Visit our websites [ www.plasticsandrubberasia.com [ www.plasticsandrubberasia.com [ www.rubberjournalasia.com [ www.injectionmouldingasia.com
T
Editor’s Note he immediate past year’s ambivalence in market demands has been counterbalanced by boosts in exports, intensified
networking via events, and several mergers and acquisitions, to mention a few strategies. On the word of industry observers, deals across industries including aerospace, chemicals, building and construction, energy, healthcare, and manufacturing have elevated market shares as well as reduce expenditures.
Inside
As well, the global plastics market is on track with its
close to US$2 trillion value by 2020, amid the continued growth
1 5 7
May
11
of the packaging materials segment that accounts to 20% of the total; a rising demand for composites and high performance plastics in major industries; discovery of new applications and technologies,
19
and more. At the same time, the rubber industry is not far behind in growth, driven by strong demand from the tyre segment.
Plastics and Rubber Asia (PRA) magazine keeps on
25
par with these growth disruptors in the industry.
PRA also adapts to these changes to remain competitive
as well as effective in its scope of delivering news and information.
28
For 2018, PRA is building up its digital edition
circulation to cater to more mobile device users. It is also introducing improvements to the design and functionality of its websites. It has
32
a fresh roster of media content as well as new offers to enhance campaigns and advertising, continually adding to its nearly 40,000 email subscribers.
Now in its 33rd year, Plastics and Rubber Asia (PRA)
magazine has been a dedicated media platform for thousands of online, digital and print subscribers in the manufacturing, processing, developing, and research sectors. For advertisers, PRA remains to be a broad faceted conduit for potential business leads, prospecting agents and distributors, and clients who may require products and services.
PRA looks forward to the New Year of bright prospects
for the industry!
Tej Fernandez Executive Editor tej@plasticsandrubberasia.com
January/February India’s machinery makers embrace challenges Vietnamese packaging maker expands boundaries March/April Material developments for 3D printing
37
Davis-Standard: Extending its reach to Asia June/July Unlocking PET packaging potential with Multi-Layer Technology for Barrier August Battenfeld-cincinnati China: Driven by innovation September IKO Polymeric: Innovative solution for energy-efficient production of flexible PVC October Thailand: A tiger economy in an era of innovation November/December Industry 4.0 takes production processes to a new level
About PRA
Published since 1985, Plastics and Rubber Asia (PRA) magazine comes out eight (8) times a year with a yearly print circulation of 110,000 copies plus bonus distribution in key international industry events; the digital editions to tap a potential 4 billion mobile device users. It is supplemented by online niche periodicals Rubber Journal Asia [ RJA] at www. rubberjournalasia.com and Injection Moulding Asia [IMA] at www.injectionmouldingasia.com.
Indian Machinery & Technology
India’s machinery makers embrace challenges The plastics industry is one of India’s major engines of growth that looks ahead to a year of increasing growth rate and expanding markets, adapting well to the flux as opportunities for varied applications for plastics continue to rise, all this against the background of a slowing GDP, the demonetising policies introduced last year and the impending implementation of GST this year.
T
he plastics industry is one of India’s major engines of growth that looks ahead to a year
of increasing growth rate and expanding markets, adapting well to the flux as opportunities for varied applications for plastics continue to rise, all this against the background of a slowing GDP, the demonetising policies introduced last year and
are cues for a more optimistic outcome. Fortunately for the Asia-Pacific region, likewise vulnerable to global risks, it is able to maintain its momentum amid soft growth prospects. In the region and the world, India has become a benchmark for growth. But again, what has been “set in stone” for many years in the past has been challenged after the Indian government demonetised high value currencies (in a bid to
the impending implementation of GST this year.
crack down on corruption and terrorism) last year.
For many economies worldwide, the previous
Though the move, critics say, may keel over
year, emblematic of events that challenge established beliefs and standardised political frameworks, has epitomised the axiom that the
India’s “world’s fastest economic growth” claim, especially since the International Monetary Fund (IMF) has downgraded the country’s
only permanent thing (on earth) is change.
growth projection, yet there are more positive
The new year brings a mixed bag of opportunities.
Economists at the Moody’s Investors Service
On the one hand it has traces of the spillover impact of 2016, yet at the same time there
than negative outcomes from this strategy. and India-based affiliate ICRA Ltd project that the disruption is only short-term; and by midyear, India’s economy will start to pick up. PRA magazine 2017 yearender edition | 1
As for the country’s plastics industry, consultancy
in 2017 with new developments that will help
firm Lucintel forecasts the plastic pipe market
sustain the growth of the plastics industry.
to grow at a CAGR of 10.4% from 2016 to 2021, owing to the growth of the building/ construction
In an interview with PRA, Sunil Jain, President of
and infrastructure sectors.
Rajoo, when asked what Rajoo expects as well as aims for this year, replied, “At Rajoo, in 2017, our
Engineering plastics have a potential CAGR of
focus will be on highoutput barrier and nonbarrier
over 13% from 2015-2020 report, finds TechSci
films lines, in addition to high-output sheet
Research. It attributes this growth to demand
extrusion lines. Thus, offering a complete barrier
from diverse
packaging solution to the industry, an application
industries including
poised for exponential growth owing to the entry
automotive,
of organised retail in India. At the same time,
electrical &
our focus on exports will be further increased.”
electronics, construction, and
While Rajoo has forged strategic partnerships with
others.
firms like Italian pipe machinery maker Bausano, German blown film machine maker Hosokawa Sunil Jain, President of Rajoo, says the company is contributing to skills development in the plastics sector by setting up an innovation centre
Alpine and Meaf Machines of Netherlands, Sunil
notwithstanding its burgeoning requirement for
since its inception. We have brought world-class
plastic packaging, forecast to reach US$73 billion
affordable technologies to the industry in India,
by 2020, according to the Federation of Indian
even in the past, and we continue to do so now.
