Coperion.

Coperion GmbH Tel: +49 711 897 0 Email: info@coperion.com Web: www.coperion.com

MACHINERY ROUNDUP Exact Position Monitoring Possible with New Limit Switch Mould components specialist Hasco has launched a new limit switch used in injection moulding tools to exactly monitor the position of the ejector assemblies.

The company states the new ‘Z1420/…’ works through precise control of the end position, meaning costly mould damage can be avoided. There are said to be many additional applications for the limit switch in the construction of tools and appliances where it is vital to determine the exact end-positions – for example with moving cores and stripper plates.

The Z1420/… has an extremely flat design. The working height of 3–5 mm

can be individually adjusted via a hexagonal spanner and a 1 mm spacer. Subsequent assembly and dismantling is also possible on the injection moulding machine.

With its moisture sealing to IP41, a maximum service temperature of +80 °C and a supply voltage of max.

VAC/24/VDC, Hasco states the limit switch Z1420/… offers optimal conditions for a controlled injection moulding process.

Hasco Tel: +49 2351 9570 Email: info@hasco.com Web: www.hasco.com

Gammaflux Launches High-Performance Temperature Control System Manufacturer of hot runner temperature controllers for the plastics processing industry, Gammaflux, has launched a new temperature control system, which it states combines improved performance with a smaller footprint.

The G24 temperature control system is said to be simpler to operate, less expensive to run through the use of fewer electronic components and smaller, taking up 48 % less floor space than the company’s TTC controller.

Gammaflux states input/output interfaces to the injection moulding machine ensure that no reject mouldings are produced and no serious damage can occur to the mould. Due to its screen input facility, the G24 software is said to simplify the interlock between the mould and the machine and also interlock simulation during machine set-up prior to commencement of production.

Gammaflux Tel: +1 800 284 4477 Email: info@gammaflux.com Web: www.gammaflux.com EPPM 9

SHOW AUTOMATION & ROBOTICS Wittmann W822 Robot Offers New Moulding Solutions The Wittmann Group has launched its long awaited W822 robot model. The W822 will now serve as the entry model for small to mid-size plastics moulding operations that can involve significant degrees of complexity such as handling a higher payload and carrying out mould insert work.

The chief technical difference of the new W822 within the W82x series of robots is a rack and pinion drive for the vertical axis. The W822 can handle 15 kg of

payload on strokes of either 1,000 mm or 1,200 mm and 12 kg when fitted with the 1,400 mm axis option.

In many other respects the W822 provides the same mechanical dimensions as the W821 model. A horizontal axis of up to 4,000 mm is possible and the W822 can be fitted with numerous automation features from the Wittmann automation stable, such

PMM Signs Distribution Agreement for Max-Robot UK Sales UK-based Premier Moulding Machinery (PMM) has announced that it has signed an exclusive distribution agreement for the UK and Ireland with the Chinese robot manufacture Ningbo Well-Lih Robot Technology Ltd (better known as Max-Robot), following an initial partnership building period.

Richard Hird, PMM Sales Director, explained: “It is common for Chinese companies to work with partners for a period of time prior to signing official agreements, as they like to get comfortable with the company and more importantly the people they intend to work with before they commit themselves.”

Max-Robot Chairman, William Qiu, commented on the partnership with PMM: “We are pleased to sign this distribution agreement with PMM. During the past 12 months, the trust and support for our products and service between both sides made the decision to sign the distribution agreement a natural one.

We will devote ourselves to providing the best turnkey solution for the customer in the UK plastic industry, together with PMM. This will meet the increasing requirement for the quality and efficiency of production, to ensure our customers gain the advantage in a competitive market sector.”

Over the last 12 months PMM has installed a number of Max Robots as part of turnkey packages alongside its other UK partners — Haitian and Zhafir moulding machines and FASI material handling equipment.

Recent packages include a Haitian Mars 800t, complete with a Max-Robot EBW20 series full servo robot and FASI material

also be easily accessed through the R8.2 control for a single point of control.

Martin Stammhammer, Sales Manager Robots and Automation Systems said: “The W822 robot is the latest in a comprehensive revamp of our Wittmann automation range. Much of this work has been inspired by an increased customer need for more automation performance beside-the-press – increased payload, performance and flexibility. Wittmann automation is enabling moulders of all kinds to be more ambitious in their production work – while at the same time resting secure in the knowledge that their robots have the capacity to handle increased payload and complexity.

However equally important and the main focus of every design effort, is the easy access to all functions through the R8.2 control system.”

Wittmann Tel: +43 1 250 39 0 Email: info.at@wittmann-group.com Web: www.wittmann-group.com

Powerful and Precise New Lightweight Arm Launched by Schunk

conveying system for a customer on the south coast. Other projects that are to be installed within the next few months include a 470T and 1000T Haitian machine with Max-Robot EBW20 and ECW15 series full servo models, and an over moulding project based on two off Zhafir Venus series All Electric machines with two off Max-Robot EA04 fast servo driven units.

PMM are working in close partnership with PC Moulding and Automation to assist in promoting and supporting MaxRobot within the UK. Peter Crossley recently commented: “To partner PMM is a very exciting opportunity, as we share the same total solution philosophy with state of the art equipment.”

Richard Hird continued: “We are equally excited to add Max-Robots to our portfolio, as they have proven to be an invaluable asset to our ability to provide the complete moulding solution, especially given their wide product range of standard units and special applications such as In-Mould Labelling.”

Premier Moulding Machinery Tel: +44 1296 658638 Email: richard.hird@pguk.net Web: www.pmmuk.net

as servo rotational axes, spare I/Omodules and vacuum and gripper circuits.

Wittmann has developed and launched the W822 in response to moulder needs for greater payload and versatility around small to mid-sized moulding machines of up to 400 tonnes of clamping force. Thus far the entry level robot for insert application work has been the W832 robot. This model however is generally too big on moulding machines of less than 200 tonne clamping force. The W822 robot now allows users a superior automation performance around the small and mid-size moulding machine range.

The W822 comes as standard with the universal R8.2 robot control from Wittmann. This includes real-time functions such as SmartRemoval, EcoMode, intelligent vacuum systems with teachable switchover levels, SoftTorque and many other advanced features. All related and attached downstream moulding operations can

Schunk, a supplier of clamping technology and gripping systems, has launched a new Powerball-Lightweight arm, the LWA 4.

The LWA 4 features a weight/payload ratio of 2:1 and is said by Schunk to be one of the most high-powered lightweight arms in the world. At a dead weight of 12kg, it can handle loads of up to 6kg and has a gripping radius of more than 700mm. With the compact design of the front end or wrist joint, the arm can be easily maneuvered in close spaces.

Schunk states the LWA 4’s excellent repeat accuracy of 0.06mm provides for high process stability for demanding measuring and testing tasks. The design also prevents dangerous crushing and shearing movements, making it safe to use around people.

Central elements of the lightweight arm are three compact ERB Powerball modules, which combine the movements of two axes. The entire electronic control and regulation circuitry is integrated in the joint drives. Position, speed and torque can be flexibly regulated. An innovative quick-change system with integrated signal feedthrough allows for fast and easy commissioning of the Plug and Performance gripping system. Since the supply lines for the gripper and tools are completely within the module, there are said to be no interfering cables on the peripheral devices. With integrated intelligence such as universal communication interfaces and cable technology for data transfer and power supply, the arm can be quickly and easily integrated into existing control concepts. The manipulator is

EPPM 10

supplemented by an industrial robot controller with an integrated CoDeSys PLC. The 24V DC supply voltage enables mobile use as well as use at alternate locations. Schunk states consistent lightweight construction and state-of-theart torque motors keep the energy demands of the lightweight arm down to an average of 80W. This consequently lowers energy costs, provides for longer work periods when using rechargeable batteries and also allows the use of small-format batteries.

Schunk Tel: +44 1908 611127 Email: info@gb.schunk.com Web: www.schunck.com

WCASE ATM Assembles Diverse Range of Automation Technologies The increasing use of technical plastics for complex components, especially within the automotive and medical device industries, has led to a growing demand for more sophisticated automation solutions. Product ranges now offer everything from a simple gripper, through to complex fully automated assembly cells often incorporating multiple technologies.

ATM, a supplier of automation and robotics across many sectors of the plastics industry, has seen a marked change in the typical automation systems in the last 30 years. In the 1980s the typical automation system supplied by ATM would include a threeaxis Cartesian robot, gripper, conveyor and safety guarding. By comparison, systems supplied today, for the optics and medical device industries, incorporate rotary indexing systems, precision fixturing, six-axis robots, vision systems for inspection plus additional processes specific to the application, all driven and monitored using a PLC or PC based control system.

ATM still sees a demand for its range of ES three Axis Cartesian robot systems, however, the company says even this type of robot is being integrated into ever more sophisticated systems. Its range of 6 and 7 axis robots

compliments the Cartesian systems offering greater flexibility for access into hard to reach areas, component re-orientation and assembly tasks.

ATM states the benefits of six axis technology can be seen in a recent system it supplied for the production of automotive components. Here the robot performs multiple operations including component manipulation, picking parts from vibratory bowl feeders, plus insertion and assembly operations.

Even in manual assembly applications, the requirements to guarantee quality, consistency and traceability mean that the once simple assembly workstation now often incorporates a range of technologies such as bar code scanners, vision inspection systems and label printers in addition to intelligent component fixturing.

These features combine to provide the levels of Poka Yoke demanded for example by the automotive industry.

ATM Automation Tel: +44 116 277 3607 Email: sales@atmautomation.com Web: www.atmautomation.com

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MACHINERY SPOTLIGHT eppm

EXTRUSION

TWIN-SCREW EXTRUDER TAILORED FOR HIGHLY-FILLED MASTERBATCH COMPOUNDS

KraussMaffei Berstorff has optimised its ZE-UT-R twin-screw extruder series by adding new features for compound filling.

This technical improvement is the result of systematic research work performed in close co-operation with renowned compound producers.

