EPPM 16.6

September 2014

Cover Story | Page 10

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GLOBAL CAREER OPPORTUNITIES EUROPE

EUROPE

UK

APPLICATION DEVELOPMENT ENGINEER Engineering Plastics Automotive PACKAGING ENGINEER Protective Packaging - SAP

TECHNICAL REPRESENTATIVE Films, Printed Packaging TECHNICAL SALES MANAGER Polymers, Colour concentrates

AREA SALES MANAGER Extruded Plastic Sheets CUSTOMER SERVICE MANAGER Corrugated Packaging

SALES REPRESENTATIVE PACKAGING Film Packaging

UK

INDUSTRY SALES SPECIALIST PLASTICS Capital Machinery

COUNTRY SALES MGR GERMANY/AUSTRIA Packaging Wine and Spirits PRODUCT MANAGER N.EUROPE Engineering Polymers PROJECT MANAGER R&D PACKAGING Medical Devices BUSINESS DEVELOPMENT ASSOCIATE High performance Polymers MATERIALS / FORMULATION EXPERT Caps & Closures COUNTRY SALES MANAGER Plastic Extrusion TOOL/DIE DESIGN/IMPROVEMENTS MGR Beverage Packaging VALVE TECHNICIAN Aerosol / Dispensers COUNTRY SALES MANAGER Plastic Extrusion LEGWEAR END USE RESEARCH Polymers and Fibres MARKET DEVELOPMENT SPECIALIST Flexible Packaging MOULD PROJECT LEADER Mould Tools China ADVANCED ADTS ENGINEER Polymer Raw Materials MANAGER DISTRIBUTION Plastics, Chemical, Refining INDUSTRY SEGMENT LEADER Engineering Plastics Automotive SALES DIRECTOR EUROPE Beverage Packaging SALES & MARKET DEV. MANAGER Polymers & Fibres FIELD SERVICE TECHNICIAN Mechanical or Electrical CONSULTANT PSA TAPE Pressure Sensitive Tape PRODUCTION SUPERVISOR Technical Blow/Injection Moulding SALES REPRESENTATIVE Film Packaging

MANAGING DIRECTOR Flexible Film Packaging MARKETING ANALYST Plastic Packaging OPERATIONS MANAGER Medical Devices POLYMER R&D ENGINEER Polymers PREVENTATIVE MAINTENANCE MGR Plastic Injection Mould PROCESS & TRAINING ENGINEER Injection Moulding AREA SALES MANAGER PU and Composites PRODUCT DESIGN ENGINEER Plastic Injection Mould PRODUCT DEVELOPMENT MANAGER Thermoplastic Compounds PRODUCT DEVELOPMENT MANAGER Extrusion PRODUCT MANAGER Polymer Raw Materials PRODUCTION MANAGER Food Packaging PROGRAMME MANAGER Injection Moulding QUALITY MANAGER Medical Devices SENIOR DESIGN ENGINEER Medical Devices SENIOR R&D CHEMIST Polymer Raw Materials TECHNICAL DEVELOPMENT MANAGER Packaging TECHNICAL OPERATIONS MANAGER Plastic Injection Moulding TECHNICAL SALES MANAGER Plastic Injection Moulding FINANCE MANAGER/OPERATIONS CONTROLLER Manufacturing TOOL DESIGNER Plastic Injection Moulding

PRODUCTION MANAGER Plastic Injection Moulding SOFTWARE ENGINEER Medical Devices GENERAL MANAGER Wood Polymer Composites SENIOR PRODUCT DESIGNER Medical Devices BUSINESS DEVELOPMENT MANAGER Plastic Injection Moulding CUSTOMER SERVICES MANAGER Plastic Injection Mould DESIGN & DEVELOPMENT MANAGER Flooring DEVELOPMENT ENGINEER Electronic Connectors EXTRUSION MANAGER Food Packaging, Thermoforming MATERIALS DEVELOPMENT MANAGER Polymers MAINTENANCE MANAGER Machinery, Automotive GENERAL MANAGER UK/IRELAND Plastic Injection Moulding

OTHER REGIONS GENERAL MANAGER, GHANA Packaging, Corrugated TECHNICAL MANAGER, SAUDI ARABIA Injection Moulding CHIEF COMMERCIAL OFFICER, OMAN Pipes & Fittings CHIEF OPERATING OFFICER, OMAN Pipes & Fittings RUBBER CHEMIST, NEW ZEALAND Rubber Products ACCOUNT MGR MASTERBATCH GCC & LEVANT, UAE Raw Materials PRODUCTION MANAGER Technical Blow/Injection Moulding DIRECTOR DIVISION AMERICAS Additives/Masterbatch

This is a small selection of our current career opportunities. To view the above in more detail along with a wider portfolio of global job vacancies visit our website www.listgrove.com Executive Search Volume Recruitment Management Coaching Career Transition Competency Frameworks

Outplacement Interim Appointments Assessment & Development Retention & Rewards Redundancy & Relocation

StandF70

Stand 138

Hall A5-5000

Call: +44 (0) 1789 207070 Visit: www.listgrove.com INTERNATIONAL RECRUITMENT & HUMAN RESOURCE CONSULTANTS TO INDUSTRY SINCE 1975

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IN THIS ISSUE

head office Carlton House, Sandpiper Way, Chester Business Park, Chester, CH4 9QE. Tel. +44 (0) 1244 680222

Page 5 INDUSTRY & EVENTS NEWS

Page 32 REPLICA 3DM

Industry and events news that caught our eye, plus we focus on recruitment in plastics with Listgrove.

Our in-depth medical feature investigates how Replica 3DM is using additive manufacturing to revolutionise surgical procedures.

Page 10 COVER STORY: POLYONE

Page 34 APPLICATIONS FOCUS: MEDICAL

PolyOne explores how far plastics can go in replacing metals in automotive applications.

Page 14 MACHINERY NEWS In this edition, we focus on automation in plastics, homing in on announcements from Arburg and JOT.

Page 16 TPES NEWS Often taken for granted, a comfy pen for serial scribblers is like a good pair of shoes. And TPEs are the unsung hero.

Page 18 BIRMINGHAM GRANULATORS We speak to Birmingham Granulators MD Tim Aaronricks about the growing business’s Interplas premier.

Page 21 FAKUMA PREVIEW With one month to go our Fakuma Preview gives a snapshot of what visitors can expect on the show floor.

Fax. +44 (0) 1244 671074 Web: www.eppm.com C.E.O/publisher mark blezard C.O.O duncan wood

editorial editor rose brooke rose.brooke@rapidnews.com

production

A roundup of some of the latest plastics innovations in the medical sphere from Bayer MaterialScience, Styron and Meech.

Page 38 INDUSTRY FOCUS: PIPE & PROFILE EXTRUSION We home in on pipe and profile extrusion developments in this issue’s industry focus.

art robert wood production tracey roberts

advertising advertising manager lucinda nicholls tel: +44 (0) 1244 680222 lucinda.nicholls@rapidnews.com

subscriptions subscriptions@rapidnews.com qualifying readers

Page 41 MATERIALS FOCUS: SPECIALISED ADDITIVES

europe - free, ROW - £115 outside qualifying criteria

Specialised additives are allowing manufacturers to achieve amazing things.

We speak to Silvergate Plastics, LCR Hallcrest and Plastics Color Corp about their work in additives.

Page 48 EUREKA

UK - £80, ROW - £115 please subscribe online at www.eppm.com Address changes should be emailed to subscriptions@rapidnews.com.

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

A new feature to EPPM, we look at some of the out-of-the-box thinking that could make a big impact on plastics.

Each issue is distributed in print and digital format to 17,845 buyers and specifiers in the European plastic processing industry. © June 2014.

While every attempt has been made to ensure that the information contained within European Plastic Product Manufacturer is accurate, the publisher accepts no liability for information published in error, or for views expressed. All rights for European Plastic Product Manufacturer are reserved, and reproduction in part or whole without written permission is strictly prohibited.

Page 28 EUROMOLD EPPM is attending EuroMold this November, where the gigantic Frankfurt trade fair will be debuting a new format.

BPA Worldwide Membership

CLASSIFIEDS

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ISSN No - 2052-3912

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“

From The Editor

Gearing Up For Show Season Far be it from me to introduce our September issue with a clichéd observation about the changing of the seasons, but with autumn comes the start of a long and exciting run of industry shows that doesn’t slow until well into next year. Hang onto your hats, folks! Because EPPM is dusting off its passport and digging out its sensible shoes for three of the biggest plastics industry events in Europe between now and Christmas.

EPPM will be wandering the halls of Interplas, Fakuma and EuroMold in Q4 and all three of these events feature in this issue, where we unveil a little of what can be expected at these major shows.

With Interplas just days away, we explore what Birmingham Granulators has planned for its debut, while EuroMold has unveiled a new format for the gargantuan Frankfurt event. The most column inches, however, have been dedicated to trade show behemoth Fakuma, as we share a sneak peek at what exhibitors will be bringing to Friedrichshafen this October in our seven-page Fakuma preview (with a second to follow in our on-site issue).

But while it’s easy to forget there is a world outside of these shows when events season arrives, EPPM has been knee deep in specialised additives with Plastics Color Corp, LCR Hallcrest and Silvergate Plastics in our dedicated materials focus in this issue, while the use of plastics processes in cutting edge surgical and healthcare applications has been investigated in our spotlight on the medical industry.

Of particular note is the exciting work Replica 3DM has been doing using additive manufacturing to revolutionise reconstructive procedures.

We will be reporting live from start to finish at Interpas, Fakuma and EuroMold so keep an eye out for our regular newsletters, reports, blogs and Twitter updates for the very latest at these events and I am looking forward to meeting as many of you as possible at all three shows - particularly if you have an interesting story to tell EPPM. Until then, enjoy planning your visits and enjoy our September issue. And dig out those sensible shoes!

Rose Brooke, Editor

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3D printing ‘to give plastics $1.4bn boost by 2019’

INDUSTRY NEWS

Words | Rose Brooke

A fresh report on 3D printing materials indicates plastic additive manufacturing materials could boost the global plastics sector by $1.4 billion in the next five years.

“

The market for polymers used for additive manufacturing is already worth $310 million

”

3D printing is expected to boost the international plastics industry by $1.4 billion (€1 billion, £0.8 billion) by 2019.

This is according to a new report from industry analyst SmarTech Markets Publishing entitled ‘Plastics in 3D printing markets: A 10-year opportunity forecast’, which states the market for polymers used for additive manufacturing is already worth $310 million and will balloon to $1.4 billion in the next five years.

SmarTech believes the increasing popularity of 3D printing in both the consumer and professional marketplaces means value-added plastic materials for 3D printing represent a high-margin opportunity for materials producers, equipment manufacturers and other related businesses in the additive manufacturing supply chain.

Value and volume forecasts In addition to looking at key players in the 3D-printed polymer space - including such major influencers and innovators as 3D Systems, Stratasys, Formlabs, EnvisionTEC, EOS, Beijing Tiertime, DuPont, Lockheed Martin, MakerBot, Bayer and BASF - the report analyses key opportunities for plastic materials and how this will change. The document looks into the application of ABS, PLA, PC, PP resins, PS, Acrylate resins, nylon and thermoplastics. Each material has been investigated and given a 10-year forecast in terms of value and volume.

Industrial, professional and consumer-grade machines have also been covered in the report and forecast for the next decade.

SmarTech reports that personal 3D printing offers the biggest opportunity for growth in the ABS and PLA print material arena for hobbyists and off-time engineers, while more durable polymers such as polycarbonates, TPU and nylon will continue to gain market share. Meanwhile, polymer powders for laser sintering technologies represent the overall largest opportunity for growth in plastic materials.

In terms of weight, ABS, PLA and nylon will continue account for the biggest piece of the 3D printing materials pie, accounting for more than 13,000 tonnes in 2019.

Victory for small batches New plastic materials for professional 3D printing will continue to gain market share as discerning users justify additional costs with end results. In particular, materials that offer lighter and better-performing components for aerospace, customisable medical implants and dental solutions, and materials that reduce sub-assemblies will provide added value to the relevant markets.

Equipment manufacturers will continue to control the supply chain for 3D printed materials and this has reduced opportunities for large materials companies.

Nevertheless some material companies are partnering with smaller equipment manufacturers and have been developing their own 3D printing equipment, with companies like CRP Technologies and DSM Somos finding business by developing specialised materials for automotive and dental applications.