Chambers of Commerce and Industry (FICCI)
Offering import substitution to the industry
and Tata Strategic Management Group (TSMG).
has been our forte. Our sister company has
As well, the country has a lucrative demand for highperformance plastics,
says the company is continuing to chalk up other plus points. “Rajoo has several firsts to its credit, not now but
successfully introduced machines for producing WPC (Wood Plastic Composite), which is a
Metamorphosis to a global leadership
E
xtrusion and thermoforming machinery
substitute for wood. Yet, another environment
maker Rajoo Engineers is an example of
friendly technology offered by our company.”
success that follows changes. The Gujaratbased manufacturer describes its more than three
As regards plasticulture, Sunil says the firm is
decades of providing technology solutions for
now executing a project for an Indian customer
the plastics industry as a “quick metamorphosis”
for a seven- layer barrier, 4.2 m-wide blown
from its modest beginnings in 1986 in the
film line to produce agriculture films. “This
Gujarat town of Rajkot to its current global
will yet be another first Rajoo’s-five-layer in
status with offices in India and overseas.
the industry in Asia from Rajoo. The slated
Technology-driven,
output to produce barrier film is 1,500 kg/
Rajoo
Engineers
PRA magazine 2017 yearender edition | 2
ushers
hour and is targeted for various applications
critical stage and is a major issue. While the
– FIBC liners, canal lining and agriculture films.”
government of India and our association – Plastics Machinery Manufacturers Association
Meanwhile, its other latest technology, Pentafoil
of India (PMMAI) – of which we are one of the
five-layer barrier film line, introduced at the
founder members, have taken effective steps in
K2016, is specifically targeted to produce all
this direction, Rajoo on its own has launched
polyolefin films for packaging, which are fully
a unique initiative, a first by an Asian plastics
recyclable unlike films with barrier polymers.
machinery manufacturer in the blown film and
“It also offers benefits of down-gauging, thus
sheet extrusion segment.”
reducing the overall usage of plastics. Energy consumption is yet another ecofriendly parameter
The company is in the midst of setting up the
and this line has been certified by TUV at a never
Rajoo Innovation Centre, based in Rajkot, to be
before 0.3001 kwH/kg of film,” claimed Sunil.
up and running in the middle of 2017. “It will be equipped with a state-of-the-art seven-layer
As for industry 4.0 or IoT-ready technologies,
blown film line and a barrier sheet extrusion line
Sunil
and will impart training to develop a skills pool
remarked,
“From
the
perspective
of Rajoo Engineers, there are two focus domains: in
automation
manufacturing
and
data
technologies
in
for the industry.
exchange
In addition to
making
contemporary
machines on one hand and our machines being
testing facilities, it
automated and using cyber technology controls.”
will also provide an impetus for
He adds that the firm has taken steps in both
development of
directions. “Cloud-based ERP for creating a virtual
barrier packaging
factory is already under implementation. Further, our customers using high-output blown film lines already get internet-based remote support. Similar technologies are also being introduced
Mamata claims that its non-woven fabric bag making machine tops speeds that are the highest in the industry
materials,” revealed Sunil. While
there
challenges
are on
in our complete range of machines. However,
the horizon, Sunil is optimistic of the future.
bandwidth and speed for internet access continues
“The demonetisation drive launched by the
to be challenge.”
government of India may have been disruptive but it is a bold step forward. We foresee it
Dealing with skills shortages
W
affecting the whole economy in the short term
the availability of technology is
including the growth of the plastics industry.
aplenty, India’s plastics sector has a
The introduction of GST, yet another major
downside though as explained by Sunil. “The
economic reform to be introduced in 2017, will
skills pool to support the plastics manufacturing
positively enhance the “ease of doing business”.
industry in India is scarce and it has reached a
Our targets for 2017 will factor the above
hile
PRA magazine 2017 yearender edition | 3
major initiatives in the country,” he concluded.
advancements in the packaging sector are taking place in the US. Our strategy is to hire design
Mamata “exports” US technology to India
A
talent in the US to develop the equipment that is
nother Gujarat-based machinery maker,
up-to-date and offer it to the rest of the world by
Mamata
leveraging the cost efficiency of producing it in
Machinery,
which
makes
converting and extrusion machinery, is expanding
India,” explained Kane.
in the North American market, where it has already installed machine-tops 200 servodriven-
He also said that though the machines will
bag and pouch making machinery.
be priced slightly higher than locally madein-India machines, the company will offer
The company first entered the market with a 5,000
greater valueadded technology to the market.
sq ft-sales and service centre for pouch making machinery in Illinois in early 2000. Later, in 2010,
The Ahmedabad-headquartered company also
it set up a 12,500-sq ft facility in Florida.