“In the course of the last two years, KraussMaffei Berstorff has already sold 15 lines for the production of highly filled PE or PP compounds with a talc or chalk share of up to 80 percent”, said Dr. Thomas Winkelmann, Head of Twin-Screw Extruder Process Technology at KraussMaffei Berstorff in Hannover.

These compounds are used in the production of blown film for carrier bags, sacks or construction film, for instance. “Thanks to their excellent mixing properties and the high concentration of functional additives that offer unparalleled logistic and economic benefits, highly filled compounds are used to an ever increasing extent as masterbatches for

film and sheet production”, explained Dr. Winkelmann.

The deep-flighted ZE-UT-R series exhibiting a D/d ratio of 1.74 and a correspondingly large free volume is particularly suited for the production of highly filled compounds. The available free volume is especially beneficial as high filler quantities or fillers of low bulk density must be mixed in. In addition, the high filler shares of up to 80 percent require long processing sections to ensure that the filler particles are perfectly incorporated into the plastics matrix. This is why the ZE extruders tailored for this task feature processing section lengths ranging between 50 and 56 D. Further highlights of these lines are the type of product addition and the number of metering systems used. In addition to the polymer in granular form and various additives, the filler material is partly introduced in the feed zone as well. The residual filler quantity is subsequently added in different portions via two side feeders arranged along the processing section.

The type and number of degassing units is of particular importance for these applications. The introduction of fillers automatically involves the inclusion of air between the particles, which is eliminated from the

processing chamber by means of three atmospheric degassing systems and one vacuum degassing unit.

The screw geometry is tailored to the specific design of the feed, degassing and mixing zones. The melt pressure required for pelletizing the well homogenized but highly viscous melt is built up by a gear pump of appropriate

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rating that is arranged at the discharge end of the extruder. The downstream underwater pelletizing system subsequently produces the final masterbatch pellets.

KraussMaffei Berstorff Tel: +49 89 88 990 Web: www.kraussmaffeiberstorff.com

MACHINERY SPOTLIGHT

High Tech HIGH TECH Extrusion, an EXTRUSION Austrian LAUNCHES specialist in extrusion lines, CONTROL SYSTEM tools and pipe AVAILABLE FOR heads has RETROFIT announced the launch of a new extruder control system, branded TEC 4s, and developed in cooperation with Siemens. An operating terminal

optimised for heavy industrial conditions enables control of the whole extrusion line in combination with HMI-Software.

The 19" touch screen has been designed for ease of operation with large soft-keys and intuitive colour and graphic design. The core of the new Theysohn Extruder Control System is a, fan-less, maintenance-free industrial-PC. The communication between the TEC 4s and all drives, peripheral devices and the downstream equipment works through the PROFIBUS bus-system.

Operational reliability and short down time are achieved by simple wiring, highclass components, an analysis program and remote maintenance via LAN and/or WAN. Retrofitting is possible following a check for compatibility with the main drive and dosing unit. Space requirement for the new control cabinet is assessed whereupon the existing control cabinet is replaced together with the installation of the 19” touch screen. This solution provides an upgrade to a new

Reifenhäuser Kiefel Extrusion has added a new highperformance cooling system to its new ‘Evolution’ blown film line generation.

The company states this advance will make it possible for film manufacturers to significantly increase output capacity.

The new Evolution Ultra Cool design is said to evenly cool from inside and out, with a heightadjustable cooling ring and an aircooled inner cooling system that optimise the air conduction inside the bubble, keeping the bubble stable even at high throughput. The system’s high cooling capacity is said to permit a die factor well above two, making it possible for manufacturers to produce more efficiently.

Reifenhäuser Kiefel states due to the high bubble stability, low thickness and width tolerances are possible even at high throughputs. Short startup times and job changeover times ensure that high-capacity production is efficient.

Priorities in the development of the Evolution Ultra Cool were not only improved performance, but also the user-friendliness of the line. Optimised cooling elements and a heightadjustable cooling ring are said to ensure that the line can be started up and operated during production.

The cooling system can be used for numerous film applications including general packaging film, collation shrink film, stretch hoods, hygienic packaging film, and stand-up pouches.

NEW HIGHPERFORMANCE COOLING SYSTEM FOR FILM EXTRUDERS

Reifenhauser GmbH & Co. KG Maschinenfabrik Tel: +49 2241 23510 0 Email: otto.kuhl@reifenhausergroup.com Web: www.reifenhauser-group.com

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management system for the entire extrusion line with its existing components whilst the overall investment remains manageable in comparison with the acquisition of a new extruder.

High Tech Extrusion GmbH Tel: +43 59 692 2210 Email: heinz.w.ebner@htextrusion.com Web: www.ht-extrusion.com

MACHINERY SPOTLIGHT eppm

TESTING & INSPECTION

Colour management specialist XRite has introduced the SpectraLight QC light booth and a training institute to give manufacturers a way to visually evaluate the colours of samples for production readiness, helping to bring products to market quicker and reducing waste.

The SpectraLight QC reduces the rate of sample rejections at multiple locations by providing better consistency of light sources and standard conditions under which the color of products are assessed visually.

The result is improved speed to market and reduced overall costs.

SpectraLight QC gives Quality Control managers new monitoring and reporting tools to more precisely control and communicate how visual assessments of samples are performed.

SpectraLight QC provides a costeffective way for companies to evaluate how the colours of products look when they are placed under the same illumination as where they are sold or

X-RITE LAUNCHES QC LIGHT BOOTH TO IMPROVE TIME TO MARKET FOR PLASTIC PARTS

used — illumination that is often specified by customers to ensure the same controlled conditions are used within their supply chains. In many cases, end users want quality control personnel and lab technicians to make judgments on the suitability of sample colours using their eyes rather than just numerical values from instrumentation.

X-Rite designed the SpectraLight QC to provide tightly calibrated illumination that ensures consistent and reproducible results, flexibility to deal with new international standards on very light and dark samples, and automation to speed the testing process and reduce instances of record-keeping mistakes.

The new light booth uses built-in sensors to monitor and automatically adjust fluorescent lamp light levels, compensating for the diminishing lux due to age and wear.

The ultraviolet light source of every SpectraLight QC is precisely calibrated at the factory and built-in sensors automatically monitor and correct UV content as the booth operates. Users can also control the amount of UV if desired for evaluation of samples containing varying levels of optical brighteners. This real-time monitoring and control provides a higher level of inter-instrument agreement, aligning visual assessment environments

throughout a supply chain.

With a modest amount of training, quality control or quality assurance personnel can create and save profiles on personal computers that detail which seven available light sources that brand owners specify when evaluating products. When performing evaluations for specific brands, only the preferred settings are available, potentially eliminating compliance problems across

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a supply chain. Companies can seamlessly and digitally share performance data on their SpectraLight QC units with their customers to satisfy ISO or other international quality standards.

X-Rite GmbH Tel: +41 44 842 2623 Email: lchin@xrite.com Web: www.xrite.com

MACHINERY SPOTLIGHT

Proco Machinery, PROCO a leading LAUNCHES supplier of TAKE-OUT UNIT automation WITH DEFLASHER systems for the plastics AND LEAK container TESTER industry, has

pending Robopik Plus, which is an upgraded version of Proco’s original Robopik model, accommodates a wide range of shuttle extrusion blow moulding (EBM) machines (including Bekum H style) without modification or adjustment.

launched the industry’s first integrated take-out system which incorporates a deflasher and leak testing system for space savings and reduced cost. The company demonstrated the new all-in-one multifunctional system earlier this year at NPE 2012.

“Our new technology has taken the take-out system to a new level, providing a reduced footprint and substantial cost savings, since processors don’t have to purchase all three machines separately,” said John McCormick, President of Proco Machinery. The company’s patent-

Proco Machinery Tel: +1 905 6026066 Email: info@procomachinery.com Web: www.procomachinery.com

The 1000kN Universal Testing Machine Q1000 by instrumentation specialist Qualitest is reported by the company to be fully equipped with many advanced technical features, and high quality of production to meet the highest demands for quality control and R&D material testing in the fields of metals, plastic, textiles, cement, concrete and more.

The Q1000 Series Universal Testing Machine ranges are designed for quick and reliable tensile, compression, flexural (bending), shear, peel, fatigue cycling, and constant load tests on metals, composites, alloys, rigid plastics and films, elastomers, textiles, paper, board and finished products.

Programming the test and monitoring the results can be controlled and performed through the GraphWork5 test software which allows complete and accurate data management according to North American, European and International test standards.

This instrument is suitable to be used in both production lines, where the operator has to be fast and efficient, and accurately control the test, as well as in testing lab environments, where using the advanced software, the users can analyze the test data, and have full control on processing, filing, management and transmitting the test data to the company network and database, plus using many more functions.

QUALITEST INTRODUCES A UNIVERSAL TESTING MACHINE

Qualitest Tel: +1 877 884 8378 Email: info@qualitest-inc.com Web: www.worldoftest.com

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New Installations

Propac Achieves Record Cycle Speeds with Illig Thermoforming Machine During the spring of 2012, Propac Thermoforming, based in the Northwest of England, added an Illig RD 53d thermoforming machine to its existing fleet of machinery. The group says it is already achieving stunning performance figures from their recent acquisition — these figures would have appeared to be impossible before.

Utilising an existing tool set, previously installed on an Illig RD 53 machine which ran at 40 cycles per minute, within a very short period of time, the RPET product is now being produced at 58.8 cycles per minute.

Illig UK explained that the main reason for the improved performance was due to the Illig Design Department in Germany listening to customer feedback. The group then considered all

the advantages related to the RD 53 and incorporated new ideas such as a refined process optimisation control system, and an improved motor drive on the punching station.

Further options available, (which may not improve performance but do improve efficiency) are HTSs heater elements and a low maintenance vacuum pump.