Despite the growth in 3D printing, material demand will not soar to the degree needed to drive major economies of scale through larger batch sizes. This dynamic will champion materials that can be produced economically in smaller batches, such as resins.

SEPTEMBER 2014 • WWW.EPPM.COM • 5

INDUSTRY NEWS

For the plastics crème de la crème ‘think global’ EPPM spoke to Managing Director of plastics and packaging recruitment specialist Listgrove Ryan Kirby about the change in mindset European companies are adopting to ensure their workforce is ahead of the pack.

Words | Rose Brooke

Bringing advancements to a fast-paced and competitive sector such as plastics is essential - but while we hear much of the latest machinery and material developments from industry leaders, it is the teams behind these announcements that are driving companies forward.

Managing Director Ryan Kirby has overseen the expansion of Listgrove’s specialist plastics, packaging and chemical recruitment division aimed at non-UK-based clients, and offers a unique insight into the sea change recruitment in plastics and packaging has experienced in the wake of the global economic downturn.

The division has grown into a multi-national, multi-lingual team from France, Sweden, Germany, Poland and the Netherlands servicing many well-known businesses within the industry. Listgrove not only weathered the storm that shook manufacturing to its core at the height of the global economic crisis, but it experienced significant uplift in demand for its services and support.

Nevertheless, Kirby believes a shift in attitude is key if the European plastics sector is to be competitive globally.

Casting a wider net “Finding people with the right level of experience who are based close to site is now extremely difficult, so companies have to consider people from different countries,” Kirby explained.

“This is something we have been quick to support, promoting the existence of people who are in different countries but have the skills, experience and potential to undertake foreign roles. Across Europe and Asia, it’s now more common to find individuals willing to relocate to secure a preferred career path.”

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“In Germany, for example, it’s been difficult to find individuals locally, which is why you see a lot of nonnationals being employed. Even further afield in the Middle East and Asia, this is something we see all the time. There is resistance in some areas to employ from outside your own country but that’s decreasing.”

“

You can expect young people to be adaptable, loyal and ready to learn

Along with a fading reluctance to recruit from overseas, plastics, packaging and chemicals businesses in Europe are, according to Listgrove, becoming more willing to take on recent graduates.

”

Fresh talent “Before, [these companies] probably wouldn’t want somebody fresh out of university because they would prefer experience with immediate impact,” Kirby observed.

“In today’s market two things have changed: it’s more proactive to consider people from other parts of the world, and people are hiring graduates.”

“I think you can expect these young people to be adaptable, loyal and ready to learn. In some cases, a more experienced person will probably want to bring their own way of thinking to a role, which is good, but sometimes you want somebody who is ready to adapt and learn. Overseas candidates and graduates tend to display a greater flexibility and innovation - they’re willing to grow.

“We try to manage companies’ expectations - don’t limit your options to those based within your own country and consider those who are willing, able and flexible.

To succeed, everybody now has to think globally.”

“

Finding people with the right level of experience who are based close to site is now extremely difficult

”

LANXESS DEUTSCHLAND GMBH I BU HIGH PERFORMANCE MATERIALS | 51369 LEVERKUSEN | GERMANY | LXS-HPM-057EN

Listgrove is currently placing a number of recent graduates and Kirby explained that for many roles, young people are ideal because they welcome a new challenge and are willing to work hard to progress and achieve recognition.

HEAT HERO ENERGIZED BY When things start heating up, you need to keep your cool. As modern engines get ever more compact and powerful, they get hotter too. With Durethan XTS you are justifiably putting your faith in high-performance materials that remain composed even in extreme situations thanks to their extraordinary heat stability. Find out more about the excellent performance of our new XTS grades by visiting www.durethan.com

SEPTEMBER 2014 • WWW.EPPM.COM • 7

COME AND VISIT US AT

Stand E80

“Visitors to the stand will have the chance to win a luxury hamper. Simply leave your business card and the draw will take place on the final afternoon by Rose Brooke, new editor of EPPM.” Tel: 01827 838840 | Fax: 01827 838853 | Mobile: 07973 674288 | Email: info@granulators.org

www.granulators.org

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INDUSTRY NEWS & EVENTS: INTERPLAS PREVIEW

Interplas is coming Interplas is just days away and here’s a sneak peak at what four innovative exhibitors at this prominent UK plastics event have in store for visitors this autumn.

Instron:

‘What’s

ation?’ the cost to your Reput

ting equipment d manufacturers of tes As one of the most truste trade show a Instron has designed for the plastics market, gh the thr itors on a journey ou experience that takes vis ials testing. ter ma nal horrors) of plastics challenges (and occasio perience like no G12 for a cinematic ex oth bo at m tea the it Vis depicting reall setting, Instron will be ica atr the ly tru a In er. oth cur in any lab. me of which could oc life customer stories, so ending to the n guarantees a happy But don’t worry; Instro e... horror story for everyon

Arburg :

‘Rolling out the Allrou

nder’

Arburg will be turning the spotlight on its lar ge Allrounder at Interplas this autumn, where the hydraulic All rounder 720 S which has a clamping force of 3,200 kN - wil l manufacture a grip for a shower hand set in situ. Thanks to its servo-hydraulic system, this exhibit fea tures optimised energ y-efficiency and bears the Arburg “e²” energy-efficiency label.

Removal and setdown of the moulded parts are performed by a Multilift Select robotic system that is fully integrated into the Selogica machine control system.

Colin Tirel, Managing Director of Arburg, sa id: “These machines cover a clamping force range from 2,500 to 5,0 00 kN and are all available as a hydrauli c, hybrid or electric op tion.”

ALBIS:

‘Hygienic protection and antibacterial perform ance’

With the product serie s Hygienic Material Bio master Protected, ALBIS PLASTIC is offeri ng masterbatches and compounds on a silver ion basis. These products provide the an tib acterial protection of plastics for the entire life cycle of a product.

According to the Biocid e Directive 98/8/EC an d the succeeding regulation 528/2012 (fro m September 2013), silv er ions can be used as biocides. In Ge rmany, ALBIS Additive -Batch HM standard products ha ve been registered wit h the biocides registration office of the BAUA (Federal Institute for Occupational Safety an d Health) under respe ctive N numbers.

The active ingredients have been registered with the EPA for use in the US. ALBIS will be bringing its innovations and will demonstrate their applications in the me dical, healthcare, food hygie ne and sports fields at Int erplas this month.

Ampacet:

ge masterbatch’

‘Presenting cutting-ed

Ampacet metallics and pastels, to nts ce es arl pe d an From satins vide the most lette of pigments to pro works with a broad pa and special ge of custom colours aesthetically unique ran st cutting edge in any is bringing the mo effects - and the comp las 2014. masterbatch to Interp e moulding hing labs and prototyp atc r-m lou co t’s ce pa Am tch customers’ its colours exactly ma re su en l wil nt me uip eq within Europe that manufacturing plants six h wit ts, en em uir req m cater for clients’ custo its colour needs, while manufacturing plant in tly Telford, UK, has recen of-the teinvested in a new sta a e vid art colour line to pro rs me sto better service to cu t and to meet marke requirements.

SEPTEMBER 2014 • WWW.EPPM.COM • 9

MATERIALS NEWS: COVER STORY

September 201 4

Still plenty of potential for metal replacement in automotive PolyOne’s Specialty Engineered Materials expert Marc Mézailles seeks to shake off the outdated misconceptions of polymers to prove plastic can now outperform metal where it once was not viable in automotive manufacturing applications.

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Words | Marc Mézailles, Global Industry Manager, Automotive, PolyOne Specialty Engineered Materials

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Technology now exists that allows thermoplastics to retain their strength and stiffness from sub-freezing temperatures up to nearly 200° C.

”

Plastic components have become an essential part of automotive manufacturing. On most models, plastics account for up to 50 per cent of a vehicle’s volume and are used in a wide range of parts that were once fabricated of metal.

Plastics processors already have made great strides, clearly, but this is not the end of the story.

Even now, plastics are frequently ruled out based on common misconceptions and unfamiliarity with new polymer developments. Take a look at three performance areas that were previously considered to be out of the reach of polymers...

Components requiring high strength, stiffness, impact resistance or extreme temperature tolerance A chief concern regarding plastics centres on their stiffness, strength and ability to withstand extreme temperatures without melting, warping or cracking.

But technology now exists that allows thermoplastics to retain their strength and stiffness from sub-freezing temperatures up to nearly 400° F (200° C). Long-fibre reinforced thermoplastics (LFTs) demonstrate excellent impact performance even at high levels of stiffness, and these materials exhibit low creep at elevated temperatures. These LFTs are up to 100 times more fatigue resistant than polymers reinforced with short fibres and offer a high degree of mechanical resistance to high loads. At equivalent levels of reinforcement and using the same matrix material, the impact resistance of an LFT formulation typically is about 70 per cent higher than that of a short fibre formulation, and it also has greater stiffness.

After injection moulding, long fibres still are up to 10 times longer than short fibres used to reinforce polymers. Fibre length and fibre type (glass, carbon, etc.) are determining factors in the strength, stiffness

10 • WWW.EPPM.COM • SEPTEMBER 2014

and durability of plastics, meaning LFTs are most ideal to replace metal components in portions of the vehicle subject to high stress from extreme temperatures or pressure. Long fibres form a ‘3D network’ within a moulded part; this network supports a part even when a polymer begins to soften (creep). LFTs effectively fill the gap for applications in which short-fibre reinforced formulations are not sufficient, but for which metals may be over-engineered, limit design or add too much weight.

Thermally conductive components Automotive engineers have also been hesitant to use plastics in applications requiring conduction or dissipation of heat because of thermoplastics’ inherent insulating properties. However, engineering thermoplastics can now be formulated to dissipate heat as effectively as metals, allowing them to be used in ways that were not always possible before.

It is possible to reach thermal conductivities up to 20 W/m.K (in-plane), which is 50 to 100 times greater than standard thermoplastics and 1/5 that of cast aluminium. The typical densities of these formulations vary from 1.65 to 1.75 g/cm3, which is 30 to 40 per cent less than aluminum.

Flame class ratings of FR-V0/1mm are possible.

Due to their outstanding performance-to-weight ratio and to their significant advantages in ease of processing, no need for secondary applications and complete design freedom, thermally conductive plastics can aid automotive engineers in many applications. External lighting is one example. Headlight and rear light fixtures produce a great deal of heat, which can stress and fatigue its components over time and even reduce a lamp’s effective lifespan. Thermally conductive plastics help dissipate the heat, adding life to the entire fixture.

For many of the same reasons, thermally conductive plastics are also useful in the design of electronic components, fluid management systems and many other heat sensitive applications.

Electrically conductive components Electrostatic charges can be a danger for a vehicle’s electronic operating systems or fuel circuit components, which are sensitive to Electrostatic Discharge (ESD). The use of electrically conductive and dissipative materials prevents this hazard.

Engine control, power electronics, infotainment, active safety systems and other electronic systems are being added to modern vehicles.

In order to make sure these systems run properly, Electro-Magnetic Interference (EMI) needs to be managed, via shielding of an emitting source or of a sensitive component. Currently, this usually is done with a metal component.

Like metals, electrically conductive polymers can help prevent ESD and protect applications from EMI. But conductive plastics have even lower density, allow for greater design flexibility and can offer a system cost reduction compared to aluminium. To cover the diversity of ESD and EMI requirements, formulations are available with surface resistivity of 105 ohms or less. These have not only excellent mechanical and conductive properties, but also facilitate electro-static painting.

These technologically advanced engineering thermoplastics solutions are opening the door for new applications in automotive design. A knowledgeable supplier can help select the correct combination of filler type and amount to meet your application’s requirements.

Is your component a good fit for polymer conversion? Ask yourself these questions.

Are there performance problems with the current metal parts — such as corrosion, fatigue or costly scrap recycling? Plastics are resistant to forms of corrosion that can compromise metal, such as rusting and other forms of oxidisation. Injection moulding of polymers often means no further assembly is required, whereas metals often require welding or other secondary processing, adding on costs and potential quality issues.

Are the parts subject to expensive secondary finishing processes?

Polymers can reduce or eliminate secondary finishing processes such as protective coating and painting. Most plastics require no protective coating, making the production process more efficient.

Answering these questions can help determine if a metal component is a good fit for polymer conversion.

The next step is to find a supplier that can develop the right polymer formulation to maximise the performance characteristics of your part.

Your chosen supplier also should offer engineering services, global service and support, and be able to work with a wide breadth of polymers to meet your specialised needs.