claims a first in the industry: the fastest bag making machine for non-woven reusable bags. “This
“The US-based team of engineers designs and
machine is three times faster than the machines
manufactures these packaging machines. We now
produced in China. It has an output of 160 bags/
offer horizontal form, fill and seal; high-speed
minute, compared to the usual 40-50 bags/
pouch fillers; and multi-
minute,” claimed Kane, adding that the prototype
lane sachet packaging
will be commercialised in the market soon.
machinery in the US,” said Apurva Kane, Senior
At the K show, it had another first: a high-speed
Vice-President.
bag maker for converting PP woven fabric into sacks and pouches for bulk packaging of
Speaking to PRA at the K2016 show, Kane, added, “The machines produced in the US are
The HDPE/PP woven-bag sack making machine is targeted at bulk packaging
commodities. The machine is completely automated; with sheeton roll, it forms side gussets and undertakes back
not only of a high speed but are produced in a
seam gluing as well cuts to required lengths; folds
high hygiene environment, making them suitable
and stitches the bags. “It is able to convert bags from
for high-speed use in the packaging of foodstuff,
5 kg up to 25 kg size that can be used for packing
like dry products such as oatmeal and dry fruits
rice, pulses and garden manure. With an output
and nuts.”
of 60 bags/minute, it is the fastest in the world.”
Such machines have been installed at one of
As for future machinery launches, Kane said
the world’s largest pistachio packer Growers
Mamata is researching into liquid packaging. “We
Express’s facility in California, a co-packer for
are targeting the production of in-line machines
Green Giant, shared Kane. This technology is now
for packaging with spouts, for normal liquid
being brought back to India. “Some of the major
juices, edible oils and drinks,” he added.
4 | PRA magazine 2017 yearender edition
Vietnamese packaging maker expands boundaries Founded in 1992, Vietnamese manufacturer of laminated flexible packaging, Thanh Phu Plastic Packaging, is a newbie in the plastics packaging sector in the country. Yet, the company is adopting progressive trends, such as making it easier for the recycling of laminated packaging.
properties, such as competitive modulus and bagdrop performance, compared to PA-laminated film at the same film thickness. It also features improved optics, such as high gloss and transparency. Plus,
R
ecycling of laminated packaging has been a long-standing challenge for the packaging
industry because of the mix of complex materials that make up the structure. The cost and effort required to separate the polyolefin layer from the laminates, like PET, PA, EVOH or OPP, are complex and an issue for packaging recycling
good thickness variation control is possible, compared to conventional PET films. “This is a true synergy between material science
companies.
and conversion
Thus, to address the market’s demand for a more
innovation,” says
technology
readily recyclable alternative to conventional laminated structures, Ho Chi Minh-located Thanh Phu collaborated with US materials firm ExxonMobil Chemical to push the boundaries for a 100% PE solution that can be recycled in the
Alex Dam, Executive
Dam says Thanh Phu is aiming at providing brand owners with 100% PE/PE solution to meet their packaging recyclability commitments while maintaining a competitive cost/efficiency ratio.
Vice-President at Thanh Phu. “We have changed the cradle-to-grave cycle into a more responsible cradle-to-cradle concept.
same collection stream as PE.
Our aim is to have
Thanh Phu was able to produce the new
compromising performance, while maintaining
packaging packaging
by
using
Example-of-laminated-
ExxonMobil’s new Exceed XP and
Enable mLLDPE polymers and by applying its
conventional
a full PE alternative to
laminated
solutions
without
an attractive cost-efficiency ratio.” Thanh
Phu
mainly
manufactures
flexible
proprietary Veloflex film conversion technology.
packaging, especially for food and hygiene,
Especially suited for use in pouches, this full-
Pacific and OCEANIA regions.
PE film alternative is comparable to traditional laminated films in terms of aesthetics and integrity, say the firms. For instance, the fullPE solution exhibits outstanding mechanical
serving key global brand owners in the Asia-
It is also looking at expanding the usage of the all-PE packaging to seafood packaging to replace the current nylon/PE laminated packaging. PRA magazine 2017 yearender edition | 5
More recently, in a collaboration with ExxonMobil,
ExxonMobil launched two new grades of Exceed
Thanh Phu produced a 100% PE/PE laminated
XP PE aimed at films for greenhouse, food
standup pouch, using Veloflex technology, for
lamination and softshrink applications.
Unicharm Vietnam. Another four new Exceed XP grades were To be able to produce the latest types of films,
launched at the Chinaplas show in Shanghai
Thanh Phu has the latest blown film line from
in April 2016. It also showcased Enable 40-
Germany-based Windmöller & Hölscher (W&H).
02 performance polymers for compression
It also has the latest
packaging and geomembranes, as well as a range
printing technology
of low viscosity Vistamaxx performance polymers
from W&H:
for home and consumer products and an array of
Heliostar S gravure
other applications.
press, installed in
Stand-up pouch launched in the market by Than Phu together with ExxonMobil
2016. According
“With new grades, we’re expanding our recently
to Dam, Veloflex
launched Exceed XP performance polymers
technology is a turn-
portfolio,” said Cindy Shulman, Plastics and
key solution that
Resins Vice-President, ExxonMobil. “Customers
is offered to brand
will now have an even more powerful toolkit to
owners to meet
grow their businesses.”
their packaging recyclability requirements, and it involves
Shulman also said the new grades were launched
all the steps “from extrusion to printing and
after a survey with customers on the current trends
downstream processing,” he adds.
and needs. “There are two mega-trends in the industry currently: quality and cost-effectiveness.