Propac has been extremely impressed with the vastly improved outputs of the RD 53d machine. “Whilst the older RD 53 machine achieved very good outputs we are now finding that all existing tooling achieve increases of outputs in the order of 20% - 50% when installed

on the new RD 53d machine” said Malcolm Gillies, MD of Propac, when asked for his comments.

Illig UK Tel: +44 1767 310555 Email: sales@illig.co.uk Web: www.illig.co.uk

Wittmann Battenfeld Gets Playful at Fakuma Fakuma 2012 was a complete success according to Wittmann Battenfeld. One of the highlights of this year’s event was an order for 14 3-component machines from geobra Brandstatter GmbH & Co.KG, based in Zirndorf, Germany.

Following the delivery of 30 injection moulding machines in 2011, including integrated parts removal robots, conveyor belts and peripheral equipment for upstream and downstream processing, the long-term cooperation has now been extended by adding multi-component technology. By placing the order for 14 HM 65/210H/210V/210S 3component machines on the third day of the fair, the longstanding Wittmann Battenfeld customer geobra Brandstatter will now utilise Wittmann’s multi-component equipment. “The way the exacting customer demands were met in terms of quick mould change, compact design and user-friendliness of the machines tipped the balance in favour of Wittmann Battenfeld”, said Robert Benker, Technical Managing Director at geobra Brandstatter. The multi-component machines, which will be used to produce parts of Playmobil figures, are to be installed at geobra’s Dietenhofen facility by the end of the first quarter of 2013.

Left to right: Johann Sturzenhofecker, Department Head of Injection Molding at geobra, Gottfried Hausladen, Sales Wittmann Battenfeld, Georg Tinschert, Managing Director of Wittmann Battenfeld, Dr. Werner Wittmann, Managing Director and owner of the Wittmann group, Robert Benker, Technical Managing Director at geobra, Enrico Dommer, Department Head of Injection Molding Lechuza.

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

Polyamide-6 Producer Invests in Underwater-Pelletizing from BKG Xentrys Leuna GmbH, part of the Belgian DOMO-Group, is expanding its capacities for polymerisation of polyamide-6. Underwater-pelletizers of BKG Bruckmann & Kreyenborg Granuliertechnik GmbH have been selected this application, offering new possibilities in the continuous process of polymerisation. According to BKG, it was relatively easy for the engineers from Leuna to decide on the machines from Muenster as the group has been active in equipment for the process of polymerisation for 15 years.

Despite the identical process technology during the polymerisation, polyamide can behave differently in the pelletizing process. It is not enough to carry out a pilot plant trial as the residual monomer content and various substance properties of the polymer bulk can only be simulated to a certain degree. As well as the selection of materials for the

die plate and the blades, the procedural arrangement and construction of the components play an essential role.

Due to space requirements and technological innovations, the functional interaction of the melt valves beneath the reactors with the gear pumps, the melt filters and further auxiliary equipment was also a tough challenge. These difficulties were resolved by process technicians from KVI Weber, a leading representative in North Germany for processing machinery for the polymerization, extrusion and compounding industries.

BKG Bruckmann & Kreyenborg Granuliertechnik GmbH Tel: +49 251 26501 0 Email: info@bkg.de Web: www.bkg.de EPPM 17

MACHINERY ROUNDUP REPORT What you should know about Plastics Industry Insurance A specially commissioned piece on this important subject In the plastics industry it’s essential to have the right insurance in place. The first step towards best practice is appointing a broker who has an extensive understanding of your business. An insurance broker’s role should be to thoroughly asses your business and use their experience and knowledge to present the risks to insurance companies. The ultimate aim of the insurance broker should be to secure you the best deal at the best price.

How insurers assess your business A plastics factory can be a dangerous place and although the risk of fire is probably no more than several other industries, if a blaze does occur there’s the added danger of causing corrosive and toxic fumes, together with running fires which can be caused by the low melting point of the material.

Due to this risk, the majority of insurance companies will expect to visit and assess your business themselves, usually by sending one of their own insurance surveyors. This is generally done before an insurance quotation has been drawn up so the insurance companies can gain a thorough understanding of your business and your insurance needs.

Dependent on the scope of the insurance you are planning on taking out, a survey will normally cover the following: • Premises – including your own building’s construction and location, as well as its proximity to other buildings.

• Occupation – who occupies the building, associated controls and trade hazards.

• Protections – the available fire protection systems such as sprinklers and the proximity of emergency services.

• Extended Perils – this includes floods, storms, accidental damage, impact and other perils that can’t be predicted.

• Security – the security measures you have in place such as CCTV, alarm systems or security staff to reduce the risk of a break in.

• Business Interruption – assessing how long your business is likely to be interrupted if damage is caused to your building.

• Liability risks – this could include extensions you may need to make to your policy, such as including courier insurance for the transportation of goods and a review of your health and safety policy.

The benefits of insurance surveys In general an insurance survey will be commissioned by the insurance company, but there are many benefits for the business owner too. A visit from a broker will let you know that the insurance company you choose has a thorough understanding of your needs. You’ll be able to discuss your business in detail and highlight any particular risks that may not apply to similar businesses. In addition the insurance broker will be able to make suggestions as to how you can improve the security of your business based on their experience of similar ventures. Many brokers will provide risk information and risk improvement advice to enhance your existing health and safety arrangements and ultimately reduce the price of your policy.

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Reducing your insurance premiums There are several ways that you can ensure you get the best possible price for your insurance policy. Firstly, pick a company that has an ‘underwriting appetite’ for the particular sector your business is in. different plastics insurers focus on different sectors so do you research and choose one with expertise in your area.

Due to the high risks involved, mainly because of the use of heavy machinery and the possible devastating effect of fire, the plastics industry is often more heavily scrutinised than others, so it pays to have a comprehensive and up to date health and safety policy.

Firms with inadequate risk assessment and health and safety documentation are likely to be charged higher premiums and could even find themselves uninsurable until adequate documentation is drawn up.

The insurance business is highly competitive with hundreds of different companies all vying for your business. In order to get a well-rounded view of the market you need to find out what all the different companies are offering, so spend time approaching different insurers, finding out about their policies and getting quotes so you’re in a good position to decide which is the best company to go for.

As with any insurance policy, the easiest and most effective way to reduce the cost of your policy over time is to stick with the same company and avoid making a claim. The most effective way to do this is by regularly assessing the risks associated with your business and making any necessary improvements to the safety and security of your premises and your staff, so you can avoid accidents and continue to reduce the cost of your insurance year on year.

MATERIALS

RTP Company Adds Antimicrobial Compounds Using ‘Bactiblock’ Additive

Global custom engineered thermoplastics compounder, RTP Company, has expanded its line of antimicrobial compounds and additive masterbatches to include new products using BactiBlock technology from NanoBioMatters of Valencia, Spain.

Efficacy testing has proven the naturally sourced, silver-functionalised clay BactiBlock antimicrobial additive to be compatible with a variety of thermoplastic resin systems including ABS, nylon 6 and 6/6, polypropylene, polyethylene, olefinic thermoplastic elastomers, and EVA with evaluation in other polymers ongoing.

“Additive masterbatches and custom compounds using BactiBlock are an exciting addition to RTP Company’s family of antimicrobial products because its unique clay carrier provides a very efficient and durable delivery system for silver ions to effectively protect plastic articles against degradation,” said Jean Sirois, General Manager of RTP Company's Colour Division.

Products incorporating BactiBlock are said to be fully colourable, easy to disperse and process at normal polymer temperatures. Loading levels vary by application and can be tailored to enduse environments to maintain desired effectiveness.

Demand for silver-based antimicrobial solutions, such as BactiBlock, are increasing due to their effectiveness at protecting polymers from degradation while being widely recognised as safe for human contact. Antimicrobial additives can be used to combat the growth of microbes like bacteria, fungi (mould and mildew), and algae that left unchecked can cause unsightly discoloration, unpleasant odours, or other polymer degradation issues.

Clarifying Agent Adds Clear Appeal to New Food Storage Range Milliken’s Millad NX 8000 clarifying agent has been chosen for Sunware’s new EClaire Fresh keepers food containers.

The Netherlands-based storage solutions creator set its sights on polypropylene (PP) clarified with the additives specialist’s newest technology clarifier in place of other high transparency plastics, in order to offer consumers a new line of Bisphenol-A free (BPA-free) food storage boxes with high visual impact and functional benefits. Quality and aesthetics are key priorities for Sunware’s ranges.

Millad NX 8000 is claimed by Milliken to be unique in achieving transparency in PP similar to that of amorphous polymers. This enabled Sunware to develop crystal-clear packaging with excellent aesthetics, while benefitting from PP’s easy processing, sealability and high stiffness performance, and environment-related advantages. Millad NX 8000 supports lower injection moulding temperatures for clarified PP, resulting in shorter cycle times and a faster, more sustainable production process for the new storage range.

The clarified PP is used for both lids and containers in sizes from 0.5 litres to 3.8 litres, designed in line with Sunware’s mission to develop storage solutions

that provide a ‘perfectly organised’ feeling to consumers.

The E-Claire Freshkeepers are microwaveable, dishwasher-proof and BPA-free.

André Jacobs, Technical Director at Sunware, commented: “Food storage solutions compete in a crowded market place and we were therefore on the lookout for a material that could give a high-clarity appearance and functional edge to our new product line. We were delighted that the introduction of high transparency PP coincided with our own development schedule, as no other random PP is so transparent. With Millad NX 8000 we have been able to use PP to take the visual appeal and performance of this new line to a whole new level.”

Sami T.K. Palanisami, Marketing & Sales Manager Plastic Additives EMEA,

RTP Company Tel: +1 800 433 4787 Email: rtp@rtpcompany.com Web: www.rtpcompany.com EPPM 19

Milliken, added: “Millad NX 8000 is creating exciting new opportunities for packaging converters and brand owners to use PP as a viable replacement in high transparency applications. By eliminating the haze and yellowing potential of standard PP materials, it is revolutionising the way the industry perceives PP for high-end products.”