With new developments in polymers, there is a widening array of automotive applications for plastics that were not feasible a few years ago. Automotive engineers need to take a fresh look at these new technologies to make sure they are using all of the tools available to them to reach their design goals. The earlier polymers are considered in the design process, the greater the benefits that can be realised.

What are the performance factors that would lead you to design this component in aluminum or steel? If heat dissipation is the primary driver, thermally conductive polymers could be an excellent alternative. If stiffness is a primary driver, consider long fibre polymer technologies.

ce help mer scien ly o p in s e ce metal Advanc ners repla ig s ls e d e v ti meet goa automo olymers to l efficiency. p y lt ia c e with sp and fue cturability for manufa

“

Conductive plastics have even lower density, allow for greater design flexibility and can offer a system cost reduction compared to aluminium.

”

The incre asing elec trification opportunit of vehicle ies to rep s creates lace meta polymers l with spec to manag ialty e EMI.

SEPTEMBER 2014 • WWW.EPPM.COM • 11

You make great things.

We make great things happen.

In March 2015, more than 60,000 professionals from every aspect of the plastics industry and its vertical and end-user markets will assemble in Orlando, Florida for the largest, most influential plastics event of the year.

Expect great things.

Register for free today at www.npeguestpass.org/EPPM1

NPE2015: THE INTERNATIONAL PLASTICS SHOWCASE March 23-27, 2015 Orange County Convention Center Orlando, Florida USA

Face-To-Face, NPE2012

AJZ230_NPE15_EPPM.indd 1

8/5/14 3:04 PM

:04 PM

Innovation and expertise in Masterbatch from Colloids: the Makers of Masterbatch Leading masterbatch expertise is coming to Interplas.

Colloids: the Makers of Masterbatch is bringing the very latest to the leading event.

Colloids: the Makers of Masterbatch has announced the products that will be on display at the Interplas trade show at the NEC in Birmingham, UK, this month (September 30th-October 2nd).

Colloids will be showcasing advances including its universal biopolymer masterbatch SUSTAIN, along with a range of polymer-specific biopolymerbased masterbatches that are ideal for film and sheet extrusion, injection and blow moulding and even fibre applications with a reduced carbon footprint and complete recyclability.

INDUSTRY NEWS

“

Clients deserve the best masterbatch with the right properties to maintain their competitive edge.

”

Bagnall added: “We ran through all our data and checked figures over time: which colours were selling, and which were not. Then we removed the worst performers and introduced new colours aligned with the latest tastes.

We know all about that already from our extensive work with designers on bespoke projects spanning consumer to domestic and beyond.”

Moreover, Colloids will be showcasing exciting new developments in colour and special effects - including revolutionary new marbling effects that are particularly striking in packaging - along with masterbatches specifically designed for laser marking, to ensure the right thermal and photochemical effects.

Colloids has a strong global reputation in the engineering and performance plastics sectors and at Interplas, specialists will be on hand to discuss these sectors as well as the full range of the company’s expertise including: colour-matching software and rapid prototyping, and one-stop-shop services for all client needs.

Josephine Bagnall, Sales and Marketing Director at Colloids, commented: “At Interplas we will be presenting the complete spectrum of our competencies. In every case, clients deserve the best masterbatch with the right properties to maintain their competitive edge.

“We go beyond ‘just’ manufacturing. We are the industry experts in black, white, colour and additives.”

Colloids is also showcasing the maxim universal masterbatch range at Interplas. The maxim range is available off the shelf or to order against bespoke colour matching and it is ideal for 26 polymers including PVC, nylon and ABS. It can be delivered next day, UK-wide.

The standard maxim range comprises 200 colours available from stock and the palette has been comprehensively redesigned to meet today’s fashions and trends.

www.colloids.com

+44 (0) 151 546 9222 Stand H37

SEPTEMBER 2014 • WWW.EPPM.COM • 13

MACHINERY NEWS

Arburg extends automation capacity in Eastern Europe Arburg is working to meet growing demand for automated production cells by investing in a major expansion project at its site in Brno, in the Czech Republic World-leading plastics processing machine manufacturer Arburg is extending its Eastern European reach and capacity for automation.

The German-born company broke the ground at its Brno site in the Czech Republic on July 14th 2014, marking the beginning of a major expansion project that will extend Arburg’s Technology Center (ATC) by 565 m sq to over 1,600 m sq. The additional floor space will help the growing business to meet burgeoning demand for automated, customer-specific production cells.

Currently the facility lacks the space for constructing and testing complex systems, therefore it was decided in 2013 that the decade-old Brno site would be extended. The ATC is currently equipped to very high specifications and at present covers 1,050 m sq of usable injection moulding machines, which is dedicated to evaluating moulds, application tests and practical training purposes.

Jaroslav Novak, Arburg Managing Director, explained: “The extended capacities will give us enough space to build, test and optimise three automated production cells. Thus delivery times will be reduced in future too. In addition, our customers will have the opportunity to find out about the current state of the art in automation technology and to witness our expertise in this sector.”

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He explained that the growing trends for automation and turnkey systems has been monitored by the company for some years, with this side of the business growing at between 10 and 15 per cent annually for some time.

“Since 2005, we are present in the automation business in the Czech Republic and Slovakia and implement turnkey projects as general contractor in cooperation with local suppliers of peripheral equipment,” Novak said. “Three out of a total of 28 employees are exclusively responsible for automation solutions and specific production cells.

These experts are being supported by additional staff.”

The extended Brno site will enhance the facility’s well-equipped parts store and will offer the company significant benefits when it is ready for occupation at the beginning of next year.

The expansion of the ATC in Brno is an important milestone in the success story of the Arburg subsidiary, which is responsible for both the Czech and Slovakian markets. Novak has managed the company since its foundation in April 1996 and thanks to his years of experience as a former Arburg trading partner, he is extremely familiar with both markets and brings invaluable expertise to the business operations. He has grown his team from three to 28 in the intervening 18 years, offering customers in the Czech and Slovak Republics first-class, comprehensive support, particularly in the booming automation sector.

JOT Automation signs distribution agreement with WKK A new distribution agreement between JOT Automation and WKK aims to speed up time to market and brings economies of scale.

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

JOT Automation, the leading supplier of test and production solutions, and WKK Distribution, the leading distributor of electronic capital equipment, materials and services in Asia, have signed a three-year distribution agreement at the NEPCON South China exhibition in Shenzhen.

Really?

Under the terms of the agreement, WKK Distribution will act as a lead distributor of JOT Automation products for Asia-Pacific. The partnership will focus on JOT Odd Shape Assembly Cell, JOT Router, JOT Tiny Test Handler, JOT G3 Final Tester, JOT M10 Functional Test Solution, JOT IDeA, JOT Vision Inspection Cell and material handling products.

MIN

“We know that manufacturing in China and Asia will require a great deal of automation in order to keep the leadership position also in the future. Because of this partnership, we are very confident that both WKK Distribution and JOT Automation will be very successful. It’s the right partnership at the right time,” stated Hamed Hassan El-Abd, CEO, WKK Distribution.

“It is an honour to partner with a company like WKK Distribution, JOT could not have a better partner for winning over the Asian market.

WKK is well positioned, a globalscale player. We are looking forward to great business opportunities for both companies from this agreement since fully-automated manufacturing will take its place,” added Matti Leirimaa, General Manager, JOT Automation Beijing.

“More importantly, our partnership will instantly benefit our endcustomers, electronics device manufacturers, by speeding up the time to market and bringing economies of scale.”

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SEPTEMBER 2014 • WWW.EPPM.COM • 15

MATERIALS NEWS

Stabilo and Kraiburg TPE:

Writing with a good feeling Kraiburg TPE is working in close partnership with Stabilo to ensure writers have a comfortable experience when scribbling for long periods thanks to THERMOLAST K. Stabilo and Kraiburg TPE have been working together for more than a decade on the future of handwriting. The specialist for TPEs supplies the international writing utensil manufacturer with THERMOLAST K, the material that makes pencils and pens pleasant to hold.

Electronic communication is fast, effective and in keeping with the times.

And yet – people who write things down often have better ideas, improved recall and a longer memory of what they have written. Prolific writers, students and everyone who knows the value of handwriting appreciate the qualities of a good writing utensil.

The quality is in the combination Stabilo has been manufacturing pens and pencils since 1865.

Today the company offers a diverse spectrum of user-friendly and highly functional products for writing, drawing and highlighting. The most recent compositions include the pointball and EASYball ballpoint pens, the worker colourful roller ball pen, the GREEN BOSS and BOSS EXECUTIVE highlighters and the SMARTgraph pencil.

Stabilo writing utensils feature a non-slip gripping surface that is pleasant to the touch. They are manufactured from Thermoplastic Elastomers of the product group THERMOLAST K from Kraiburg TPE. Excellent adhesion to PP and other thermoplasts such as PC/ABS and the fast and easy two-component injection moulding manufacturing process make

16 • WWW.EPPM.COM • SEPTEMBER 2014

THERMOLAST K ideal for Stabilo writing utensils. The material can easily be dyed and offers virtually unlimited possibilities in terms of design and functionality. THERMOLAST K compounds are suitable for all conventional manufacturing processes; in addition to their excellent adhesion they also feature outstanding sealing and non-slip properties. The highly specialised products of Kraiburg TPE, tailored to suit market demands, are the result of many years of development and experience.

Sustainability – for lasting results THERMOLAST K is certified for contact with foods and features temperature stability and weather resistance, in addition to being free of latex and PVC. It is also easy to recycle. Both manufacturers develop their products with a keen focus on sustainability and environmental consciousness.

“Sustainability is gaining in importance with respect to customer requirements and the standards placed on suppliers, as well as the processes within companies. In Kraiburg TPE we have found a partner that has the same standards of quality,” explained Sigrid Hell, Director of Purchasing at Stabilo International GmbH. In addition to internal quality assurance, prevention and improvement measures, Kraiburg TPE is certified in accordance with ISO 9001, ISO 14001 and the energy management system ISO 50001.

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At the heart of better plastics

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Hall 4, Stand G68

SEPTEMBER 2014 • WWW.EPPM.COM • 17

INDUSTRY NEWS & EVENTS

Tapping Europe at Interplas EPPM spoke exclusively to Birmingham Granulators founder and MD Tim Aaronricks about the company’s Interplas 2014 debut with Inan Plastik, and how this buzzing industry gets under your skin.

Words | Rose Brooke The press has heralded Interplas 2014 as a return to form, with an expanded floorplan and an anticipated 12,000 visitors stalking the buzzing show floor for leads and the latest technology.

One company that has been watching the re-emergence of the ‘mustattend’ plastics show of the year is Birmingham Granulators, who will be exhibiting for the first time at this year’s showcase.

Birmingham Granulators’ timing is strategic. The company started in 1996 as a one-man business carrying out the repair and refurbishment of granulators and the sale of used machinery. In 2008, the company was bigger and busier, and founder Tim Aaronricks was working with a skilled team of engineers and other staff enjoying the boon the company experienced from the global economic crisis, as interest in good secondhand machinery rose with budgetary caution.

In 2006, Birmingham Granulators partnered with Turkish company Inan Plastik, a 25-year-old manufacturer of granulators, with whom the Staffordshire-based company will exhibit at Interplas 2014.

Better than a brochure “Interplas is going to be a big showcase for us,” said Aaronricks. “We remember the show back in the day when it was the place to be, but it lost its way over the years with the massive increase of Dusseldorf (K Trade Fair). But we’ve been following the show and it’s come along in massive strides both in quality and content.

“That’s why we’ve decided to be there this year. Apart from wanting to showcase Birmingham Granulators, we’ll be showcasing Inan Plastik.

We always share their stands in Dusseldorf and at Plast Eurasia in Istanbul and do quite well and this year they decided to come to Interplas and we’re taking the lead.”

Aaronricks explained that while Birmingham Granulators sells Inan Plastik’s hardware, it is difficult to do this with only a brochure, but at Interplas, the team will have real machines on its stand to show prospective customers the technology in the flesh and it is this type of selling that excites the Managing Director.

“We think it’s good to be able to interact with existing and potential customers on mutual ground,” he said. “Everybody’s busy these days and getting hold of people is always difficult - there’s a lot of people chasing the same business. But we hope people take the initiative to come to Interplas and use their time wisely to go around and look at possible new suppliers.

“We need to be seen as well ... There’s no doubt you need to be constantly in customers’ memory. We think our Interplas appearance will show the industry what we’ve got - and that we’re serious.”