When asked how the Veloflex technology is used
And we work with partners to translate these
to produce better quality films, Dam replies,
onto the market.”
“The specific orientation of polymers under the extrusion process provides a good balance
Thus, the ability to replace conventional laminated
of mechanical properties for both MD and TD
packaging with packaging that can be recycled
direction (this is different from the MDO process
will allow the industry to take a significant step
as normally seen in the market).”
towards food-lamination developing solutions with more benefits that consumers are demanding.
Furthermore, Dam says Thanh Phu is aiming at providing brand owners with 100% PE/PE
“We hope to develop the Veloflex technology into a
solution to meet their packaging recyclability
full scale solution to address the flexible packaging
commitments while maintaining a competitive
recyclability requirements of the market. The “new
cost/efficiency ratio.
plastics economy” concept recently introduced at the World Economic Forum in Davos has given a
Meanwhile, at the K2016 show last year, 6 | PRA magazine 2017 yearender edition
true validation to our initiatives,” Dam concludes.
The 3D printing market is estimated to grow at 24% CAGR till 2022, with investment in services, materials and hardware to reach US$58 billion by 2022. While 3D printing has taken off in the aerospace, automotive, consumer, healthcare, E&E and biomedical industries, other sectors are being targeted, too, thus, the requirement for new materials.
Material developments for 3D printing New UV curable elastomers with better To enrich the design and fabrication flexibility,
stretching
E
lastomers have been used in a host of
researchers have used 3D printing techniques,
applications,
elasticity,
such as UV curing-based 3D printing techniques
resilience, and electrical and thermal insulation,
that solidify liquid polymer resins to 3D
for fabricating soft robots, flexible electronics
objects through patterned UV light, to fabricate
and smart biomedical devices that require
elastomeric 3D objects.
soft
and
due
to
deformable
their
material
properties
to establish safe and smooth interactions
Nevertheless, most of the commercially available
with
UV-curable (3D-printable) elastomers break at
humans
externally
and
internally.
less than 200% (two times the original length), However, to date, the most widely used silicon
rubberbased
elastomers
require
which makes it unsuitable for many applications.
a
thermal curing process that limits fabrication
Recently, researchers have developed a family
in
cutting,
of highly stretchable and UV-curable (SUV)
constrains
elastomers that can be stretched by up to
design freedom and geometric complexity.
1,100%, five times the elongation at break of any
traditional
moulding
and
ways,
such
casting,
as
which
by
PRA magazine 2017 yearender edition | 7
commercially available elastomer, and are suitable
enhance the capability of fabricating soft and
for UV curing-based 3D printing techniques.
deformable 3D structures, including soft actuators and robots, flexible electronics, and acoustic
This work is a collaborative effort between researchers
from
theSingapore
metamaterials.
University
of Technology and Design’s (SUTD) Digital
New filaments from an unconventional extrusion
Manufacturing and Design (DManD) Centre,
process
which is funded by the Singapore National Research
Foundation
(NRF),
the
Hebrew
University of Jerusalem (HUJI), and the Campus for
Research
Excellence
and
Technological
Enterprise (CREATE), also funded by the NRF.
M
eanwhile,
not
satisfied
with
the
performance of 3D printing filaments
available on the market, a Dutch supplier of
engineering
filaments
for
3D
printing
has developed an extrusion system and as a result, filaments boasting higher strength and
Using high resolution 3D printing with the SUV
printablility. Started by a father and son team,
elastomer compositions enables the direct creation
Jan-Peter and Jasper Wille, 3D4Makers says that
of complex 3D lattices or hollow structures
its new filaments eliminate problems such as
that exhibit extremely large deformation. The
breaking and bubbling and better meet roundness
researchers also say that complicated geometric
and tolerance requirements in parts.
structures and devices, such as a 3D soft robotic gripper, can be printed in an hour.
As for the extrusion process, standard filament extrusion equipment is water-cooled and the
Compared to traditional moulding and casting
filament is dipped into a water bath at a set
methods, using UV curing-based 3D printing
temperature to cool it down as it extrudes. This
with the SUV elastomers reduces fabrication time
moisture degrades the performance of PLA and
from many hours, even days, to a few minutes
engineering plastics, says the team.
or hours as complicated and time-consuming fabrication
steps,
such
as
mould-building,
The extruder developed by 3D4Makers uses
moulding/ demoulding, and part assembly, are
a multiplejet air system to precisely manage
replaced by a single 3D printing step.
water-free cooling of the filament. With this, the company claims that parts printed 3D4Makers
The SUV elastomers not only sustain large elastic
with its filaments feature higher impact resistance
deformation, but also maintain good mechanical
and achieve tighter tolerances in ovality and
repeatability, which makes them good materials
inner and outer diameters, than those made with
for fabricating flexible electronics. To demonstrate
conventional materials.
this, the researchers fabricated a 3D buckyball light switch that still works after being pressed
The company says it can also produce 3D
for more than 1,000 times.
printing filaments without plasticisers or other additives, many of which are approved for food-
The
researchers say this new elastomer will
8 | PRA magazine 2017 yearender edition
contact applications and are biocompatible or
setups:
biodegradable.
extruder
screw design, drive
and
spool ABS-grades-3D systems. The objective The technology has found initial acceptance
is to obtain the filament with the best quality
in
and
properties in typical thicknesses of 1.75 mm
polycaprolactone (PCL) filaments are used for
and 2.85 mm and validate the material to meet
biofabrication of skin and organs.
the requirements of the final application.