Milliken Tel: +32 9 265 11 00 Email: eurochem@milliken.com Web: www.millikenchemical.com

MATERIALS REPORT

Masterbatch in the Automotive sector A report by Bob Thomas, Technical Director, Colloids Where will you find Colloids’s products in the automotive sector?

It would be easier to turn the question on its head and ask where don’t we feature, Colloids pioneered masterbatch companies in attaining the demanding ISO/TS 16949 accreditation. Prepared by the International Automotive Task Force, this quality management system focuses on: • continual improvement • defect prevention • reduction of variation and waste Certification must be confirmed annually, to ensure that standards are maintained.

The company’s early and ongoing commitment to the sector can be witnessed almost wherever you look on a vehicle. Of course, the demands on components and their constituent raw materials - vary, depending on location and function. But throughout, there is a theme that persists amongst automotive manufacturers and their suppliers everywhere: a rigourous demand for the best expertise. And when it comes to selecting and processing the right masterbatch in this fiercely competitive market, it is

expertise that sets the exceptional apart from the merely adequate.

Inside the cockpit Ask most owners, drivers or passengers, and it would never cross their minds that what they see all around them inside a vehicle will have been produced by multiple suppliers, using different processes, working with a variety of raw materials.

Good. We would like to keep it that way. Because that means we are doing our job.

Whether it’s polypropylene, ABS, nylon or other engineering polymers, getting exact colour matches across different finishes while maintaining properties is an art, and not just for day one. Protecting those colours long term against fading and the plastic materials from mechanical failure, especially with magnified heat coming through windows is an essential requirement.

Under the bonnet For masterbatch suppliers with a pedigree in technical, speciality and functional black masterbatch, lifting the bonnet on a modern car is an invitation to excel.

Such a demanding environment, with all the challenges to improve properties while pushing performance and reducing weight is a proving ground for the advanced thermoplastics industry - especially with the ongoing drive for better fuel economy.

Once and always Across automotive - from dashboard to engine to bodywork - performance, properties and aesthetics all have important roles to play. And plastics are essential, starting with masterbatch and the expertise to deliver the right results.

But for a global industry on this scale, achieving such results is just the beginning.

Consistency, repeatability, reliability of supply and accreditation to international standards are also prerequisites, on an ongoing basis. The components and the vehicles that are made today must match those that follow - whenever and wherever they are produced.

Which brings us back to quality management, and ISO/TS 16949: the perfect bedfellow to expertise.

Because together they deliver the results not just today, but tomorrow and beyond.

Everywhere, almost ...

Most of the public have no inkling just how prevalent plastics are throughout vehicles. For many, the first time they realise may only be after a visit to a repair shop.

But the improved performance and fuel efficiency of today’s cars are largely down to the strength and performance achievable with plastics while reducing weight, in bumpers, under the bonnet or interior trim. And with ongoing advances in electric and hybrid vehicles this will only become more and more significant.

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Bob Thomas, Technical Director, Colloids - the Makers of Masterbatch

MATERIALS ROUNDUP UK Firms Produce Simple Guide to Colour Matching for Packaging

UK groups M&H Plastics and Silvergate have joined forces to produce ‘A Simple Guide to Colour Matching’ to help customers in the selection of colours for their packaging.

A range of 40 different colours has been selected which are featured in the style of a paint chart. Colour plaques have been produced, thus avoiding the need to undertake colour matching.

Accurate colour control is critical to many projects and is an essential part of ensuring brand integrity especially across a range of products. New concepts for packaging need to consider colour in both component selection and final decoration.

M&H Plastics is a supplier of plastic packaging components and Silvergate is a UK producer of masterbatch used in the manufacture of plastic packaging.

M&H Plastics Tel: +44 1502 715518 Email: sales@mhplastics.com Web: www.mhplastics.com Silvergate Tel: +44 1978 661496 Email: info@silvergate.co.uk Web: www.silvergate.co.uk

BioSphere Launches New Biodegradable Additive BioSphere has launched a new biodegradeable plastic additive.

President Rob Huegli said of the development: “We believe that our technologies can, and should remain cost effective to the entire marketplace enabling all manufacturers and partners alike to be able to manufacture their products with cutting edge biodegradable technology. For this reason we have embarked on this journey to research and produce a competitive product offering within the biodegradable additive space and are now offering our new BioSphere additive at a competitive price and with versatility that our competitors simply do not offer in this space.”

Biosphere's additive sits between USD 712 a kg depending on order quantities, with a load rate of 1%. The new biodegradable additive technology is in high demand in regions such as the UAE, Mexico, Ghana and the Philippines due to the current bans on nonbiodegradable plastics in these countries. BioSphere says it is seeking distribution arms within all countries except the USA and Canada for its biodegradable plastic additive. The company believes it not only has the best enhancement of biodegradation for plastic in the marketplace today, but also the best product prices available.

Teknor Apex Expands Range of ETP Compounds for European Processors Custom Compounder, Teknor Apex Company, has restructured and expanded its portfolio of engineering thermoplastic (ETP) compounds for use

by European processors, offering products ranging from general-purpose formulations to a wealth of specialty modified grades, and now including many polyamide (PA) compounds developed for automotive applications.

“We now offer European customers a product range that is broader and more globalised than ever, providing customers with an unlimited choice of custom formulations based on PA, PET, and PBT, along with full technical backup, product development support, localised service, and worldwide availability for any compound required by companies that manufacture internationally,” said Neil Croucher, Sales And Marketing Director, Teknor Apex.

The products now fall into two broad families: Beetle, a range of PA, PET, and PBT compounds including products for automotive, electrical, consumer, industrial, construction, sport and leisure, and wire coating applications and Chemlon PA, a range of compounds for automotive applications including dozens of formulations developed for powertrain, chassis, exterior, and interior components.

The latest example of a PA automotive compound available worldwide is the new Chemlon 800 Series of injection moulding compounds. These are based on polyamide 6 /12 but are said to provide comparable performance in the fuel-line components that comprise the major application for polyamide 12.

The new compounds provide a practical alternative for processors amidst industry concerns about PA 12 supplies.

Teknor Apex Tel: +44 121 665 2100 Email: eutpe@teknorapex.com Web: www.teknorapex.com

BioSphere Tel: +1 503 530 8674 Email: info@biosphereplastic.com Web: www.biosphereplastic.com EPPM 21

MATERIALS SPOTLIGHT eppm

CLEANING & PURGING

TO PURGE OR NOT TO PURGE? That is the question

Why would you use a purging compound?

There are a number of theories about using purging compounds and whether they are cost effective or cost prohibitive. The question is can you afford to pay for a commercial purging compound or can you afford not to? The first thought for purging is usually when there is a contamination issue as the mounting scrap levels become more visible. Scrap levels are often overlooked or regarded as a normal cost to the manufacturing process. Using a good quality purging compound can improve the performance of plastic processing machinery and reduce the need for costly mechanical strip down and maintenance.

There are a number of different types of commercial purge compounds available which have been designed and engineered by their manufacturers based on many years of experience of purging plastics machinery.

Although they are designed to achieve the same end result they work in a number of different ways.

Abrasive Purge Purging compounds containing small amounts of glass fibre or a fine mineral which scours the polymer away from the metal, allowing the contamination to be flushed away Mineral Filled These use fillers such as chalk or talc at a very high filler level. These have a level of abrasion and are used to push the contaminated polymer along the screw.

Foamed Purges with a controlled amount of blowing agent expand, allowing the purge to clean the low flow areas and move stubborn contamination.

Mechanical non-abrasive These contain no chemicals and combine foam with non abrasive scrubbing granules. These work together to move colour and remove contamination.

What Causes Contamination?

Colour Change: moving from black to white can be a long, troublesome affair as the black pigment will have coated every internal part of the barrel, and after lengthy production runs the colour will start building up layers of a very fine coating in low flow areas of the screw, around check rings, in melt pumps, around spiders and screen changers. As they are in low flow areas purging with polymer will take a long time.

Purging compounds are designed to clean these areas much quicker and with less wasted polymer, they will scrub, clean and lift the colour by using their unique properties.

Black specs: as these coatings take hold they become very firm and start to carbonise — each time the machine temperatures increase and decrease the degradation becomes more severe. As new prime materials flow over the contamination it slowly accumulates. As a result, when using stiffer or abrasive filled polymers, or changing from high to lower temperature ranges, the little bits start breaking away causing black specs. At this stage the options are a mechanical strip-down or many kilograms of wasted polymer.

The key factor in achieving a successful purge is to understand what’s going on in the machine and how best to process your chosen purging compound.

Finding the best solution can take some time and evaluation work in the short term; an initial purging trial is the starting point. Most purging compounds need no more than a pass along the screw to achieve a cost effective clean but, for more stubborn contamination or complex machinery, more purge compound may be required. Agitating the purge compound in the barrel is also crucial to achieving a good result.

When to use a purge compound is ultimately decided by the processor, however the use of purge compounds to change polymer, change colour and remove carbon can achieve significant cost savings.

The key is little and often to keep your machinery free from contamination. In addition plastic processors can utilise purge compounds as part of their shutdown and startup procedures to reduce the amount of scrap containing black specs on restarting their machines.

£10.00 £1.00 £2.50 £2.50

Total purge cost

£16.00

Polypropylene Blue PP to White PVC 6 kg PP 30 minutes 20 scrap mouldings x 40p

£7.50 £15.00 £8.00

Total purge cost

£30.50

Example

The principle is the same when using a purge compound; creating movement in the melt improves the pressure and agitation of the purge, which in turn becomes more effective at removing stubborn contamination.

Counting the cost of purging

Chemical Liquid Purge Sometimes based on solvents they are designed to mix with your materials and be left to soak while the chemical agents actively break down the polymer and dissolve the contamination to be flushed away

Blue PP to White PVC 1 kg purge 0.5 kg polymer to flush 5 minutes to purge @ £30 hr 5 minutes to flush @ £30 hr

How and when to purge

Take a 500ml of bottle of ketchup, when all the ketchup is used and we want to clean the bottle, we could take the lid off the bottle and run under a cold water tap.