18 • WWW.EPPM.COM • SEPTEMBER 2014

“

If we’re a little more open and prepared to work together, it would enhance the industry

”

KW TRIO: The Next Generation in Lump and Neckdown Detection

Bread and butter Birmingham Granulators will exhibit granulators and shredders - the company’s “bread and butter”, according to Aaronricks - at Interplas, in addition to Inan Plastik’s expanded machinery range, which includes, but is not limited to, pulverisers, wash plants and extruders.

Stray Light Stays Out

After the show, the machines will be shipped back to Birmingham Granulators’ premises for demonstration purposes, giving customers the opportunity to trial their product and ensure the end results are as desired.

Inan Plastik may be bringing a lot of hardware to the table in the partnership, but Birmingham Granulators is securing sales. Aaronricks explained that enquiries for Inan Plastik’s machines from France, Spain and Portugal get passed to his team because it is much easier to travel from the UK to the western continent.

“They need visas, we don’t. We can just jump on a plane. Although at this stage we are mostly covering the UK and Ireland, we can see that we’re going to be doing much more in Europe. Also, it is easier for European clients to visit the UK than for them to travel to Istanbul,” Aaronricks explained. “We’re actually looking to take on a sales executive to work on this side of the business. The European market is huge and because of the support we’re getting from Inan, we need to look at that.”

A pulsing light source and automatic ambient light adjustment guarantee the best detection performance – even for the smallest faults

Under your skin But while Aaronricks is passionate about growing his business and being seen alongside the biggest names at Interplas, he is refreshingly antiprotectionist and open to an industry mentality that encourages working together and supporting your peers.

“You have to be careful with these shows, that you don’t go there and be protective. It’s a showcase and there’s plenty of room in the industry for everybody. If we’re a little more open and prepared to work together, it would enhance the industry without necessarily harming anybody.”

Ultimately, Aaronricks is passionate about what he does and believes he is not the only dyed-in-the-wool industrialist in this game. “I’ve been in this industry since 1980,” he said, “if it’s in your blood, it’s in your blood. You still have the MDs and owners out there in their 70s and they’re never going to retire - it just gets under your skin.”

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He added: “It’s good to see what everybody is up to and from my experience of being on show stands it’s a massive buzz. It can get you on the sales road. We think Interplas has legs and if we can get this trade show back to where it should be and we can encourage European and other foreign investment, then it’s going to be a good future.”

Visit us at:

ZUMBACH Electronics sales@zumbach.ch I www.zumbach.com

NEC Birmingham, UK 30 Sept. – 2 Oct. 2014 Stand A82

SEPTEMBER 2014 • WWW.EPPM.COM • 19 EPPM_Zumbach-KW_75x240.indd 1

7.8.2014 7:59:56 Uhr

www.kraussmaffei.com

We have made our smallest one top of the class.

Find out more at Fakuma in Friedrichshafen, hall A7, booth 7303/7304

Engineering Passion 20 • WWW.EPPM.COM • SEPTEMBER 2014

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01.09.14 09:41

INDUSTRY NEWS & EVENTS

The 23rd Fakuma draws near Building on over 30 years in plastics, the 23rd edition of Fakuma promises the latest innovations from around the world will be in Friedrichshafen this autumn.

The 23rd edition of Fakuma, one of the world’s best-known trade fairs for plastics processing, is back in Friedrichshafen this October, running for the full week of the 14th to the 18th.

There, some 44,000 visitors from around the globe will get a first-hand look at the latest innovations in the fields of injection moulding, extrusion technology, thermoforming and more.

For more than three decades, Fakuma has been recognised as a leading European platform for plastics, with more than 1,700 exhibitors from 35 countries taking their place on the show floor.

When it comes to raw materials, processing machines, peripherals, solutions for automation or C Technology - FAKUMA functions as a source of information and ideas displaying the newest products and innovations.

Here is a glance at what just some of the exhibitors at this vast event have in store.

Can’t see your company in our Fakuma Preview? Send your Fakuma news to Editor Rose Brooke to be included in our on-site issue of EPPM at the big event. Email rose.brooke@rapidnews.com.

AUTENRIETH KUNSTSTOFFTECHNIK

ARBURG

SMEs are in good hands with Fakuma exhibitor Autenrieth Kunststofftechnik. Autenrieth takes meticulous care of its customers’ demands all the way from expert counseling to production and logistics, with WITTMANN BATTENFELD’s latest injection moulding technology playing a pivotal role in production.

Autenrieth Kunststofftechnik stands out primarily due to its comprehensive, targeted customer counseling service. From counseling, product design, material selection and prototyping, right up to production and logistics, customers are supplied with everything from a single source and the company’s product range is virtually unlimited.

Because of this great service, customers can be sure that they really get exactly what they need. Moreover, Autenrieth Kunststofftechnik’s customers appreciate the company’s high degree of flexibility and short response times.

Arburg will present the next step in its production efficiency strategy.

In addition to an holistic approach, the focus will also be on the cost-effective production of plastic parts, from one-off parts to massproduced items. Thanks to the expansion of the product portfolio to include the Freeformer, Arburg is now the only manufacturer to cover the entire spectrum from additive manufacturing to injection moulding.

The total of 11 exhibits on the exhibition stand in Hall A3 will also present innovative applications, special industrial and automation solutions as well as practical examples regarding the future topics of Industry 4.0, functional integration and lightweight construction.

SEPTEMBER 2014 • WWW.EPPM.COM • 21

09:41

BAYER MATERIALSCIENCE

BRAUNFORM

Bayer MaterialScience will be bringing its material solutions dedicated to innovation and sustainability to Fakuma 2014, along with current developments from efficient lighting to customised car interiors. The company will showcase exciting material solutions for key trends at the trade fair in Friedrichshafen, Germany, from October 14 to 18, 2014.

Visitors to Stand 2406 in Hall B4 will be able to find out about the latest developments in the automotive and LED lighting sectors and about new production processes. The company’s programme will be rounded out by speedtalks from experts - short, concise presentations about key themes.

Braunform will welcome Fakuma attendees to its living room this autumn, where the team will focus on the specific-designed Braunform MED mould standard for clean rooms represented by modular inserts of a 96-cav. injection mould for a Pen Hub (needle holder). During the exhibition period, the corresponding high cavity injection mould with a cycle time of 3.9 seconds will be exhibited at the booth of ENGEL on a fully electric ENGEL e-motion 220t. The high cavitation injection mould processes the article in a highly automated manufacturing cell under constant visual monitoring.

COPERION K-TRON

BILLION

Two complementary companies from the Plastics Valley in Oyonnax are working together to highlight the innovative technology IMA during this year’s Fakuma. Billion and MIHB join together to create an IMA experience to enable all visitors to understand the profits of the technology thanks to a unique part specially created and made exclusively during the show. Thanks to a very technical mould, the IMA is a technology allowing to overmould two components of the same part inside the tool. The impressive efficiency of the process bases in its reliability and its productivity. Other solutions are possible by including inserts, filters or other components inside the tool, always in the same cycle. More than a “technology”, the IMA is intelligent based on the synergy of skills, the ingenuity, the experience and the toughness of Billion and MIHB teams.

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Coperion K-Tron presents a BSP135 Bulk Solids Pump feeder on a pivoting base as well as a Gravimetric Batch Blender with integrated Vacuum Receivers and Powder Feeder on its booth A6507 in hall 6 at this year’s Fakuma. The patented Coperion K-Tron Bulk Solids Pump (BSP) feeder line has been specifically designed and engineered to provide gentle, precise feeding of free-flowing pellets, granules, and friable bulk materials. BSP feeders do not use the usual screws/augers, belts or vibratory trays to convey the material.

They utilise positive displacement action to feed free flowing materials with highest accuracy, offering uniform discharge, consistent volume and gentle handling.

DUPONT

EREMA

The DuPont exhibit at Fakuma 2014 reflects the important role plastics play in society and how DuPont is enhancing its advanced materials technology to help companies innovate and compete in the global economy. Under the banner of “Welcome to the Global Collaboratory”, DuPont presents how its Computer Aided Engineering (CAE) and Predictive Engineering Solutions, coupled with its broad portfolio of advanced materials, can provide outstanding benefits in a wide range of industries, including automotive, electrical and electronics, and healthcare.

Global market leader in plastic recycling systems EREMA’s focus at Fakuma will be on its new plant generation INTAREMA. The system is based on the newly-developed and globally patented Counter Current technology and brings together in an unparalleled way top productivity, flexibility and extremely easy operation with considerably lower energy consumption. “The new INTAREMA system has been extremely well received in the marketplace and initial sales have been highly encouraging,” reports CEO Manfred Hackl. EREMA’s Laserfilter technology – which has likewise been enhanced – for the processing of highly contaminated materials will also be presented at the show.

ESC ENGEL

With a view to focus on its strong expertise in the field of special machinery for the plastics industry, ESC is participating in FAKUMA alongside COMEC. For over 65 years, ESC has been leading the international market for screen, pad and digital printing machines and is designing semi-automatic up to all-automatic special purpose printing machines in close cooperation with their customers. Due to rising demand for customised processing solutions, ESC and COMEC will offer their knowhow to Fakuma visitors who intend to realise special projects in plastics finishing.

Barrier-free mould area, compact manufacturing cells and a high capacity for innovation: ENGEL will be celebrating 25 years of tie-barless technology at Fakuma 2014. With numerous innovative applications on show, the injection moulding machine manufacturer will use the event to demonstrate how tie-bar-less machines can continue in future to meet the highest demands in terms of efficiency and cost-effectiveness.

The new tie-bar-less, all-electric ENGEL e-motion 50 TL will also be making its world premiere in Friedrichshafen. Other innovations on show at the ENGEL stands will include double technology integration and the ENGEL e-flomo closed loop temperature-control water distribution system.

SEPTEMBER 2014 • WWW.EPPM.COM • 23

ETTLINGER

ADVAL TECH FOBOHA Adval Tech FOBOHA is set to take Fakuma by storm with its made-tomeasure injection moulds with outstanding technical and economic features. An experienced team will advise prospective customers on booth 3212 in hall B3. Consulting often begins with the development of plastic parts and creating added value with a plastic-compatible design and a tailor-made product solution – Adding Value – is the company’s corporate philosophy.

Whether single-component standard moulds, stack moulds or highly efficient cube and twin-cube systems with in-mould assembly: FOBOHA builds made-to-measure injection moulds with outstanding technical and economic features. Modular mould concepts and the guaranteed interchangeable design of all mould components provide highest availability at shortest cycle times.

Ettlinger Kunststoffmaschinen is set to showcase two new high performance systems for continuous melt filtration, the ERF 500 and ECO, at Fakuma this autumn. The two new developments will be added to the ERF melt filter series, already proven in numerous installations for filtering heavily contaminated feedstock, and the ECO, specially developed for complex extrusion processes in the manufacture of films, sheets, and other semifinished products. Thanks to this unique combination of exceptionally durable filter medium and continuous, trouble-free production, the investment in the ERF or ECO filter pays for itself very quickly.

GRAFE

FERROMATIK MILACRON At Fakuma a complete system consisting of a Ferromatik Milacron F 220 injection moulding machine with Kortec Coinjection Molding technology and one Mold Masters injection unit will be displayed.

With the Coinjection Molding, Ferromatik Milacron now offers options in multi-component technology to make barrier injection moulding in the thin-wall packaging market profitable. At their booth #3203 in hall B3, Ferromatik Milacron will show an ELEKTRON 30 with an injection unit with international size 55. On this machine applicators or 1 ml medical ampoules on a four-cavity mould in a cycle time of 9.1 s, and a part weight of 1.6 g will be produced.

Laser markings on plastic parts are resistant to chemicals and abrasion, and result in a permanent and clear inscription. The plastics experts at GRAFE provide their customers with masterbatches for plastics which can be written on with lasers. In pretests using their own in-house laser marker, they are able to determine the ideal settings for writing on the plastic. GRAFE supports its customers by providing the perfect laser marking solution with a comprehensive range of services.

“Laser marking is a highly efficient process in the design of plastic products and has become a real alternative to conventional printing methods over the past years,” says Lars Tonnecker, Head of Sales at GRAFE. “It is quick and economical, and it results in a durable, very clean, precise and well-defined marking without having to pre-treat the parts.”

24 • WWW.EPPM.COM • SEPTEMBER 2014

HENNECKE

HEXPOL TPE At Fakuma, HEXPOL TPE will be showcasing the array of properties and design possibilities their portfolio of customised TPEs has to offer.