It also offers “a unique PEEK grade with higher
Meanwhile, US biopolymers maker NatureWorks
printability” and adds that “few companies
has introduced a PLA, Ingeo 3D870, for filament
have managed to make PEEK filament this
manufacturers who have trialled the product and
successfully”.
commend the ease of processing and printability.
In addition, the company offers PEI, PPSU, ASA
Ingeo 3D870 is said to comply with chemical
and 100% pure PLLA (mainly for biofabrication
inventory listings in key markets in North
and
3D4Makers
America, Asia and Europe. Parts produced
also claims to be the first in the world to have
are said to exceed ABS 3D parts in impact
developed PCL filament in two grades of 99%
strength and with post-print annealing, and
and 100% pure formulations. It says this non-
NatureWorks says it rivals ABS heat resistance.
research
institutes,
bioprinting
where
PLLA
applications).
toxic and biodegradable material is used mainly in medical research and is suitable for making
Though NatureWorks offers a general purpose
custom braces, grips and prosthetics.
PLA, it says 3D850 and 3D870 have been designed specifically for 3D printing, with good UV colour lightfastness, low yellow index, and additional heat
Optimised ABS and PLA grades
S
panish materials supplier Elix Polymers says it
and impact properties as a result of cyrstallisation.
has optimised five ABS grades for 3D printing,
with improved printing performance, low warpage, dimensional precision and high resolution.
Asian development trio
S
ingapore’s National Additive Manufacturing Innovation Cluster’s (NAMIC) portfolio,
It says some new grades have already been
made up of Nanyang Technological University
validated at filament producers, 3D printer makers
(NTU), the National Research Foundation and
and part manufacturers who use Fused Filament
SPRING Singapore, was formed last year to help
Fabrication (FFF) or FDM (Fused Deposition
companies develop capabilities in 3D printing.
Modelling). Elix says it is already cooperating with several printer producers and 3D software
It has successfully established joint funding for 39
providers to identify the right partners and create
projects between companies and academic research
a database with validated filament producers.
institutions, with S$3.8 million from the government via NAMIC and S$2.8 million from the companies.
It is offering technical support, including recommendations
on
correct
processing
Of the research projects in the works, NTU PRA magazine 2017 yearender edition | 9
is working with a local 3D printing start-up focused on healthcare to develop tissue implants customised for patients. The new printer can print the supporting structure layer by layer and insert living cells to form a live tissue that could aid in the regeneration of particular tissues or organs. Another
research
collaboration
between
the
Singapore University of Technology and Design (SUTD)
and
Gilmour
Space
Technologies
is
looking at developing a 3D printer to produce
SUTD and Gilmour Space Technologies are working on 3D printed fuel, by combining two materials, known as the “secret sauce� that dramatically reduces the cost of rocket launches from about US$1 million to US$750,000
prototype solid fuel mixtures for rockets, which is made up of two or more fuels comprising wax and plastics and is
designed and printed in a
way that provides the rocket with the required thrust, but in a more cost-effective manner. With the barrier of entry being quite high, due to the high cost of printers/machinery and a lack of expertise in additive manufacturing, this is one way that organisations can reach out to educate and help link companies to research institutes that already have existing 3D printing machines and the
technical
know-how.
10 | PRA magazine 2017 yearender edition
Davis-Standard
Extending its reach to Asia
A
ccording to market research company Ceresana, in its latest report on flexible
plastic films, the sale of plastic films for the packaging, agriculture, construction and technical sectors will reach a volume of about US$250 billion until 2024. Emerging countries in the Asia-Pacific region, particularly China and India, are expected to expand their packaging requirements, owing to rapid industrialisation and urbanisation, among other aspects in the region. Plastics
are
also
enablers
of
healthcare
innovations and medical breakthroughs due to their barrier properties; light weight, low cost, durability, compatibility with other materials, and sterilisability, among other characteristics. One of the most important developments in modern healthcare that is aided by medicalgrade plastics is the rising preference for minimal to non-invasive surgeries and diagnostics, as well as drug delivery systems, all of which require precision devices. This trend bodes well for the medical tubing market, which is poised to nearly double from US$3.7 billion in 2015 to US$5.8 billion by 2021, PRA magazine 2017 yearender edition |
11
or an estimated CAGR of 8%, during the period covered by research firm Markets & Markets. The report predicts further growth for the medical tubing market, given that awareness about healthcare has significantly increased; and quality of healthcare delivery has become
Jim Murphy Davis-Standard President/CEO
pivotal to the extent that government initiatives and policies are including healthcare and medical infrastructure in priority agenda. Murphy:
Davis-Standard
will
promote
its
As the market needs become more sophisticated,
growing regional presence and capabilities
the requirements for processors and machinery
during the Chinaplas show. As an example of
suppliers are being increased, to up the ante with
the company’s extrusion technology, Davis-
innovative processes.
Standard will exhibit an HPE-H extruder for medical tubing applications.
Thus, extrusion systems supplier Davis-Standard, LLC offers solutions that impact everyday life,
The HPE-H offers a compact design and is one
from food packaging and data cables to IV tubing.
of the industry’s most widely used extruders.