Cleaning the bottle could take 50 lt of water and around 10 minutes. Alternatively, you could add 225ml of water, replace the lid and shake the bottle for 10 seconds, tip out and flush with 225ml of clean water for a better faster result.

Types of Purging Compounds

Purging Compound

To fully understand the cost of using a purge compound, it is vital that you fully compare the cost of your current method in terms of purging time, wasted components and wasted polymer. You can then appreciate the cost savings achievable by using a purge compound.

The following example demonstrates the comparative cost of purging a typical 150 tonne moulding machine with a 320 gramme barrel capacity. One scenario uses a commercial purge compound and the other uses polymer to purge. The savings in time, scrap and cost to purge are apparent.

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The purging compound has cleaned the machine within 10 minutes whereas the polypropylene, after 30 minutes of purging, has moved the colour but left most of the carbon behind to contaminate another day.

MATERIALS SPOTLIGHT eppm

CLEANING & PURGING MATERIALS

In extensive testing conducted on a Van Dorn injection moulding machine comparing Purgex commercial purging compounds (CPC) to using in-house resins for changeovers, Purgex reduced the amount of otherwise usable resin needed to purge by 94%. Tests included the amount of purging compound, amount of resin used, and scrap material produced.

PURGEX REDUCES RESIN WASTE BY 94% FOR CHANGEOVERS

The resins tested against Purgex were polypropylene (PP) copolymer, high-density polyethylene (HDPE), polystyrene (PS), acrylonitrile butadiene styrene (ABS), and Nylon 6,6. Parts produced in the mould were circular disks (102 mm diameter x 6.4 mm thick).

On average, it took 7.9kg of usable resin to change from dark to light resins and only 0.5kg of Purgex and carrier resin to make the same changes from the last good part to the first good part. All tests for each resin were conducted three times for reliability. Contact Purgex for more details on the test results and additional information about Purgex commercial purging compounds.

Purgex division of Neutrex, Inc. Tel: +1 281 807 9449 Email: global@purgexonline.com Web: www.purgexonline.com

MATERIALS ROUNDUP Croda Launches Anti-Fog Concentrate for Polypropylene Food Packaging Croda Polymer Additives has launched a new anti-fog concentrate which is claimed to provide a unique solution to fogging in clear polypropylene food packaging. Proven in tests to be effective in both hot and cold fogging applications, Atmer 7373 works by preventing droplet formation on plastic surfaces, keeping food looking fresher for longer.

Adam Maltby, Croda’s Polymer Additives Applications Manager, said: ”Atmer 7373 is effective in most grades of polypropylene, and results have been particularly good in PP homopolymer. We have not seen any other product on the market that delivers such effective performance in both hot and cold fogging environments.

“As a highly loaded concentrate it is particularly useful for converters who can easily handle its pellet form. It is also useful for masterbatch producers who either cannot or do not wish to handle soft and pasty raw materials.”

The product’s formulation is said to overcome many of the processing difficulties encountered when using traditional additives at the levels needed to impart effective anti-fogging. Typical processing problems can include screw slip or over-lubrication in the extruder barrel, and excess fuming.

“Atmer 7373 is a 40% concentrate supplied in pellet form for easy dosing, so opens up new opportunities for film and sheet producers in particular. It additionally

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helps to control the rate of migration and allows an even dispersion of the additive on the polymer surface,” concluded Maltby.

Scientifically formulated for clear polypropylene films and containers, Atmer 7373 is fully food approved. A short demonstration of the product’s performance in a hot fog test over two hours is available on the company’s website. Visit www.croda.com/pa to find out more.

Croda Polymer Additives Tel: +44 1405 860551 Email: pa-europe@croda.com Web: www.croda.com/pa

MATERIALS ROUNDUP Event Review: 5th Annual Gala Symposium 2012 On September 11th and 12th this year, Gala Kunststoff- und Kautschukmaschinen GmbH of Xanten, Germany, held its 5th Gala Symposium.

More than 130 attendants attended presentations from independent guest speakers from the plastics processing and plastics machinery industries.

Efficiency and flexibility in processing compounds, plastics recycling and natural raw materials were the general themes of the Symposium. In terms of efficiency, the aim was to present opportunities and ideas that can be easily implemented in compounding, recycling and plastic processing plants in order to improve the efficiency and effectiveness of the machines in use.

With regard to flexibility, speakers also reported on various methods of costefficient plastics processing in multiple industries, and outlined the work taking place to design advanced machinery that provides cost-conscious users with increased economic benefits. The target was also set to identify new innovations in the compounding arena. The theoretical considerations were complemented by in-depth studies of various system suppliers with a focus on long-term cost-efficiency, equipment layout, application characteristics and the resulting potential for the future.

As part of the series of technical presentations, which took place at the Gala Technical Center, various pelletizing processes were demonstrated in sequence on three

extrusion lines. A high degree of automation, low manpower requirements and the automatic and risk-free shutdown of the process in borderline situation were identified as particular advantages of underwater pelletizing compared with other processes. In addition to the technology selected by Gala for the demonstrations, the practical processes themselves were met with strong interest among the attendees. After the equipment demonstrations of the individual machines it became quite crowded for pellet collection and their evaluation at the outlets of the equipment.

One of the processes demonstrated was the pelletizing of PP for automotive applications. For this demonstration Gala invited ROC (Rapid Optical Control) to help demonstrate the flexibility of the Gala pelletizing lines.

Colour was measured on the pellets and corrected online during production, a concept that holds great potential for the compounding industry. The accompanying technical presentation highlighted the significant economic benefits of the ROC method and its related pay back for the market. On the first day the colour measurement was introduced and the online correction on the running machine was demonstrated successfully and extremely quickly.

Within minutes the correct colour was achieved while the whole extrusion and pelletizing machine didn’t need to be stopped or cleaned during its operation.

Another presentation on the first day of the seminar involved the direct crystallization of recycling PET material supplied by recycling group 4 PET from the Netherlands.

Gala invited Leuders Extrusionstechnik to help with melt filtration to clean out the dirt and metal parts from the contaminated recycling PET flakes continuously. This demonstration resulted in clean and spherical PET pellets made with the Gala Underwater Pelletizer running the Gala CPT (Crystalline Pellet Technology) process with airflow accelerated, and at safe production conditions and temperatures. Pellets left the Gala dryer at well above 140°C, high enough for direct crystallization through sufficient latent heat inside the pellet for crystallization. Observers could physically see the pellet colour change from almost opaque directly at the dryer exit into white/crystalline further down in the pellet container. Visitors were impressed by the ease of processability and the potential economical benefits.

The final practical presentation of day one was on the topic of micropelletizing a bio material, which was demonstrated on the Gala LPU (Laboratory Pelletizing Unit) System. On the smallest scale machine that Gala builds, participants could see that micro pellets can be easily produced even in small scale and at small rates.

On the second day of the Symposium, guests saw the production of another

automotive colour PP, but this time with the complete colour change online.

Gala’s tools were principally the die plate concept for such online colour changes and the MB 500 BF2 water system and dryer with integrated band filter. In this demonstration there was no need to clean the downstream equipment such as the water system or the centrifugal dryer as the line stayed in production without interruption.

Participants were able to witness the changeover from a darker brown PP to a white-yellow PP in an extremely short time. The visualisation of the graphic demonstration based on the L-a-b colour levels enabled participants to follow the formula change live and during operation of the machine.

The brown formula with a total pigment level of about 2% was run on SPC (Single Pigment Concentrates) with pigment concentration of about 30%.

After reaching the required tolerances La-b = 0,4 the next formula was loaded to produce the next colour, a whiteyellow PP. For this colour, white and yellow SPC were used instead of brown, black and white SPC, as used earlier.

After about 12 minutes and several online corrections the new white-yellow PP colour formula had reached the required tolerance of L-a-b = +/- 0,4.

Neither the upstream nor the downstream side of the equipment was cleaned manually for this colour change during production.

The automatic sampling station ROCContinued on page 26

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MATERIALS ROUNDUP ContiSampling, the colour measurement of the pellets ROCColorControl, the dosing system ROCColorDosage and the GALA-MB 500 BF2 Pelletizing and drying system enable increases of productivity of 20% and more. This equipment package also allows compounders to produce small lot orders even on large extruders with large capacities, but efficiently.

On the same day, the small LPU pelletizing system was used to study the processing range of a Gala underwater pelletizing system for wood filled compound supplied by Tecnaro GmbH. The results concluded that it was possible to produce perfectly round pellets with low surface moisture quality.

The implementation of the Gala MCD (Melt Conditioning Device) was another key attraction. This new device eliminates the creation of large melt blocks usually produced during the startup phases, as it makes more manageable portions and so reduces significantly the known hazards and workload for the operators.

In addition to the practical demonstrations, Gala also opened its doors to permit a look on quite a number of machines under construction.

Gala Kunststoff- und Kautschukmaschinen GmbH Tel: +49 2801 980 0 Email: gala@gala-industries.com Web: www.gala-industries.com

Additive Solution for Polycarbonate Sheet Lets the Sun Shine In Polycarbonate (PC) “sun sheet”, used for clear or tinted roofing panels in outdoor venues such as stadiums and arenas, must have superior weather resistance and high durability. Additives are commonly used to protect the polymer from damage caused by ultraviolet (UV) radiation from the sun and other light sources such as fluorescent lighting. However, lowmolecular weight components in some formulations can build up on the sheet die during extrusion. One PC sun sheet manufacturer’s extrusion process was experiencing frequent downtime because excessive die build-up required shut-downs for cleaning every three to four days.

The sheet manufacturer approached global additives specialist PolyOne for help in solving this costly problem.

PolyOne’s technical team developed a specialised UV stabilizer additive masterbatch based on its portfolio of OnCap UV stabiliser masterbatches. The solution featured high heat stability and low volatility that would reduce die buildup and provide superior weatherability.