Visitors will be able to experience the flexibility, transparency, adhesion and processability of their Dryflex, Lifoflex and Mediprene range of compounds based on TPS, TPO and TPV technologies.

The HEXPOL TPE group brings together the ELASTO and Müller Kunststoffe businesses; at the show each European business will present unique compounds that address growing trends and application requirements in important market sectors.

Sven-M. Druwen, European Sales Coordinator for HEXPOL TPE said: “Our technical experts from industry specific teams in the consumer, medical, automotive and construction markets will be on-hand for consultations and support in the development of unique, custom formulated TPE compounds.”

Hennecke GmbH has been developing polyurethane processing machinery and equipment for over 65 years. At this year’s Fakuma, the company - which is headquartered in Sankt Augustin - will present new machine concepts and further developments in the arena of state-of-theart and established processing technologies. Hennecke’s presence at the trade fair will be focused on a new energy-saving technology which is referred to as BLUE INTELLIGENCE and brings together various measures required for energy saving and reducing CO2 emissions for foaming machines.

HUNTSMAN This October Huntsman is heading to Fakuma where its thermoplastic polyurethane (TPU) specialists will be exhibiting alongside Chemie Plast – a leading plastics distribution house and one of Huntsman’s long-term business partners. Together, the two companies have hand picked an eclectic mix of Huntsman’s plastic processing materials to discuss with event attendees.

For manufacturers of consumer goods, there is AVALON AHT – a highly transparent TPU that combines excellent UV resistance with high mechanical properties. Extremely stable, this clear material is easy to colour and mould and has excellent melt stability, making it ideal for the creation of wristbands, watchstraps and protective covers for phones and tablets.

For automotive manufacturers, Huntsman has an endless array of materials for under-bonnet, interior and exterior applications.

WIPAG Carbon-fibre-reinforced plastic (CRP) is very light and stiff and consequently a very attractive material. Up to now, it has been very difficult and costly to use CRP for product manufacturing. Now WIPAG’s carbon-pellets make it possible to use the material for the relatively easy procedure of injection moulding. Furthermore, WIPAG can produce its carbon-pellets costeffectively because it uses secondary carbon-fibres.

Learn more at the WIPAG booth at Fakuma this autumn.

Hall 6 Booth 6401

SEPTEMBER 2014 • WWW.EPPM.COM • 25

ILLIG Sheet processing machines of Illig’s UA series will be the core element of the company’s appearance at this year’s Fakuma exhibition. The legendary, upgraded ILLIG UA 100Ed will be presented at the stand - from this autumn it will be available again as standard version. The UA 100Ed, designed with a forming area of 960 mm x 560 mm, is a universal machine with manual loading – a highperformance “entry-level machine” with attractive price-performance ratio.

The central supply of cooling air employed for cooling of formed parts, a technology module developed by ILLIG for UA-g machines, will be another focus of the trade fair appearance.

And this new technology where cooling air is aspirated in a controlled way helps to maintain a constantly high part quality almost regardless of climatic influences.

WITTMANN BATTENFELD

KRAUSSMAFFEI KraussMaffei’s entire portfolio of standard injection moulding machines will be represented, from all-electric and hydraulic all the way to hybrid, at Fakuma.

The industry giant is focusing on all-electric, hydraulic and hybrid injection moulding solutions based on the standard machines of the AX and CX series. The production solutions demonstrate the high productivity and innovative detailed solutions with respect to energy efficiency, automation, space-saving design and zero-defect production. The trade show appearance of KraussMaffei Reaction Process Machinery is expanding to include the new, smallest size of the EcoStar 8/8 mixing and metering system.

SCHMOLZ + BICKENBACH The SCHMOLZ + BICKENBACH Group and its subsidiary Deutsche Edelstahlwerke are presenting their portfolio of high-quality tool steels for the first time at FAKUMA. One of world’s leading special steel producers will showcase the Corroplast FM plastic mould steel, a special steel with excellent machinability and good resistance to corrosion for dimensionally accurate and long-lasting tools and mould bases, eg. for the PET packaging industry. SCHMOLZ + BICKENBACH will also inform visitors about their support and service offerings available worldwide and tailored to meet customer requirements.

Trade visitors to the Fakuma stand shared by SCHMOLZ + BICKENBACH and Deutsche Edelstahlwerke can also learn about the process steps required until delivery of the customer’s specific sophisticated special steel solution from an example of a rolled, partiallymachined flat dimension made of Corroplast FM.

WEMO

Under the motto “be smart”, WITTMANN BATTENFELD will present smart injection moulding technology combined with ultra-modern processes at this year’s Fakuma in Friedrichshafen. On display will be the complete range of the PowerSeries – to which the new SmartPower machine series has been added. The SmartPower, equipped with servo hydraulics as standard, is the youngest member of our PowerSeries. In a smart way, it combines the advantages of hydraulic machines with those of all-electric machines: energy efficiency, precision, user-friendliness, compact design, high speed, cleanness – everything you could desire in a machine. Simply smart.

26 • WWW.EPPM.COM • SEPTEMBER 2014

High flexibility and minimum energy consumption - these are the outstanding features of the new X Design linear robots by WEMO, which will be on display at Fakuma this autumn. They are the perfect all-rounders for removing a wide variety of different plastic parts also under complex requirements and with maximum performance. Powerful components guarantee ultimate stability and precision. The different axes are made of heavy duty steel which boasts extreme rigidity and low weight. This makes the motion sequences faster and more dynamic because less mass needs to be moved. WEMO will showcase two X Design robots in action at Fakuma. Further exhibits will be a fast handling from the S Design Series for packaging applications and two E Design robots for standard applications.

MAS

PET

Passion Week 2014 NUREMBERG, GERMANY

10-14 NOVEMBER

Since its founding in 2006, the Upper Austrian company MAS (Maschinen- und Anlagenbau Schulz GmbH), has been gaining attention through a variety of technical innovations in the area of extrusion and recycling technology. This includes the co-rotating conical twin-screw extruder, the continuous melt filter system with a rotating disk filter (CDF series), and the dry cleaning system for film flakes. All three product groups are available in the throughput range of 300 to 2,000 kg/h and can be tailored to the specific needs of the individual application. MAS is capable of providing complete systems for plastic recycling, compounding and most importantly, the combination of both the re-compounding.

MORETTO

2014 CONFERENCE 10-11 NOVEMBER www.petnology.com

PET AT BRAUBEVIALE 11-13 NOVEMBER Italian ancillary equipment producer Moretto S.p.A. gives pride of place to its Eureka plastics material conditioning system on its stand at Fakuma 2014. The Eureka system consists of three elements, a FLOWMATIK airflow management and distribution system, the OTX hopper drier and the X Max drier and has been developed over a 13year period of simulation, experimentation and testing, leading to what company founder and CEO Renato Moretto describes as “the most ambitious project in the history of dehumidification during my 45 years carrier in the plastics world”.

www.pet-arena.com

Moretto says Eureka is “the only drying system that can process 10,000 to 12,000 kg/h of material in compounding, extrusion and PET processing – where it has up to 56 per cent lower energy consumption than traditional drying systems as observed by customers”.

Lead Sponsor:

PETnology/tecPET GmbH | Regensburg, Germany Phone: +49 941 870 23 74 | Fax: +49 941 870 23 73 info@petnology.com

ptl_107x320_eppm.indd 1

Supported by:

SEPTEMBER 2014 • WWW.EPPM.COM • 27 08:38 28.08.14

INDUSTRY NEWS & EVENTS

EuroMold 2014 promotes whole plastics process chain This year’s EuroMold trade fair in Frankfurt will promote the entire plastics process chain in an optimised hall concept, with some 1,000 companies anticipated to fill the Messe with the very latest in mould-making, tooling and additive manufacturing this November.

Words | Rose Brooke

EuroMold, one of the world’s leading specialist trade events for mouldmaking and tooling, design and application development, aims to promote the entire plastics process chain in an optimised scheme for this vast fair’s show floor this winter.

The expo, which takes place from November 25th-28th 2014, spreads across halls 8.0, 9.0 and 11.0 in the gargantuan Messe venue in the European heart of business and finance, with the themes of these massive halls reflecting the synergy and prospects of mould-making, tooling and additive manufacturing.

By redesigning the layout of the exhibition areas, visitors will be given an even clearer impression of the possibilities of collaboration, innovation and future prospects across the entire plastics process chain.

Hall 8.0 will be the centerpiece of EuroMold 2014 with its special exhibition Additive Manufacturing and Tooling, which will demonstrate examples of profitable cooperation between these processes, along with the Stark im Formenbau mit Generativer Fertigung (strength in mould-making with additive manufacturing) theme park. Also featuring in Hall 8.0 will be a dedicated Thermoform Area and visitors can sit in on topical forums concerning Materials and Lightweight Construction, in addition to the Design and Engineering, and CAE forums, which will focus on the latest technologies in the field of computer-supported design and engineering.

Moreover, the CAMPUS area will concentrate on lightweight construction, offering businesses and universities the chance to share ideas and network.

AM and Asia

Managing Director of EuroMold organiser DEMAT Eberhard Döring explained: “With the new structure of the exhibition halls, we are better positioned to meet the desires of exhibitors and visitors. We will arrange the exhibition areas in exhibition halls 8.0, 9.0 and 11.0 in such a way that the added value to be found in inter-industry collaboration becomes even more apparent.

In Hall 9.0 Asian exhibitors will be the stars of the show representing mouldmaking and tooling industries, and many more. This spotlight on Asia is key to the growth of European manufacturing, as this rapidly growing and developing marketplace is becoming increasingly important for European companies, representing the sales market of tomorrow. Hall 9.0 is also where visitors will find the most recent and innovative products from the Far East and visitors will also have the chance to establish direct contacts with manufacturers from Asian countries.

“This year the strong trend towards joint stands is an encouraging development. For example, a large number of associations, countries, regions and research institutes are set to present their work alongside one another. This demonstrates the spirit in which the EuroMold takes place year after year: ‘Success through Diversity’.”

Additive manufacturing will be at the heart of activities in Hall 11.0, along with rapid prototyping, rapid tooling and 3D printing. Innovations from the creative sector and the field of application design will be on show, while 2014 will see the debut of the EuroMold 3D School, which will offer students the chance to get hands-on experience with 3D printing in a classroom in the show floor.

Success through diversity

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'Made in Germany': An interview with Dr Eberhard Döring Dr Eberhard Döring, Manager of EuroMold, shares his vision for the world-renowned trade fair and how he sees it evolving in the years to come.

EuroMold is a highlight of the business year for many companies. Why is that?

Firstly, the trade fair is a communication platform for representatives from along the entire process chain, "from the design, to the prototype, to series production". We bring industrial designers, product developers, processors, suppliers and users together. There is no comparable trade fair where you have this type of scope with regard to the industrial sector represented. And the true social network is still personal contact. People share their thoughts face-to-face, present genuinely good products, discuss exciting ideas and exchange opinions as to which direction developments are heading. Many exhibitors and visitors consider this absolute added value.

“

Why do companies and industry professionals return to EuroMold time and again?

The spirit in which the EuroMold takes place year after year: ‘Success through Diversity’

”

As the world’s only specialist trade fair of its kind, EuroMold covers the entire industrial production process chain – operating under the slogan, ‘From idea to series production’. This year, more than 1,000 exhibitors from around 40 countries are expected.

While there is a very high level of return bookings for the winter trade fair, there is a slew of newcomers for 2014’s outing, with 88 companies from 19 different countries making their debut at the leading industry event, with a notable concentration of first-timers from Portugal, China, the Netherlands, the UK and Germany, in addition to a rise in the number of joint-transnational stands run by various organisations and associations.

EPPM will be attending EuroMold this November. If your company is launching a new development in plastics processing at the event, contact EPPM Editor Rose Brooke today. rose.brooke@rapidnews.com

EuroMold outlines strategies for the faster, cheaper and more efficient development and manufacture of new products. In the modern economy this fact is taking on an increasingly significant role.

What significance do mouldmaking and tooling, design and application development have for Germany as an economic location – including with regard to the European and global competition?

Almost every aspect of our modern lives uses products or components that were initially realised as the result of innovative mouldmaking and tooling: from dental technology to aerospace solutions. The basis for the success of 'Made in Germany' can be found in the most important raw materials that we have at our disposal in Germany: ideas and expertise. Germany plays a prominent role when it comes to highquality, cost-efficient and innovative products. This is recognised and valued by European and global competitors.