In other words, the markets served by Davis-
Available in 20 mm, 25 mm, 30 mm, 40 mm,
Standard are broad, ranging from packaging,
and 45 mm sizes, the HPE-H is known for a
construction, medical, consumer products and
fast delivery and rugged design that is energy
electronics to automotive, agriculture, energy,
efficient and easy to maintain.
and more. PRA: Which growth markets is Davis-Standard What’s more, the company offers a comprehensive
looking at expanding to?
range of plastics and rubber extrusion machinery, wire/cable machinery, blow moulding machinery,
Murphy: As far as geographic markets, we seek
and converting systems and technology; as well
to be strong in every market where we have a
as a full range of extrusion aftermarket services.
presence. North America and Europe continue to be staples for us. China, the rest of Asia and
PRA caught up with Davis-Standard President/
South America continue to present growth
CEO Jim Murphy to find out more about the
opportunities that we will capitalise on.
company’s plans for the year and highlights from last year.
With regards to applications, we can support all of them no matter where our customers
PRA: What has Davis-Standard lined-up for this
are located. Film, extrusion coating, sheet and
year’s Chinaplas 2017 show in terms of technology
medical tubing are among our strongest areas
offerings?
worldwide.
12 | PRA magazine 2017 yearender edition
Davis-Standard also continues to enjoy strong
extrusion system and multi-purpose microbore
growth in the Chinese marketplace, benefitting
tubing line.
from a regional manufacturing presence and full-scale R&D laboratory at Davis-Standard
The FPVC line is capable of line speeds from 5
(Suzhou) Plastics Packaging Machinery Co.,
to 100 mpm for processing 2 mm to 8 mm OD
Ltd.
tubing with accuracy of +/-50 microns. Line spareparts(gearcase) components include a 63 mm
Davis-Standard has continued to gain market
extruder, 8 m watercooling, precision internal
share in China due to outstanding customer
air supply, OD gauge and combination puller-
service, innovative feedscrew designs, control
cutter.
systems and modular technologies. The multi-purpose microbore tubing line is PRA: How has the Suzhou facility contributed to the
designed for single or dual-layer tubing, and
company’s services since it opened in 2012?
single lumen tubing with or without a stripe. It is equipped with two extruders, OD/ID wall grew
thickness measuring and controlling system,
its sales team in Asia while also increasing
closed-loop control via vacuum sizing tank and
manufacturing and laboratory capabilities at its
puller, and a high level central control system.
Murphy:
Last
year,
Davis-Standard
subsidiary in Suzhou, China. This has improved Davis-Standard’s response and delivery time
PRA: How will China’s Made in China 2025 agenda
while providing versatile and cost-competitive
impact Davis-Standard?
equipment options. Murphy:
The Made in China 2025 agenda is
several
consistent with our plan to support our customers
products in Suzhou including extruders up
in Asia from our Suzhou site. We will continue to
to 114 mm, PLC control systems, high-speed
add capabilities and products to support the high
systems for medical tubing and a full offering of
growth in the region.
Davis-Standard
now
manufactures
wire and cable systems. PRA: With the full integration of Gloucester Additionally, the facility is equipped for gearbox
Engineering Company (GEC) technology into Davis-
and control panel assembly and refurbishing
Standard, how has this expanded the offerings from
services, and there are plans to add fabrication
Davis-Standard?
and assembly of downstream equipment. Murphy:
Gloucester Engineering Company
Regional manufacturing has been key to Davis-
(GEC) has always been a market leader. Having
Standard’s ability to serve every major converting
the brand under our umbrella broadens and
and extrusion market in Asia. To support regional
strengthens our product offering in blown film,
customer trials and application development,
cast film and foam sheet. Together, we offer
the Suzhou laboratory offers a high-speed FPVC
industry technology that is going to be tough to PRA magazine 2017 yearender edition |
13
beat. We offer aftermarket support to the largest installed base of GEC equipment including opportunities to improve performance and machine control upgrades. Our customers now benefit from single-source manufacturing and service from a company with one of the largest installed base of blown film equipment in the world.
The Suzhou facility has become a huge part of supporting the healthcare/medical tubing sector, as healthcare services continue to grow in Asia
This includes lines from one to 11 layers and up to 9 m in width, pre-engineered options, precision gauge control, air rings, screw designs and dies
global polymer and rubber processing industries,
from 7-11 layers, plus pending innovations to
providing exceptional value to our customers.
improve
extrusion-machinery
productivity Our laboratory in Suzhou is a huge part of
further.
supporting the healthcare/medical tubing sector. In fact, Davis-Standard recently patented a
Healthcare continues to grow in Asia and the
spiral design for reducing thermally sensitive
need for medical products and devices single-
polymer degradation in blown film dies and has
layer-tubing-line grows with this demand.
provisional patents for a unique driven lay-on Plastics are a high-performance material for the
winder and self-threading winder.
medical industry, providing disposable products Fully
integrating
GEC
also
included
an
that reduce the possibility of infections.
expansion of our primary manufacturing facility in Pawcatuck, Connecticut. The 15,000 sq ft
We are seeing increased development of multi-
addition is complete with manufacturing cell for
layer structures and smaller diameter tubing to
producing highly technical blown film dies used
provide better physical property performance
in multilayer packaging and pharmaceutical
across a range of new applications. Customers
applications.