In addition, PolyOne’s formulators

determined that the customer could use the PolyOne masterbatch at lower percentage, while still meeting weathering requirements.

PolyOne’s technical service personnel attended extrusion trials at the customer’s facility and observed that using the PolyOne additive instead of the existing additive resulted in lower die build-up and a more stable thickness of the coextruded layer. In addition, PolyOne completed 10,000 hours of accelerated weathering testing and found that PC sheet made with the PolyOne UV stabiliser exhibited better long-term appearance and impact property retention and fewer surface cracks.

PolyOne’s solution saved the customer US$120,000 per year in lower masterbatch loading, as well as additional savings from reduced maintenance and downtime. After using the PolyOne formulation for a period of time, the customer discovered that the sheet die could go a week or more between cleanings, instead of only three to four days. This dramatic improvement made the manufacturing process more efficient.

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In addition, PolyOne offered local supply, reducing the customer’s inventory and lead-time requirements as well as freight costs. The customer benefited from PolyOne’s commitment to providing high-quality, local product supply and technical support. “This project demonstrates our commitment to helping our customers in China grow by differentiating their products, enhancing their operations and providing them with significant competitive advantage,” said Mark Crist, Vice President, PolyOne Asia.

PolyOne Asia Tel: +86 21 5080 1188 Email: info@polyone.com Web: www.polyone.com

In Review: Fakuma 2012

More than just an ‘injection moulding show’ - as those in the industry hear it termed so often - Fakuma this year was an international showcase for injection moulding technologies, new tempering processes, bioplastics or woodreinforced plastics with antibacterial attributes, unconventional and creative engineering solutions and individualised material recipes, energy-saving production processes and increasing automation solutions – to name but a few!

With injection moulding, extrusion and thermoforming, as well as micro injection moulding and sintering processes, Fakuma 2012 was once again characterised by the latest developments in all applications for modern plastics.

1700 exhibitors from 35 countries around the world brought these technologies to the European marketplace, with 31% of the exhibitors coming from outside of Germany.

The organisers have reported sightings of several “Sold!” signs during the show - cementing its status as an “order placing trade fair” - quite a rare trait in capital equipment exhibitions.

Ulrich Eberhardt, Chairperson of The Exhibitor Advisory Committee and Managing Director of motan-holding gmbh, said of this year’s show: “Fakuma has been, is and will remain an outstanding platform for leading

companies in the plastics industry for the presentation of comprehensive, innovative offerings covering all aspects of injection moulding and extrusion to national and international expert visitors.

Fakuma is an information and communication forum, a source of new ideas and a trend barometer for the plastics industry.” Helmut Gries, Sales and Marketing Manager at gwk, expressed similar sentiments: “Based on our highly authoritative trade fair reports, on Wednesday we were able to break all previous records for visitor numbers on any given day at all of our Fakuma appearances – and we’ve been exhibiting right from the very beginning!”

Temperature Control Tricool Thermal, a UK manufacturer of tool heaters and temperature controllers launched its latest range of products at the show.

The temperature control specialist showcased a selection of new units including its T90 water heaters, HTF oil heater and ECO-T heat cool unit. Some of the units now feature the latest C7 advanced touch screen controller, which offers recipe control, remote probe monitoring, a range of global languages, cascade control and options to connect to MODBUS and Profibus.

If a particular process requires something a little different, Tricool says it has the ability to provide tailor-made

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Continued on page 28

FAKUMA 2012 REVIEW options with keen price/performance ratio. With a team of experienced designers and engineers, units can be customised to cater for specific requirements, including: • Special construction and dimensions • Voltages and temperatures • Flow rates and pressures • Controller specific special applications and functions Systems can also be designed to communicate with higher level machines or line controls via a wide range of different electronic interfaces. The group’s stand proved an exciting and interactive arena for the Tricool team to discuss these solutions with the international visitors to the show.

Injection Moulding Arburg exhibited on a two-storey, 1,300 m² exhibition stand which, the group reports, was extremely well frequented every day, with ten exhibits and applications on display.

The injection moulding specialist said it welcomed more guests than ever from overseas, including customers from as far afield as Brazil and Singapore. New contacts were made, primarily from the packaging sector. In an attempt to be able to provide individual support to all the domestic and international visitors, around 150 Arburg employees were apparently on hand each day at the stand.

The company, which is also one of the co-founders of the Friedrichshafenbased fair, has reported that it was the largest exhibitors in attendance, with a stand measuring around 1,300 m².

Moreover, several Allrounder machines were also to be found at other locations throughout the halls. With more than 20 exhibits and a wide variety of different applications at the Arburg stand and others, the diversity of the Allrounder range was clear to see. The application spectrum comprised multi-component technology, the processing of liquid silicone (LSR) and solid silicone (HTV), particle-foam composite injection moulding (PCIM), long-fibre direct injection moulding, powder injection moulding, packaging, medical technology and optical applications, as well as the overmoulding of inserts, also using the hotmelt process.

Arburg says that its objective was always to increase the costeffectiveness of moulded part production for its clients. In terms of

machines, this was mainly highlighted by way of the new 630 A size for the electric Alldrive machine series, the productivity package for the hydraulic Golden Edition series and the servo-hydraulic drive concept for the large Allrounder S. With the Allrounder 630 A, featuring a clamping force of 2,500 kN and a size 1300 injection unit, it is possible to precisely tailor the machine to the application, which is a major factor in the efficient production of moulded parts.

With the productivity package, the efficiency of the hydraulic Allrounder Golden Edition machine series can also be increased. This package comprises the Arburg energy-saving system (AES) with variable speed pump drive and a water-cooled drive motor.

The advantages here are a reduction in energy requirements by up to 20%, 5% shorter dry run times and minimised emissions.

The large hydraulic Allrounder S machine with a clamping force of 2,500 to 5,000 kN enables energy savings of up to 50% compared to earlier machines when using the servo hydraulic drive concept.

The new long-fibre direct injection moulding process developed together with Süddeutsches Kunststoff-Zentrum SKZ in Würzburg, allows inline feeding of the fibres and melt, enabling longer fibres than ever before to be processed, so that even lighter injection moulded parts with thin walls and high strengths can be produced. Further advantages of this process are that the fibre length, fibre content and material combination can be individually influenced.

Particle-foam composite injection moulding (PCIM) is a joint project with Krallmann and Ruch Novaplast in which a foamed component is combined with polymer for, according to Arburg, the first time using the injection moulding process. The two components are bonded together, so that there is no need for subsequent assembly steps and a finished part is produced in a single step. This production of composite parts made from particle foam and injection moulded plastic opens up completely new options in the fields of electric mobility, lightweight construction and insulation.

The KraussMaffei Group has also reported a very successful Fakuma 2012. Both visitor figures and on-site orders increased considerably in comparison to the previous year, said

the group. In particular, the visitors and customers were said to be impressed by the premium quality of the machines and the powerful applications for efficient production processes.

The feedback to the GX series from KraussMaffei, which was showcased for the first time at a trade fair, was particularly positive. The GX 450-3000 produced a telephone cradle for an automotive interior using CellForm technology with physical foams (MuCell). “Furthermore, the worldwide demand and the sales figures to date exceed our expectations”, said Frank Peters, Vice President Sales at KraussMaffei. KraussMaffei also showed potential for more efficient processes and production flows, which offer options for function integration. The 3-K process with metal injection moulding on a CX 160-750 machine was a “visitor magnet” said the group. “This technology shows very clearly what potential lies in combined processes for the production efficiency and design of plastic parts with integrated functions”, continued Peters, “We are delighted with the very high influx of customers at Fakuma. This is why Fakuma is and remains one of the most important trade fairs for us”.

For the first time Netstal showcased the new ELION 3200 at a trade fair. Using a complete system for the manufacture of thin-walled lids for cream cheese

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packaging, the innovative hybrid drive concept and the new drive unit EcoPowerunit for a noticeable improvement in energy efficiency were well-received.

“We were able to significantly increase the number of orders and conducted high-quality customer discussions. We are very satisfied”, stated Dr. Hans Ulrich Golz, President, Injection Molding Machinery.

“Our expectations were well exceeded; we were also able to welcome many visitors from neighboring countries and Eastern European states”, said Dr. Jens Liebhold, Business Unit Manager at KraussMaffei Berstorff. Very specific requests were received for pipe extrusion, where the trend for complex system solutions and complete systems for the production of peroxide crosslinking hot water pipes or polyurethane-insulated pipes or the extrusion of large pipes for example remains strong.

Detailed requests were also received for equipment for film and foam extrusion, and high-fill and glass fibre reinforced compounds; some of these products should be established within the next six months, said the group.

The next Fakuma international trade fair for plastics processing will take place at the Friedrichshafen Exhibition Centre on Lake Constance where Germany, Austria and Switzerland meet, from the 14th-18th of October, 2014.

THE GREEN ROOM

Plastic from Sewage Waste? Researchers Now in ‘Negotiation Phases’ in Europe A recent innovation claims to be able to turn municipal sewage sludge into raw materials, to be used by the plastic industy around the world.

The technology, developed by Applied Cleantech, an Israeli company founded

by Refael Aharon, will reportedly enable turning the solids in municipal sewage systems into raw materials for the plastic industry. Scientific research has led over the past few years to this technology’s development which enables sewage sludge to be used as a base for raw materials that are later sold back to the industry. The technology is applied by way of a compact, automatic and efficient facility that recycles solids from raw sewage and turns them into highquality consumer products through a continuous process (SRS- Sewage Recycling System). At the end of the process, sewage solids are turned into high quality, clean and environmentally friendly raw materials, thus naming the purification facility to a manufacturer with extra “green” points.