What is the 'future vision' for EuroMold? How will the trade fair look in 10 years?

As a leading global trade fair, EuroMold will continue to be an indispensable point of reference for the entire tooling, engineering and product development industry. At no other venue in the world do exhibitors receive insight into the most recent technologies, products and trends in such a short period of time. This isn't set to change any time soon. We also want to continue as the world's largest communication platform, offering unique opportunity for synergy between industrial sectors. Specifically, in the coming years we are planning to grow sustainably and to maintain our high level of quality.

With regard to our international sister trade fairs, there are still some regions – for example in Central America – that definitely have the potential to be considered for this type of trade fair. So you can see that we have big plans for EuroMold!

Copyright: EuroMold

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23rd Fakuma – International trade fair for plastics processing

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

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

INDUSTRY NEWS & EVENTS

Eurotec offers new dimensions to engineering plastics compounds Eurotec has developed food contact-compliant, metal-detectable compounds to be used in the production line.

The food and beverage production and packaging sectors are highlyregulated industries that adhere to strict contamination policies. Producers have to deliver healthy and safe goods to their costumer without any contamination present in their products.

Risk is significant due to the wearing and breaking of the parts during the production process and the most common means of detecting this wear and tear is to use metal detectors on the production line.

On the other hand, using plastic components in the production line, generates cost savings by reduced maintenance due to improved design, reduced energy consumption thanks to the components being more lightweight. The down side, however, is that conventional plastics cannot be detected by metal detectors.

Eurotec offers a wide range of intelligent solutions for its customers by developing creative plastic compounds to satisfy a varied range of requirements. Indeed, eurotec has developed many food contactcompliant, metal-detectable compounds under its brand names Tecomid (PA6, PA66, PA66.6, PPA and its blends), Tecodur (PBT and its blends), Tecopet (PET and its blends), Tecolen (PP and PE specialties) and Tecoform (POM).

Eurotec’s food contact-compliant, metal detectable compounds enable its customer to produce food processing equipment components, conveyor chains and hoppers with ease of processing, consistent quality and reliable contamination control.

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MEDICAL

3D printing the surgical revolution The development of new and cutting-edge materials goes hand in hand with new and cutting-edge processes, which is why Replica 3DM believes it is revolutionising surgery with innovative polymers and inert plastics using 3D printing.

Words | Rose Brooke

Managing Director of Salisburyheadquartered Replica 3DM Matthew Sherry spoke to EPPM in August about the company’s leading work in the field of surgery. The company has been operating for around 18 months and uses patient data sent from NHS trusts, which is then transformed into digital 3D reconstructions to be 3D-printed for surgical guides.

Sherry explained that in the instance of a jawbone for example, the surgeon can then use the 3D-printed model to either pre-bend titanium plates, or they can use the model for pre-operative investigation. This allows them to rehearse the operation using a dummy, consequentially reducing theatre time, recovery time and the amount of post-op care the patient would then require. Moreover, by reducing theatre time, NHS Trusts are slashing costs.

This side of the business, according to Sherry, makes up 80 per cent of Replica 3DM’s work, while the other 20 per cent centres around more commercial work such as architectural models.

“

This is the first job I’ve had where you feel like you’re doing something genuinely constructive

”

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“No comparison” The business has two Stratasys Objet 3D printers (Stratasys Objet24 and Objet30 Pro) that print using photopolymer acrylics, which, according to Sherry, maxillofacial technicians prefer because it retains its structural integrity but can be drilled easily for plate fittings. Replica 3DM uses a VeroWhite material allowing for high-accuracy printing of up to 28 microns, while surgeons prefer this material visually because it looks more like bone. The team at Replica 3DM, however, believe VeroBlue gives the most pleasing results to the eye. In addition, Replica 3DM produces models in PLA, building models both in white PLA and in a Ninjaflex rubber material.

Before surgeons could use surgical guides produced to this degree of accuracy with real digital data, plate bending and other procedures were much more hands-on.

“There wasn’t a solution other than going to the operating theatre, opening up the patient and trying to bend a piece of titanium plate there, switching between workbench and patient until it fit. It added about an hour to surgery” Sherry explained. “For pre-op, you used to have to rotate the image made from CT data on a 2D screen but the problem is, there’s a lot of artefact with a CT and that can sometimes obscure the bone, whereas this gives you a real item in your hand. There’s no comparison, really.”

Working by hand cannot guarantee accuracy like 3D printing, ensuring surgeons only make the incisions they need to and have 100 per cent confidence the plate will fit. “It’s revolutionised this sort of surgery,” Sherry said.

“We’ve done a number of facial reconstructions of the mid-face from the upper teeth to just above the eye sockets where the patient has a bone deformity or has had a road traffic accident. What we do is make two models and the surgeon uses one to demonstrate what the patient currently looks like and then the second is used to make incisions so the bone is readjusted to demonstrate how the surgeon will do the surgery. It allows the surgeon to practice and know what they need to do in surgery and if they don’t get that first one right then they’ll just work on the second model. It allows them to do reconstruction on a model rather than practicing on a patient so they can go into surgery and know where to make the cuts. Also, maxillofacial technicians can make templates and stents off that model to help the surgery,” Sherry said.

“

If they don’t get that first one right then they’ll just work on the second

”

In addition to producing 3D-printed models for NHS trusts across the UK, Replica 3DM is involved in its own research work that could further develop how plastics are utilised in the medical field.

In collaboration with Southampton University, the company is developing a 3D printer that can print hydroxylapatite (ha), which replicates bone and has a programmable dissolution rate, and polyaryletheretherketone (PEEK), which is inert and can therefore be implanted in the human body.

“Because you can set the rate at which ha dissolves, you can print small scaffolds with it. The ha dissolves and what you have left is bone.”

Innovation at a snip The cases Replica 3DM deals with are mostly very serious, but it is all in a day’s work for the team, with projects varying from facial reconstructions after accidents to large-scale cranioplasties and even building interim prosthetics for those with congenital digital deformities.

But with 3D printing becoming increasingly mainstream, will NHS trusts not be investing in their own 3D printing laboratories? Sherry does not believe so.

“We have about 15 trusts come to us for models and we are set up as a 3D hub for the NHS, but this is growing. We can cover those trusts for a fraction of what it would cost them to set up their own 3D printing operation themselves, when most trusts only need about 10 models a year,” Sherry said.

“

The government-funded project will take up to three years to complete, but Sherry has ambitions of this technology becoming part of the NHS. “It will revolutionise things like cleft palate surgery, which requires grafts such as bovine grafts or in some instances I’ve heard they can use coral. With this, though, we could revolutionise how cleft palates are treated.”

Sherry remarked: “Every week we produce something quite new and exciting, we do a lot of innovation work and we’re always looking to 3D print items that are innovative.

“This is the first job I’ve had where you feel like you’re doing something genuinely constructive and useful.”

There wasn’t a solution other than opening up the patient

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MEDICAL

Intelligent structural material for medical technology Emaform produces high-quality components made of Bayer polyurethane integral skin foam.

Bayer MaterialScience-developed polyurethane is doing ground-breaking things in the medical field.

Medical technology suppliers such as Swiss-based Emaform AG have high expectations when selecting appropriate structural materials. The polyurethane integral skin foam systems Baydur 66 FR and 110 FR from Bayer MaterialScience are right at the top of their game, meeting every need in terms of functionality, design, strength and fire protection for housing parts.

Medical technology products like the TrueBeam system from Varian Medical Systems are complex devices. This is also true of housing parts that protect the technical components inside against environmental influences and contamination. They are manufactured from the polyurethane integral skin foam systems Baydur 66 FR and 110 FR from Bayer MaterialScience, which are meeting every need in terms of functionality, design, strength and fire protection for housing parts.

Cost efficiency, high quality Customised coating of mouldings at Emaform ensures that demanding surface requirements can also be satisfied. Furthermore, they are ideal for meeting one particular challenge - the cost-efficient production of highquality, complex components in the small and medium volumes that are typical of this industry. One example is housing parts for equipment from Varian Medical Systems.

Today’s medical technology products are often complex devices. This is also true of housing parts that protect the technical components inside against environmental influences and contamination. Emaform uses the proven and cost-effective integral construction method for production, with bushings and threads being included in the moulding process. Brackets, sheet metal and Plexiglas parts are bonded to the moulding, to which various add-on parts are then screwed or bolted.

The high vertical range of manufacture enables Emaform to supply complete assemblies. This cuts the workload for final assembly by the customer, Varian Medical Systems, which is also based in Switzerland.

In turn, Varian Medical Systems can also offer hospitals and other end customers efficient spare parts management.

Aesthetic appeal Acceptance of medical equipment today does not solely depend on its ability to function reliably over the long term. A decorative or ergonomic design is also key, as this facilitates operation of equipment and creates a pleasant environment for patients and staff. Here, too, Baydur systems are the material of choice, offering outstanding design freedom and meeting manufacturers’ requirements for high-quality mouldings.

For the production of the housing parts, Emaform AG uses the proven and cost-effective integral construction method. The high vertical range of manufacture enables the company to supply complete assemblies. This cuts the workload for final assembly by the customer, Varian Medical Systems.

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Baydur 66 FR produces sandwich structures with excellent stiffness and low weight thanks to the hard surface and a microporous structure inside the components. Baydur 110 FR is ideal for thin-walled parts with high-quality surfaces that should nonetheless be highly stable. The option of using lowcost aluminium moulds offers a cost saving over thermoplastic materials, as polyurethane mouldings are manufactured at much lower pressures.

MEDICAL

Plastics material providers respond to healthcare trends Three trends being tracked by medical device manufacturers today are infection prevention, demand for single-use devices, and the shift toward home healthcare. Styron explores how materials suppliers are adapting their materials to support these market needs.

Styron uses patented colour-compensation technology in its CALIBRE MEGARAD 2081 and 2091 Polycarbonate Resins to improve the rate at which the desired colour of the material is reached following irradiation.

In an effort to reduce hospital-acquired infections the Centers for Disease Control and Prevention in the US have issued guidelines for disinfection and sterilisation in healthcare facilities. These guidelines include disinfectants and cleaners for sanitising medical devices, including passive and powered medical equipment.

Up until then, there were few solutions to colour stability and recovery. The most common solution required the addition of a tint to compensate for the colour shift. This resulted in a more aesthetically-pleasing initial colour, but it was temporary and manufacturers needed a stable appearance over a longer period.

Disinfecting solutions contain ingredients ranging from alcohol and bleach to more aggressive solvents like butyl cellulose. These chemicals have a tendency to attack the surface materials. In the case of plastics, constant cleaning can cause cracking and embrittlement, and eventually shorten equipment life.

Aesthetic plastics designed for home

Today’s plastics need to withstand the conditions in a variety of healthcare settings, as they need chemical resistant properties. Polycarbonate (PC) grades in particular have proven to be extremely successful in chemicalresistance tests. PC grades are now being used in chemical-resistant applications including surgical staplers, endoscopic surgery tools, dialysis machines, and equipment used in rehabilitation medical devices.

New material development is a continuous and critical process. Bacteria becomes more resistant over time and requires harsher chemicals to ensure proper cleansing, which in turn requires advanced material options.

Styron’s chemical-resistant EMERGE Advanced Resins for use in medical housings can resist an assortment of chemicals used in cleaners to fight healthcare-related infections.

Radiation-stabilised plastics suited for single-use devices In an attempt to control the risk of infection, medical device manufacturers are turning to single-use devices. And manufacturers must consider their need to be sterilised when developing their applications.

Strength, clarity, and dimensional stability along with extensive biocompatibility data make PC the thermoplastic of choice for many singleuse medical devices.

But despite its excellent properties, when sterilised by irradiation PC can exhibit a significant discolouration and reduction in light transmittance.

To overcome this, resin manufacturers have responded by developing radiation-stabilised PC grades that can withstand the highest sterilisation processes and allowing PC colour to equilibrate following sterilisation by irradiation to an acceptable threshold level.

The surge in demand for home healthcare devices has arisen due to a desire on the part of our healthcare system to control overall system costs and the aging population, which brings with it more chronic conditions that may require long-term care from home.

Provider services are being offered in decentralised facilities including clinics, extended care locations and at home and this model offers patients the flexibility to receive convenient support and care. This is a much more economical model as consumers and insurers do not have to finance lengthy stays in a hospital environment.