are able to test new resins and processes prior to making a large capital investment. The versatility
PRA: Since end-users/consumers are more aware
of our systems is also essential.
now when it comes to quality and cost effectiveness of products across a majority of applications, how
We’re able to accommodate customers with
does Davis-Standard contribute to these changing
technology that addresses a variety of tubing. In
consumer standards?
the flexible packaging market, Davis-Standard dsX-flex-pack developed the dsX flex-pack
Murphy: Davis-Standard is committed to
(extrusion coating). Asian converters are seeking
supplying advanced extrusion solutions to the
the
14
| PRA magazine 2017 yearender edition
advantages
of
high-speed
lamination,
subsequent waste reduction and improved quality
last year?
offered by this machine. The economical benefit of these 450 mpm machines is allowing many
Murphy: We finished 2016 stronger than 2015,
regional converters to separate themselves from
with a 10% growth, and anticipate 2017 to be
the competition. The flex-pack is also built with
even better. One of the highlights of 2016 was
an adaptable machine configuration to support a
the transition of our blow moulding accumulator
variety of end-use markets.
head production to Fulton, New York.
Packaging continues to grow in Asia based
We also created a new cutting and feeding machine
on strong demand for packaged products and
for low voltage wire and cable processes for
continued growth of the economy. Flexible
insulating applications. This unit facilitates timely
packaging is growing faster than the overall
transfers from one take-up to another and minimises
packaging market due to the many benefits
operator involvement, speeding up reel change.
it provides. Flexible packaging provides a lightweight package that is durable and often re-
We introduced a new energy-efficient barrel
sealable – these are features that consumers desire.
heating/cooling
system
to
reduce
energy
consumption by up to 50%. The patented design PRA: What strategies does Davis-Standard employ to
acts as a blanket for the extruder and is available
stay competitive?
on new machines or as a retrofit for existing machines.
Murphy: Davis-Standard is recognised as the global leader in high-performance plastic and
We developed an extruder
rubber extrusion and converting systems.
adapter called the QSE
Our capabilities go far beyond our extrusion
(Quick Screw
technology and extruder processing equipment.
Exchange)
They extend to our professional design engineers,
to enable fast
laboratory personnel, training experts, talented
screw changes without
commercial force, hands-on field engineers, and
dismantling feed pipes
aftermarket parts and service specialists.
- a big time saver!
As a team, we work together to support our
For thin substrates,
extrusion and converting customers from the
we engineered a high-speed film and foil
very first inquiry to commissioning and final
unwind for 800 pm splice speeds for sensitive
acceptance of the project, and beyond. Our focus
webs such as aluminium foil at 6 microns.
Davis-Standard’s HPE-H extruder
has always been, and continues to be, excelling in price, performance, delivery and service.
Lastly, we installed the largest seven-layer blown film die in the world. The 2.3-m, seven-layer
-PRA: What were the highlights of the company
Centrex IBC die is for agriculture applications. PRA magazine 2017 yearender edition |
15
An upside to packaging technology
T
he Asia Pacific region, with its sizeable consumer base of 4.5
billion, is a fast growing market for the packaging sector. Among the top Asian countries vying for a large market share in the packaging sector is South Korea,
especially since
efforts to push “green” practices are prioritised by way of national policy. According to a 2016 report by Euromonitor
on
South
Korea’s
packaging industry, the Ministry of Thanks to water cooling, films can be produced with especially good optical and mechanical properties
Environment has enforced a number of pro-green environment initiatives that also cover packaging for food, medical, beauty and personal care products, and home care products.
T
Strict compliances to packaging regulations have o meet the region’s growing appetite for packaging, South Korean packaging
maker SR Technopack is positioning itself to be at the forefront of the industry with high-quality films, mainly for the food and
been in check, too. Meeting this demand for packaging is South Korea’s SR Technopack. Established in 1992, the Chungnam-headquartered firm was acquired by
medical sectors.
Samryoong Co in 2012. Later, it revised its name
With a focus on R&D, the company
CEO as well as owner of SR Technopack.
is employing the latest Aquarex watercooled blown film line, an extrusion process that extrudes upside down, to meet challenging requirements in the bag infusion sector.
to SR Technopack. Hong Ro Cho is President/
It offers an array of plastic packaging for food and beverage, and medical products. Its plant in Cheon-an city manufactures sheets, trays, cups, and medical packaging. “We not only produce, we also design, assemble and support commercial packaging and develop advanced systems and technology to meet
1 6 | PRA magazine 2017 yearender edition
customers’ needs,” said Anna Song, Manager
“It was developed for perfect roll quality, even
for Overseas Marketing, adding that the firm
for films that are difficult to process. A weight-
employs 190 people.
compensated and highly accurate lay-on roll ensures perfect roll edges during gap winding
Not stinging on the latest technology
W
ith the stringent demands placed on
from the moment the new roll is started,” explains Neves.
today’s packaging solutions, making
it necessary to continue to adopt the latest
When asked why SR Technopack decided to
raw materials and production methods, SR
invest in the machinery, Anna replied, “It was
Technopack has in its stable 30 machines made
due to the extensive know-how of W&H and
up of rigid sheet extruders, thermoformers and
especially considering the specific references that
injection moulding machines.
W&H has in water-cooled blown film lines and innovation.
It is also in the process of installing Aquarex watercooled blown film lines from German machine
For example, the new Aquacage developed by
maker Windmöller & Hölscher (W&H).