Aside from the raw materials created at the end of the process, the new plants assist in reducing regional sewage purification plant loads by about 35%. As a result, purification plants enjoy reduced

energy consumption and reduced operational and maintenance costs in their water cleaning process in favor of reuse. In addition, sewage recycling provides three major benefits. First, reducing regular operational costs by approximately 30%, as well as gaining raised capacity. Second, manufacturing and selling high quality consumer goods by utilising sewage materials, and third - reducing greenhouse gases, thus preventing environmental hazards.

Applying this system will allow turning purification facilities into a true asset - a source of income and environmental contribution.

The company's development was intended to provide a solution for issues in sewage care. Today, a certain percentage of the massive amount of solid municipal waste is cleared through garbage systems to landfills, and some is cleared through the sewage system through sewage purification facilities.

The raw sewage that reaches the sewage purification facilities contains suspended solids, soluble solids, minerals, oils, and toxic compounds.

Speaking in environmental terms, sludge is currently considered one of the major issues that need to be solved.

Dr. Refael Aharon, CEO and founder of Applied Cleantech, said: “The revolution is in regarding these solids not as waste that must be hidden, consumed by bacteria, or buried, but as a resource and base for raw materials that is sold back to the industry.”

The technology is currently being utilised in a few cities around the world, and is

reported to be in advanced negotiation phases with municipalities and investors in Europe and the United States.

Applied Cleantech Tel: +972 2 5617341 Email: info@actsrs.com Web: www.applliedcleantech.com

Nike Football Boot Uses Bio-Based TPU in the Sole Merquinsa, a Lubrizol company, has announced that its Pearlthane ECO TPUs are incorporated into Nike's recently released GS football boot. TPUs (thermoplastic polyurethanes) are reportedly known for outstanding mechanical properties, and Pearlthane ECO is no exception, says Merquinsa.

This bio-based product line provides an alternative to 100% petroleum-based TPU materials, and, according to Mequinsa, without compromising any performance properties. The Pearlthane ECO product line has an 82 to 95 Shore A hardness and covers a range of 32% to 46% bio-based content as demonstrated according to ASTM D-6866.

The Pearlthane ECO product line was specifically designed for the sports and recreation market aims to provide the required performance properties for high quality footwear. These properties include abrasion resistance and cold flexibility combined with improved hydrolysis resistance and good adhesion to other non-TPU shoe components. With a low density (when compared to its petroleum-based counterparts) Pearlthane ECO TPUs

provide sports footwear manufacturers with a lightweight and cost-efficient material that contributes to making the Nike GS football boot’s sole plate 15% lighter than a traditional plate composition.

“The Nike GS is the lightest and fastest football boot we've ever made and really defines a new era in how we create, design and produce elite football boots,” said Andy Caine, Global Design Director for Nike Football. “When you can deliver a boot that combines high-end performance and a low environmental footprint, that's a winning proposition for players and planet.”

According to Dr. Jesus Santamaria, Global Bio TPU Platform Manager: “Combining Merquinsa's ECO portfolio with Lubrizol's bio-based products

allows us to continually innovate and cater to the needs of environmentallyconscious footwear manufacturers with high-end performance and bio-based specialty elastomers. We intend to continue to find new ways to position ourselves as a global solutions provider for the sports and recreation industry.”

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Merquinsa Tel: +34 93 579 9522 Email: info@merquinsa.com Web: www.merquinsa.com

GREEN ROOM ROUNDUP Bioplastic Resin Nominated for Best Material Award Cereplast, Inc., a manufacturer of sustainable bioplastics, has announced its Hybrid 651D resin has been nominated for the ‘best material’ award at Materialica 2012, a European event for material-driven and supplier-oriented product innovations.

Hybrid 651D is the only bioplastic material that was nominated for this year's award, the ceremony for which took place at the Materialica trade fair on October 23, 2012.

A new addition to the Cereplast Hybrid Resins product line, Hybrid 651D is the first EA and starch hybrid resin. According to Cereplast, Hybrid 651D is a tough, soft touch, pliable material that is ideal for extrusions and soft injection mouldable applications, providing the desirable properties of conventional EA while offering a lower carbon footprint and expanding the range of properties available for durable bioplastic materials.

It can be used for the manufacture of consumer goods and packaging, footwear, handbags and other fashion

Milk Bottle Manufacturer Achieves to Zero Waste to Landfill

accessories, as well as wire and cable insulation, soft plastic goods such as tubes and hoses and adhesion layers for multi-layer films.

Cereplast Tel: +1 310 615 1900 Email: sales@cereplast.com Web: www.cereplast.com

Nampak Plastics, a UK manufacturer of HDPE milk bottles, has announced it has achieved a key goal of ‘zero waste to landfill’ following a company-wide drive to enhance sustainability through recycling and waste management.

As part of Nampak’s focus and commitment on further reducing its environmental impact, ‘Carbon Champions’ were appointed at each of the company’s nine UK sites, with responsibility for ensuring waste recovery and recycling best practice on a day-to-day basis. In addition, Nampak has been working with waste management company, Prism, to review waste handling across the entire business.

The approach taken by Nampak is in line with Government policy to create a zero waste economy. Commenting on the achievement, Eric Collins, Managing Director, said: “Sustainability is at the very heart of our business, from our commitment to producing innovative, lightweight packaging to our understanding of how our processes impact on the environment.”

“The receipt of our zero waste to landfill compliance certificate demonstrates a significant step for Nampak and recognises the commitment of all employees in the company towards an environmentally sustainable business.”

As well as taking measures to reduce its own impact on the environment, Nampak states it is helping retailers and

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dairies to meet their growing environmental commitments with the introduction of Infini – a new, lighter weight plastic milk bottle.

Nampak stated that to the consumer, the Infini bottle has a similar look and feel to the industry standard model, but has been redesigned to allow for substantial weight savings and carbon reductions of up to 25 percent. In addition, the bottle contains up to 15 percent recycled highdensity polyethylene (rHDPE).

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

SHOW RECYCLING

High Quality PET Textile Yarn from Recycled PET There is a lot going on in the world of synthetic fibres: parallel to growth in the market for staple fibres, the fibre market throughout the world is seeing an increased demand for environmentally friendly production processes which offer economic advantages. The Multi Rotation System (MRS) extruder from Gneuss Kunststofftechnik GmbH has been designed as a response to both challenges. The unique multiple screw extruder permits high throughput rates and the use of up to 100% recycled content.

Resources are saved, energy use is minimised and raw material costs are reduced.

Many synthetic fibre manufacturers throughout the world have already chosen the MRS extrusion system from Gneuss. One of these is a Brazilian company which uses two MRS extruders to produce bicomponent staple fibres with two extruders: an MRS 130 for the main component with a throughput rate of up to 900 kg/h and an MRS 110 for the second component with a throughput rate of up to 500 kg/h.

Both are fed with the same undried post-consumer PET bottle flake material and extrude the PET with different IVs on each extruder.

The Belarussian company, Mogilevkhimvolokno in Mogilev is one of the biggest Eastern European manufacturers of staple fibres and also decided on the

MRS extruder from Germany. Mogilevkhimvolokno manufactures a wide range of staple fibres including bicomponent fibres with a low melting point and an IV value of 0,55 through to industrial quality fibres with an IV of up to 0,9. During manufacture of these fibres, production wastes of all types are created, some including spin finishing oils. In order to recycle this wide range of wastes, an MRS 90 extruder from Gneuss was installed which is used to devolatilize the undried material and to glycolyse the material to a uniform IV before it is filtered and pumped into the final reactor (finisher) where polycondensation takes place.

The PET melt then goes to the spinning beam (direct spinning). This process permits recycling of practically all the production waste and the quality of the fibres manufactured with this recycled content is practically no different to that of fibres manufactured using virgin material.

Silon s.r.o. in Prumyslova is another leading Eastern European manufacturer of staple fibres. Silon also operates an MRS extruder: an MRS 130 in an extrusion

fibre spinning process. The MRS 130 replaced a conventional single screw extruder, dispensing with pre-drying of the material. It was possible to increase the production capacity by 30% with significant energy savings. The extruder can process up to 100% PET bottle flake with a residual moisture level of as high as 2%.

Gneuss Tel: +49 5731 5307 10 Email: gneuss@gneuss.com Web: www.gneuss.com

Axion Polymers Introduces New Recycled Polymer Colours Axion Polymers has expanded its wide range of colours matched to exact customer requirements using its 100% recycled Axpoly PS01 high impact polystyrene (HIPS) grade derived from refrigerator liners.

Beige, grey and pastel shades of blue, green and red are now included in the HIPS grades with performance equivalent to virgin polymer that are available from the UK-based plastics recycler.

Axion says its Axpoly product, manufactured to defined specification, offers customers cost savings of up to

20% compared to using virgin-based colour compounds, with no compromise on quality.

Suitable for injection moulding, the precompounded HIPS polymer also reduces resource consumption and can contribute to significant CO2 savings. As well as supplying specific colours, Axion can also modify formulations to achieve particular physical properties for various product applications.

“Manufacturers are increasingly looking to reduce material purchasing costs without compromising quality or performance,” said Neil Quinn, Axion’s Plastics Sales Manager.

“They are also recognising that sustainability is also a major deciding factor at the point of purchase for end-users, so our recycled polymer range ticks a number of boxes for them.”

Axion’s extensive in-house colour-matching expertise means any colour can be supplied to precise customer requirements using specialist laboratory and compounding equipment. Using this pre-compounded coloured HIPS eliminates the need for injection moulders to blend masterbatches themselves.

Steve Bell, Axion’s Product Development Manager, who is a fully trained plastics colourist, said: “Our process gives better colour dispersion, resulting in improved visual quality of the final product as opposed to adding the masterbatch shade to the polymer when it is injection moulded.”

Axion is currently working on a number of exciting colour projects with high profile companies and its custom-colour HIPS polymers are being supplied to customers in Europe, North America and China.

Deliveries range from one tonne to full truckloads.

Market sectors interested in custom-colour Axpoly PS01 grades include household products, stationery items, electrical equipment and general industrial goods.