From a manufacturer perspective, OEMs are experiencing a demand for non-industrial, attractive equipment. This creates a demand for materials that can fulfil appearance, performance and haptic requirements. These new materials must still meet regulatory requirements, however, and where necessary be capable of being sterilised. PC compounded products and Acrylonitrile Butadiene Styrene grades work exceptionally well here, as they are aesthetically pleasing and meet regulatory standards.

Styron’s MAGNUM ABS Resins portfolio includes grades for equipment housings that are manufactured using a masspolymerisation process that offers lot-to-lot consistency, thermal stability and numerous colour options.

Responding adequately to the above trends is a challenge for material suppliers and it is something that requires close collaboration with OEMs and moulders to understand specific needs. It is no surprise that the key suppliers in the materials business have decades of experience in development work for the medical industry and often leverage experiences across market segments to overcome these challenges. Nevertheless, it is an exciting market with many outstanding opportunities for innovation and continued growth.

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MEDICAL

Meech International: Static Control & Cleanroom Moulding Why is cleanroom moulding essential for medical plastics applications and how can static charges be combatted in these environments?

Meech’s Export Sales Engineer Stewart Gordon-Smith explains.

In-mould labelling (IML) decoration requires a label to be fitted inside the cavity before injection moulding commences. Once the plastic material has been injected into the mould and allowed to cool, the label becomes amalgamated with the product.

But while this method proves effective for labelling applications, people need to take into account that static can have an effect on contamination control, with the attraction of dirt impinging on the quality of a product.

Many businesses cannot allow their products to be affected by dust or dirt, which is why they utilise ‘cleanroom moulding’.

While the food industry is more concerned with brand protection and ensuring their products’ image isn’t tarnished, the medical sector is more concerned with contamination control from a sanitary perspective. The presence of a static charge is capable of attracting fibres to products that need to be kept sterile, such as syringes and hypodermic needles.

If a statically-charged container were placed in a plastic bag after the moulding phase, there is a risk the charge will not neutralise for as long as it is contained within the sealed environment. Consequentially, once the bag has been removed, a high degree of contamination is instantly attracted to the product.

Furthermore, for a number of small medical components, accumulated static charge is greater than the weight of the product itself, which in turn causes them to stick to the surface of the moulding components. If the mould tool closes with the product attached to the tool face it causes damage.

Meech International is aware of the effects of static charges, which is why it has come up with ionising solutions to meet the increasing demands of businesses operating within the medical sector. By employing pulsed DC static control systems, such as the 971IPS and 929 IPS Hyperion bars, a longrange ionising system removes and controls the static charges, while the product cools to meet ambient temperature. If air-assisted ionising systems are used in this process, a possible side effect is that the airflow may redirect airborne contamination towards the mould’s surface. Pulsed DC has the ability to create an ionising field large enough to not require air assistance.

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Intelligent Solutions

PIPE & PROFILE EXTRUSION FOCUS

First 2,000 mm Pipe Extrusion Line with Internal Cooling System in Asia A Vietnamese manufacturer is set to be the first in the country to produce large PE pipes of up to 2,000 mm in diameter.

Haiphong, Tien Phong Plastic Joint Stock is set to be the first pipe manufacturer in Vietnam able to produce large PE pipes with external diameters of up to 2,000 mm.

For this purpose, the long-standing customer of battenfeld-cincinnati has now ordered a complete pipe extrusion line, which is to be delivered in spring 2015.

In 2011, Tien Phong had already decided to acquire a turnkey PE pipe extrusion line including a die with an innovative cooling system. This equipment proved so good that the customer chose a similar die with internal cooling the second time around.

State-owned Tien Phong ranks among the leading Vietnamese producers of pipes and fittings made of u-PVC, HDPE and PP-R. Nguyen Quoc Truong, Tien Phong’s General Director, said: “Our pipes are manufactured to international standards, which is why we pay special attention to the quality of our production lines. We are already operating several lines from battenfeld-cincinnati and are particularly pleased about the material- and energysaving operation of this equipment and its easy handling.”

The core components of the energy-efficient line ordered most recently for the production of pipes with dimensions ranging from 630 to 2,000 mm are a solEX single screw extruder and a helix VSI-T+ pipe die. In addition, an EAC Drying System has been installed. It uses heated air from the internal pipe cooling in the die to dry raw material, thus saving energy. High-performance extruders from the solEX series are particularly recommended for the production of HDPE and PP pipes. With their processing length of 40 D, they offer extremely high throughput

rates with optimal melt homogeneity and low melt temperatures. The AC motors built in as standard ensure low energy consumption. In the line for Tien Phong, a solEX 120 is integrated, which manages an output of up to 2,200 kg/h with only modest space requirements.

Another contribution to minimising space requirements is made by the helix 2000 VSI-T+ pipe die, which operates with active intensive melt cooling in addition to an internal cooling system and with the well-known two-step distribution concept consisting of a spiral mandrel distributor and a lattice basket, which guarantees best possible distribution, homogenisation and throughput with low pressure build-up. The extremely efficient cooling system reduces sagging, which is of vital importance especially in the production of thick-walled pipes. Consequently, high product quality is ensured. At the same time, the intensive cooling system permits significant shortening of the complete line, which, in turn, reduces space requirements and makes the line particularly cost-efficient.

HPE Extrusion Solutions champions PP plastic extrusions A suburban Philadelphia manufacturer is championing extruded polypropylene plastic parts, products and profiles for industrial applications.

HPE Extrusion Solutions, a complex plastic extrusions specialist, is championing extruded customised profiles, parts and products from various grades of polypropylene for industrial, commercial and institutional applications.

Demand for polypropylene (PP) the second most important plastic in terms of revenue - was estimated to have grown at the rate of 4.4 per cent per year between 2004 and 2012.

Extrusion is the single most popular process for forming polypropylene, accounting for about 45 per cent of consumption in the US alone.

Although the vast majority of polypropylene extrusions are for

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fibre, filament products and film, HPE Extrusion Solutions specialises in the manufacture of extruded polypropylene profiles, parts and products.

Although polypropylene is translucent in its natural state, a wide variety of colours, additives and combinations is available. Many physical finishing techniques can also be used on polypropylene, such as machining. Surface treatments can be applied to polypropylene parts in order to promote adhesion of printing ink and paints.

Because of its diverse properties, polypropylene lends itself well to a large number of end-use

applications. For example, polypropylene plastic items used for medical or laboratory applications are able to withstand the heat in an autoclave. Its heat resistance also enables it to be used in the manufacturing of consumer products, such as food containers subject to dishwasher heat. Rugged, translucent, reusable plastic containers made in a wide variety of shapes and sizes are often made of polypropylene. Other polypropylene end-use applications include disposable containers for liquid or powder, plastic pails, car batteries, wastebaskets, pharmacy prescription bottles, cooler containers, dishes and pitchers.

HPE’s machines’ single screw units range from 3/4” to 2 1/2” which permits extrusions of a wide range of sizes and shapes, including profiles ranging in size from 1/16” to 5” profile with a virtually unlimited length.

Polypropylene is just one of the many common and advanced thermoplastics resins that HPE is capable of extruding. Others include flexible and rigid PVC and polypropylene and innovative engineering resins, such as ABS/PVC alloys and difficult-to-run elastomers, such as Santoprene, nylon and glass-filled ABS.

PIPE & PROFILE EXTRUSION FOCUS

Zumbach’s new KW TRIO lump detectors reliably eliminate stray light from fault detection Zumbach has unveiled its new 3-axis lump detector range, KW TRIO, which reliably eliminate any stray light from the fault detection process.

Zumbach has launched its new 3-axis lump detector family KW TRIO for extrusion lines, optical fibre draw towers, rewinding processes and others.

The first technology with a pulsing light source and automatic ambient light rejection after the cycle makes these detectors impervious to stray light and the pioneers in their class. Line speed or iridescent light have no influence on measurement results – even the smallest surface faults are detected reliably on a micrometre scale.

In insulating, sheathing, enamelling, wire drawing and other processes, surface faults such as lumps and neckdowns must immediately be detected. Zumbach has developed a new concept eliminating stray light as a factor in fault detection in order to enable production processes with the highest quality possible at extrusion lines, optical fibre draw towers, etc.

The one-of-a-kind combination of an electronic measuring principle and a complex optics solution sets a new standard in fault detection reliability and performance.

Since faults often only cover a limited angle on the product circumference, eg. lumps, neckdowns, blisters, etc., 2-axis detectors (X/Y) are usually used. However, reliability can be three times as high by using the 3-axial measurement of the KW TRIO models. This is due to the significant reduction in blind spots that only the KW TRIO models enable.

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ADDITIVES

Silvergate engineers revolutionary antibacterial to cut soaring fish deaths Silvergate Plastics engineers have succeeded in developing a specialised additive to prevent the transfer of bacterial disease via infected fishing nets.

Silvergate Plastics has played an integral role in the development of a revolutionary anti-bacterial additive that can be used in a variety of applications, including fibre. This ground-breaking technology has been developed with Aquatech Technologies and will be used in next-generation fish safe nets to prevent the transfer of bacterial disease.

Fish deaths have been rising and although the angling press has focused greatly on the transfer of viruses amongst the fish population, the Environment Agency has confirmed a small group of bacteria caused the greatest number of fish mortalities in 2013.

Keen angler Derek Willan was greatly concerned about the rising number of fish deaths and wanted to find an effective and permanent solution to curtail this growing problem.

As diseases pass on via fish nets, Willan began exploring whether it would be possible to incorporate anti-bacterial properties into the manufacture of the nets. BSafe, the brand developed by Aquatech Technologies, is the new technology that offers an active and long-lasting bacterial-killing layer to the surface of polymeric materials. An anti-bacterial additive forms part of the monofilament used to the make a yarn from which the nets are manufactured and provides a permanent solution for fisheries, anglers and conservationists.

Working collaboratively with Biomaster, Silvergate Plastics developed a bespoke bacterial-killing additive in a masterbatch that can be engineered into yarn. The anti-bacterial additive works for the lifetime of the product, when wet or dry, to stop the transfer of disease between fish and fisheries.

The technology has been comprehensively tested by an independent laboratory.

Working on the project for CEFAS, the Centre for Environment, Fisheries and Aquaculture Science, Jason Weeks said: “The results were stunning.”

Comprehensive testing against five key bacterial pathogens prepared by CEFAS showed a greater than 99 per cent kill rate was achieved for each bacteria within 24 hours. A simple device can be used by fishery owners and fish farmers to detect the presence of the BSafe technology in any product to verify its presence, offer total peace of mind and provide a permanent solution to this major problem.

BSafe is available to all manufacturers of angling equipment on a non-exclusive basis. For more information, visit www.bsafeangling.com.

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Int

ADDITIVES: NEWS

Additives specialist’s cooling masterbatch keeps lid on hot greenouses A cooling masterbatch for greenhouse films from Tosaf claims to cut down peak interior temperatures in hot regions following success in South Israel field tests.

Following successful field tests in South Israel, a cooling masterbatch developed by an additives specialist has succeeded in curbing soaring temperatures in greenhouses in hot regions.

IR8783PE, the new cooling masterbatch from Tosaf, for greenhouse film applications was designed to support optimal plant growth in hot climate zones.

Films produced with IR8783PE block a significant amount of the near infrared radiation (NIR), which would otherwise intensely heat up the greenhouse interior.

Using IR8783PE, most of the photosyntheticallyactive radiation (PAR) - which is required for a healthy plant growth - can pass through the films unhindered and field trials in South Israel revealed a four-to-five degrees centigrade lower peak temperature in comparison to conventional light diffusing film with no undesired overnight temperature drop.

With a recommended rate of addition of approximately five per cent for a 200-micron film, the new masterbatch is suitable for single, three- and five-layer films.

Cultivating crops in very hot regions, such as the subtropics or southern Europe is made difficult by the plants’ ability to produce pollen being reduced at high temperatures. The most common remedy, namely painting the films with whitewash, not only requires additional labour but at also cuts out some of the essential PAR. Films produced with IR8783PE can save this extra labour while lowering the temperature without significant PAR loss.

such as UV-/light stabilisers, flame retardants and customised additives for applications including BOPP, agricultural, packaging and industrial films, polycarbonate sheets, pipes, foams and other products; and colour masterbatches for a wide range of applications.

Tosaf Group, founded in 1985, is a joint venture between Megides Holding and the Ravago Group.