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

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

Axion Polymers Tel: +44 161 737 6124 Email: sales@axionpolymers.com Web: www.axionpolymers.com

WCASE Erema Combines Multiple Processing Stages with New System “Corema” is a brand new product concept from Austrian group Erema. The development is based on the idea of processing inexpensive recycling raw material to make customised plastic compounds in a single step without intermediate cooling. This combined recycling and compounding system means “forward integration for the recycler in the direction of material production and reverse integration for the compounder towards material procurement”, according to the group.

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

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

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

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

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

construction industry, PP/talcum compounds are used mainly for white household goods and in the automotive industry. The amounts of PP recyclate used in these applications are still relatively small, yet the potential is big, says Erema.

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

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

Mark Langenhof of Rodepa explained:

“This is why we looked very closely into compounding and had a look at what machines were available on the market.

When we heard that Erema covers this topic with their own product line we contacted them straight away.” Rodepa is now moving into the compounding business with Corema.

Langenhof continued: “The recycled material is processed and filtered in the robust and proven cutter/compactor single-screw system. The clean melt then moves directly to the twin-screw unit which is available for a wide variety of compounding tasks. All in all you can expect outstanding energy efficiency from this process. Besides this it is also important for us to have a strong partner by our side, especially in this field.

Thanks to its excellent after-sales service Erema is second to none and has been for many years.”

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

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

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

Coca-Cola to Boost Plastic Recycling Coca-Cola in the UK is adopting the British Retail Consortium's (BRC's) OnPack Recycling Label (OPRL), giving an enormous boost to efforts to reduce the proportion of plastic drinks bottles ending up in landfill.

Coca-Cola Enterprises (CCE) is rolling out the widely recognised OPRL system, which gives consumers standardised information on which packaging materials local authorities collect for recycling. More than 90 percent of councils now collect plastic bottles at the kerbside but, despite massive growth over the last few years, consumers are only recycling around half of plastic bottles.

The relevant OPRL logo – plastic, widely recycled – is starting to appear initially on 500ml bottles of Coca-Cola, Coke Zero and Diet Coke sold in Great

Britain, but will be introduced over time across other products and packs made

by CCE. The BRC says that CCE's adoption of the scheme will see a significant increase in the number of bottles and cans that will now carry this clearer recycling advice.

British Retail Consortium Director of Food and Sustainability, Andrew Opie, said: "The On-Pack Recycling Label has become a familiar sight to consumers in the three years since it was introduced. It's great to welcome CocaCola Enterprises to the list of nearly 150 signatories, particularly because of what we hope this will mean for plastic bottle recycling.”

Patrick McGuirk, Coca-Cola Enterprises' Recycling Director, said: "We are serious about setting the industry

standard for sustainable packaging and are committed to transforming recycling in this country.

"Our bottles and cans are easily recycled and our research shows consumers will recycle more if they know what can be recycled. We have had a recycling logo on our packs for many years but the inclusion of OPRL information makes it easier for consumers to recycle their bottles through kerbside collection schemes.

Our message is simple – recycle your bottle at home and it can be back on the shelf within six weeks."

BRC Tel: +44 20 7854 8900 Email: info@brc.org.uk Web: www.brc.org.uk

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ADVERTISERS’ INDEX

EPPM CLASSIFIEDS PROCESSING EQUIPMENT

Company

Page

Abbey Masterbatch

12, 35

ACS/Cumberland Amut/Renmar

34

Birmingham Granulators

34

Blow Moulding Machinery

34

Boussey Control Europe

34 7, 23

Kentya K/TC 60-22 (30kw) Technoplast KT8000-1 Technoplast RZ30-SA-1 Technoplast RZ30-SA-1 Technoplast 8m

Extruder : Table: Haul-off: Saw: Tiptable:

12, 34

Bausano

CJP

TWIN SCREW EXTRUSION SYSTEM

18

Unused machinery – all offers considered View in storage in Frodsham, Cheshire Tel: 01928 734724 Email: sales@herbold.co.uk

RE-PROCESSING EQUIPMENT Cont’d

Granulators – Shredders – Pulverisers New and second hand systems bought and sold Spares for all machines blowers – cyclones – pipework – conveyors blades – screens Contact: Dick Monkhouse Tel: 01928 734724 Email: sales@herbold.cu.uk

Blow Moulding Machinery Ltd All makes in stock

Colloids

27

Dalesway

35

DB Automation

34

DME

11

Elasto

19

Engel

2

Equipnet

35

Ferromatik

29

To Advertise Here...

Gala

21

Contact Tim Guest Tel: +44 (0) 7581 398 723 Email: tim.guest@rapidnews.com

Herbold

34

ICS Tricool

26

Instron

15

Koch-Technik

17

Lanxess

9

Maschinenhandel Borowski

35

Renmar Ltd

Max-Robot

31

Tel: +44 844 6933225 Email: info@renmarltd.com Web: www.renmarltd.com

Mouldshop

16

Netzsch

36

Pentacore Industries sa

11

Plastico Trading

34

Process Control

18

PTI-Europe

35

Purgex

24

Rawmec

35

Ray-Ran

14

Semoflex Romania

25

Summit

34

Tappex

34

Tinius Olsen

32

TransXL

35

Ultrapurge

25

Unicor

13

Vinyl GB

35

Zerma

34

Zumbach

14

• • • •

Bekum Kautex Battenfeld Magic Automa Others 1/2 ltr - 1000 ltr P.E.T. Lines

STOCK LIST Many machines 1/2-1-2-3-ltr from £4000 Blow moulds 10ml-220ltr over 300 toy moulds Spares, Heads, Screws, Barrels FOR SERVICE - REBUILDS - BREAKDOWNS BD REPAIRS LTD TEL: +44 (0)1767 318910 • FAX: +44 (0)1767 600097 www.blowmachine.com CHILLERS - GRANULATORS - COMPRESSORS MANY INJECTION MACHINES

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ANCILLARIES, AUTOMATION & TESTING EQUIPMENT

For further information: T: +44 (0) 1789 206600 F: +44 (0) 1789 206651 E: sales@enquires.co.uk Or scan the QR code below:

RE-PROCESSING EQUIPMENT www.tappex.co.uk

Granulators Shredders Pulverisers Blowers-cyclones All spares Contact: Dick Monkhouse Tel: 01928 734724 Email: sales@zerma.co.uk

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

EPPM 34

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

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Find what you need, sell what you don’t, and manage what you have.

EquipNet has been providing asset management sales and solutions to leading corporations in the plastics and chemical industries for more than 12 years. The EquipNet.com MarketPlace is the world’s largest online venue for buying and selling pre-owned manufacturing equipment.

www.EquipNet.com/EPPM Sales@EquipNet.com • Tel: +44.118.901.6161

OTHER

PRINT EQUIPMENT

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

Over 35 Years of Service

1650mm Kaufman super-2 Sheet Line. 1983.

120mm cascade extruder. 1400mm wide Edi die. 1650mm kaufman 3 roll stack. Pump group Haul off and guillotine.

1300mm wide Battenfeld coextrusion sheet line; 2 x 90mm single screw extruders.

1300mm x 600mm 3 roll polishing stack+ haul, 2 station winder, 1995.

Tel: +44 (0) 1793 827666 Fax: +44 (0) 1793 823826

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

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

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

Email: sales@transxl.co.uk Web: www.transxl.co.uk

4.5” Welex single screw extruder. 30D vented. 2003.

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

GRANULATORS SHEET LINES

600 x450mm Rapid Gk6040 600 x400 Cumberland 6/84 900mm Cumberland Model 4590

2300mm Omipa Pmma Sheet Extrusion line.

1700mm Bandera Virginio Mai PMMA line 1650mm Welex Co-extrusion line

EXTRUDERS

1650mm Kaufman P.P Sheet line 1500mm Bandera 3 roll stack

120mm Union extruder.

1350mm Welex 3 roll Stack.

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

1300mm Battenfeld coextrusion sheet line.

1040mm Welex Coex sheet line.

1040mm Welex 3 roll stack

70 to 1200Kg/Hr Kreyenborg Infrared rotating drum (IRD) Dyer Model 140/270.

2005. For the drying and crysallising of pellet/ reclaim in medium throughput range.

120mm Kuafman Super 2 extruder 890mm Wide Welex World Standard sheet Line. 90mm Extruder. Gear Pump 900mm Die. 890mm Welex Stack winder. 1997

115mm Hartig Extruder, 30d 90mm Welex single screw extruder 90mm John Brown Egan single screw extruder

1000mm Esde 3 roll Stack

1000mm Wide Omv Coextrusion Sheet Line.

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

70mm Battenfeld-kuhne Extruder

1000mm OMV co ex sheet line

60mm Alpha Cincinnati coextruder 50mm Krauss Maffei KMD twin screw extruder

THERMOFORMING

50mm Betol co extruder. 25:1 l/d ratio.

45mm Kuhne model K45E 30D

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

1350mm wide Welex 3 roll polishing stack, pump group and haul off. 450mm diameter rolls, with dc motor control, 4 speed gearbox .

1016mm (40”x 60”) Lyle thermoformer 700mm Illig RDM 63/15B cup forming line 605mm Kiefel KL2 SH Thermoformer, 540mm Kiefel KL2EH vacuum former 530mm Illig Rv53 former 500mm Illig RDM 50/3 Lid Thermoformer 6 colour Omso DM144 lid priner Van Dam 580 8 colour rectangular tub printer

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

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

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

890mm Wide Coextrusion Welex World Standard sheet Line. 90mm Extruder. Circa 50mm Coextruder. Gear Pump 900mm Die. 890mm Welex Stack winder. 1998

900 X 450mm Cumberland Model 4590.

Soundproofed Granulator, Nip Roll Infeed 1997.

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

6 Colour Omso DM 144 lid printer. UV curing.

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

Maximum lid height - 25mm. 1997

Climaventa chiller model WRAT 1302/B. 331kw capacity, dual circuit. Was running 2 sheet extrusion lines.

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

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

EPPM 35