The group operates nine factories in Israel, Turkey, Germany, UK, the Netherlands and the Ukraine and offers a wide range of products including mineral-filled compounds for white goods, automotive and other plastic industries; additives

AkzoNobel introduces version of antistatic additive for film and packaging Producer of polymer additives, AkzoNobel, has launched an easyuse, high concentrate version of its Armostat 1800 antistatic additive for plastics.

Armostat 1800-XP75 has reportedly been developed to address the need for a cost-effective, vegetable-based antistatic additive for PP film and rigid packaging applications.

Once added to the polymer during the extrusion process, the antistatic additives migrate to the surface giving the required effect. Armostat 1800-XP75 contains 75 percent Armostat 1800 when used on polypropylene.

“Armostat 1800-XP75 perfectly fits our portfolio of high performance concentrates and specialty additives,” commented Haimo Tonnaer, Business Development Manager for AkzoNobel’s Polymer Additives business. “This cost effective high concentrate allows for easy handling and dosing while offering all the advantages of pure Armostat 1800.”

42 • WWW.EPPM.COM • SEPTEMBER 2014

Armostat 1800-XP75 has been developed for PP film and rigid packaging applications

Interplas Advert REGISTER NOW_Layout 1 02/01/2014 10:16 Page 2

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

R E T S I REG

. . .

W NO

30 September-2 October 2014

NEC, BIRMINGHAM, UK

www.interplasuk.com

SEPTEMBER 2014 • WWW.EPPM.COM • 43

ADDITIVES: PLASTICS COLOR CORP

Finger on the pulse Tim Workman, Vice-President of Business Development at Plastics Color Corporation, spoke to EPPM about what innovative specialised additives are coming out of its research labs and shaking up the global marketplace, and what enthuses him about the work this dynamic plastics giant is doing.

Words | Rose Brooke

For half a century, Plastics Color Corporation has been bringing pioneering innovations to what has become a gargantuan, international industry. And the Illinois-headquartered company show no signs of slowing.

EPPM spoke to Vice-President of Business Development Tim Workman about the latest developments in specialised additives to come out of PCC, and what excites him about the most cutting-edge products to make it to market.

“We’re an organisation that is instrumental in bringing trends to our products, especially in industrial products. We try to keep our finger on the pulse as to what’s trending and we’re actively involved in a lot of industries,” Workman explained.

PCC’s active engagement with trends is by no means general. The company trend-gathers for every application, with teams working on the latest in consumer products, automotive, food packaging and more.

Colour by numbers To assist customers looking to keep up-to-date with colour trends, PCC has developed isaac, an app that allows users to access and manipulate colours by superimposing them directly onto a digital 3D image of a product.

Named after Sir Isaac Newton whose Theory of Light centred on the refraction of light through a prism reflecting the colour spectrum, isaac is an interactive customer portal aimed at getting products to market faster by speeding up the process of choosing the right colour for a product.

44 • WWW.EPPM.COM • SEPTEMBER 2014

“It’s important to understand a lot of companies will get out a colour swatch and say ‘here’s a representation of a colour’, which is fine, but what we try and do is take these colours and attach them to a formula. That way, when a customer looks at these colours, there’s a physical formula for them and we’re not finding a formulation from scratch,” Workman said.

He continued that, should the customer wish, they can be sent a sample plastic part in that colour formulation within 24 hours of requesting it.

“Pantones are great, but there’s no formula attached to it, you’re just dealing with a swatch, so this takes that first-level design work out.”

Another of PCC’s recent innovations is its anti-microbial and anti-fungal MicroBlok line of additives, which impede the growth of bacteria on the surfaces of products, reducing odours, stains and product deterioration.

Designed for consumer contact applications including medical and the transportation of goods, MicroBlok covers the surface of the plastic and ensures an inhospitable environment for microbes.

The never-ending quest MicroBlok is made using silver ions, which are dispersed throughout a polymer matrix creating an internal surface that is a very efficient antimicrobial. The silver ions do not deplete during the inhibition process and the anti-microbial effect does not diminish over time.

“Anti-microbials are something we’re pretty high on both here in North America and in China,” Workman noted, adding that plastic pallets transporting goods through humid environments and medical devices, as well as headgear and clothing for operating rooms, are good examples of where MicroBlok is best used.

“

We’re always looking for new opportunities and products in our labs.

”

PCC’s specialised additives work for medical applications extends into anti-counterfeiting. Its Mi Batch chemical marking additive is incorporated into the product allowing it to be identified. Using fluorescent reflective technology and X-rays, the particle taggants can be picked up, thus identifying an authentic product and ratting out a counterfeit because it is, according to Workman, “virtually impossible to replicate” due to the way it is produced.

“It’s gained interest all over the world and we’ve been using it a lot in medical devices,” he stated. “We have two very high profile medical clients that are putting Mi Batch into their product right now to do two things: avoid counterfeiting and track shipments.

“They can use it as a tracking mechanism so the end product is exactly what the customer says it should be and we’re pretty excited about that.”

It seems PCC’s never-ending quest to bring new and interesting innovations to the market is an infectious mentality.

Workman said: “We’re always looking for new opportunities and products in our labs and we’re in contact with our cutting-edge customers and material suppliers for the latest in plastics as well. But these three products I would say are the most interesting things we’ve been doing recently.”

The question is, what’s next for PCC? This dymanic business has plenty up its sleeve, including SoluPur, an additive that accelerates the degradation of petroleum-based products, while the company has also done extensive work in flame-retardant additives.

“We’re working on a lot of different things. There’s pretty exciting things going on.”

SEPTEMBER 2014 • WWW.EPPM.COM • 45

ADDITIVES

Fun to Safety!

At the forefront of innovation Masterbatch is constantly changing colour LCR Hallcrest is at the cutting edge of colourchanging thermochromics, making countless consumer products on the market safer, fun and more intuitive.

“

Usage limited only by the imagination

46 • WWW.EPPM.COM • SEPTEMBER 2014

”

Expand your capabilities with

LCR Hallcrest is at the cutting edge of colour-changing thermochromics, making countless consumer products on the market safer, fun and more intuitive.

LCR Hallcrest has been at the forefront of the colourchanging world of thermochromics since the early 1990s, producing products for world markets within both the safety and promotional arenas.

From the early days of the first big in-pack colour changing spoon promotion for French company, Poulain Hot Chocolate, and the company’s pioneering award winning Baby Safety Feeding Spoon the company has gone from strength to strength.

Today, Chameleon thermochromic masterbatches are used in many areas and applications and with a selection of award-winning products behind the company, its specialist masterbatch can be found in virtually any industry with its usage limited only by the imagination.

LCR Hallcrest’s most recent application success is within the baby safety sector. The first ever self heating baby bottle, Yoomi, which has won many awards for its innovation incorporates a small but vital piece of the clever colour-changing thermochromic technology, a visible thermochromic button within the heating system of the bottle which changes colour from orange to blue to alert parents that the milk has begun heating to the required safe temperature for a baby to drink.

The clever bottle gently and safely warms the milk to the natural temperature of breast milk in just 60 seconds.

The warmer works in the same way as the gel handwarming packs that warm up when you click a metal disc inside – when the orange button on the Yoomi warmer is pressed, the user is effectively clicking the

metal disc and it is the phase change from liquid to solid inside the warmer that creates the instant warmth. After 30 seconds the orange button starts to fade and turns to blue.

The Yoomi is very clever and has been selected as one of the top 15 British inventions of the last decade.

With a strong R&D department the company likes to work very closely with other businesses and plastic moulders, building relationships to provide solutions and ideas for applications whether for fun or safety, creating memorable products with a colour-change feature.

KEM

Colouring device with volumetric chamber metering

From producing giveaway colour changing ice cream spoons for the launch of a blockbuster children’s film, to being involved with Pringles on their collectible hand touch colour-changing mini plastic containers which were designed to hold just 12 Pringles for lunch boxes, to working with agencies on projects such as the big Shell Oil Dipper forecourt promotion, to safety items for major products and brands, LCR Hallcrest looks forward to the years ahead as the vision for the many uses of its temperature reactive colour-change technology constantly moves forward.

Learn more about LCR Hallcrest’s work at Interplas 2014 Stand A27.

“

EKO EKO dehumidified air dryer for plastic materials – the highest level of quality with 40% energy savings

Selected as one of the top 15 British inventions of the decade

” GRAVIKO

GRAVIKO series – Gravimetric metering, mixing and weighing system, check, correct and evaluate all in one operation Werner Koch Maschinentechnik GmbH Industriestr. 3 75228 Ispringen/Germany

T: +49 7231 8009-0 F: +49 7231 8009-60 info@koch-technik.de

Manufacturers from all over the world trust in the outstanding technology of the KOCH modular system.

www.koch-technik.com/en SEPTEMBER 2014 • WWW.EPPM.COM • 47

EUREKA SERIES

Could origami teach us to make new materials?

Origami could help scientists to develop flexible, programmable materials according to a recent report, but will this theory open up avenues for plastics material development?

Words | Rose Brooke

The oft-admired art of Japanese paper folding, origami, is inspiring scientists to explore the foundations of potentially new materials.

According to a report published in an early digital version of Science last month (August 18th 2014), researchers at Cornell and Western New England University along with physicists Arthur Evans and Christian Santangelo, and polymer scientist Ryan Howard from the University of Massachusetts Amherst, are using origami-based folding methods for “tuning” the fundamental physical properties of any kind of thin sheeting.

This could eventually lead to the development of molecular-scale machines that could snap into place and perform mechanical tasks.

Mysteries unfolding The team developed this idea in their search to design controllable new materials that exhibit desired physical properties, rather than relying on those properties to emerge naturally.

At a physics summit in recent years, Santangelo mentioned the unusual properties of a special kind of origami fold called Miura-ori to fellow physicist Jesse Silverberg of Cornell - a fan of the paper folding art.

When paper is folded in this way, the object contracts when squeezed much like an accordion, allowing it to be packed into a small shape, but unfolded with minimal effort from the corners. This technique has, in fact, been used in space to launch satellites with solar arrays that can be unfolded using only small motors on the edges.

Santangelo explained: “As you compress most materials along one axis, they expand in other directions. In other words, squeezing a hunk of material causes it to leak out the sides. A rare class of materials, however, does the opposite. If you compress them along one direction, they collapse uniformly in all directions. Miura-ori shows us how to use this property to make new devices. Exotic materials can be formed from traditional materials simply by altering microscopic structure.”

48 • WWW.EPPM.COM • SEPTEMBER 2014

The scientist, along with Silverberg and their colleagues from Cornell and Western New England, explain in their report how to alter patterns and introduce defects to tune a thin sheet’s stiffness and create a material with programmable and reprogrammable properties.

Totally bizarre “The work brings together origami, metamaterials, programmable matter crystallography and more. It’s totally bizarre and unique to have so many of these ideas intersecting at the same time,” stated Silverberg.

Santangelo explained that active materials can change their shape, size and physical properties with changes in temperature, electro-magnetic fields and pressure, with such materials, researchers may be able to create materials that are flexible, elastic and durable.

The team stated that it is rare to find metamaterials that can be reconfigured beyond their original design, but origami-inspired mechanical metamaterials offer enhanced flexibility due to their properties being linked to a folding pattern that may be altered.

It remains to be seen whether this theory is applied to plastics, but programmable materials such as biodegradable plastics are already being explored and utilised in the mainstream.

Meanwhile, scientists are already looking at structure for altering the colour of materials. Recently, Nano Letters published a study by Danish scientists who were looking at the structure of colourful organisms found in nature in their search for making the process of manufacturing colourful plastic less harmful to the environment than using dyes.

SEPTEMBER 2014 • WWW.EPPM.COM • 49

FREE set of Plastics Timeline Posters Pre 1900 - 2010+

The BPF Plastics Timeline is a set of 10 poster that have been put together by the British Plastics Federation with the backing of our Sponsors. These posters depict the significant developments and milestone throughout the history of plastics dating back to 1284 and through the years up until the current day and beyond.

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Available from www.bpfshop.com

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Visit the British Plastics Federation on stand A88 at Interplas

Over 40 Years of Service

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

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

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50 • WWW.EPPM.COM • SEPTEMBER 2014

EPPM Classifieds

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To advertise here please contact Lucinda Nicholls: USED MACHINERY MATERIALS T: +44 (0) 1244 680222 E: lucinda.nicholls@rapidnews.com

Abbey Masterbatch Classified_68.5x90_Layout 1 17/01/2014 0

BLACK MASTERBATCH Compounding

44 Years in New & Used Machinery to the Plastics Industry Worldwide.

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EPPM_144x90_09-14.indd 1

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