W&H is the first water calibrator for blown film extrusion lines allowing continuous adjustment
The Aquarex water-cooled blown film extrusion
of film width without needing to stop the
concept allows films to be manufactured with
extrusion line for an exchange of calibrator. This
properties that clearly differ from those obtained
technology will be a focus for the next investment
by blown and cast film extrusion, says W&H..
of SR Technopack.”
Aquarex is a modular blown film extrusion line with water cooling and extremely fast cooling to
As for W&H, its advantages are its comprehensive
keep the crystallinity of the film low, giving it an
offering from a single source: from expert advice
exceptionally amorphous structure.
and engineering to the delivery of high quality machines, said Neves.
“The
highly
amorphous
microstructure
significantly improves weldability and sealability.
“Furthermore, W&H is able to provide solutions
It also results in a soft, elastic film characterised by
in extrusion, printing, and converting, and we see
high clarity and gloss and exceptional puncture/
this cooperation definitely on route to a long-term
tear resistance as well as dart-drop-value. The low
partnership,” said Neves, adding that W&H has
tendency to curl is also a clear advantage when
equipment and systems currently in operation in
asymmetric multi-layer composites are processed
more than 130 countries and at more than 5,000
further,” explains Marcos Dehm Neves, Area
customer plants.
Sales Manager for W&H. Non PVC-based bags
The machines will be paired with W&H’s Filmatic N, a modular surface/centre/gap winder with optional automation levels.
I
n the medical sector, SR Technopack specialises in the manufacture of IV solution film for non-
PVC fluid bags. Traditionally, infusion bags have PRA magazine 2017 yearender edition |
17
Infusion bags are just one of a number of products within the flexible packaging industry that can be made on the Aquarex line been
made
from
PVC but processors expect PP film to replace PVC, which is a naturally hard, brittle form of plastic that has to be mixed with phthalates to make it soft and pliable. Such softeners used with PVC are meeting with criticism in the industry. According to the Environmental Protection Agency, PVC is associated with health risks, with some countries, including China, having banned PVC infusion bags altogether. Thus, PP film infusion bags are a welcomed alternative. “Our IV solution film is a well-known product in this field globally, as well as proven under international certified levels. Not only are we a main key player in this sector in South Korea, but we have also been supplying to reputable companies globally since 2000,” said Song. Infusion bags are just one of a number of interesting products within the flexible packaging industry for which films made on the Aquarex line are suited. Neves says that with the Aquarex, amorphous, waterquenched films are no longer a niche product for special applications, “rather they enhance product presentation, which in turn can impact sales.” The “crystal clear” film looks more like window glass than film, in which some degree of opacity would be expected. This clarity, achieved from 18
| PRA magazine 2017 yearender edition
the shock cooling of the melt, is especially important for the production of infusion bags. Packaging outlook remains strong
W
hile the outlook of the packaging industry
remains
promising,
Song agrees that growth is not without its
challenges, such as increasing raw material costs that are influenced by crude oil prices. “But we are ready to meet any challenges. With the increase of single-person households, economic participation of women and preference of convenience food, the prospect of the food packaging industry will be favourable,” said Song. The company has also received a US$10 million award for its exports last year. “By installing new machines from W&H, we are confident of becoming a major leading global company in the packaging industry, especially in the medical film field. We plan to penetrate not only the China market but Middle East, Europe and South Asia,” adds Song. The company intends to push its efforts through R&D. “Our team is focusing on developing medical and packaging for bio industries in order to expand the business. Our ultimate objective is to become a total packaging solution company that is able to handle the entire gamut of packaging,” said Song. SR Technopack is on its way to achieving its goals as with the simultaneous installation of Aquarex water-cooled blown film lines, it not only is capable of producing quality film but will also be able to improve its productivity.
Unlocking PET packaging potential with Multi-Layer Technology for Barrier By Peter Yankov, Team Leader, Advanced Solutioning Process & Technology, Husky Injection Molding Systems
S
ince the early days of PET adoption in the packaging industry, it has been recognised
for its outstanding properties, allowing it to replace glass and aluminium in many food, beverage, home and personal care products. In addition to the functions of containing and dispensing a product, as well as delivering a marketing message to the consumer, a package must provide necessary protection for its content, at least for the duration of the planned shelf life. Some simple examples include the need to keep the carbon dioxide content of a carbonated beverage from escaping, preventing oxygen from reaching sensitive juice and sauce products and limiting exposure to light for dairy applications,
Comparison of CO2 loss – mono-layer versus mono-layer blend versus Multi-Layer Barrier Technology leave a package is dictated by the product volume. Surface to volume ratio inevitably increases as package volumes
decrease. This requires
packages to have improved barrier properties to support the necessary product shelf life. Market trends, driven by a consumer preference for smaller packages (portion control and on-thego consumption) and the ever-increasing need for brand owners to differentiate their products on store shelves, suggest that smaller volume packages
will
become
increasingly
more
including visible, ultra-violet or infra-red.
common.
While PET provides a better gas barrier than many
A small volume package also allows brand owners
other packaging polymers, it is still permeable and some gas exchange takes place between the content of a package and the environment, often
mono-layer to offer their products in emerging markets at a price point that is accessible to the larger group of potential consumers without
becoming the factor that limits product shelf life.
eroding the value.
The challenge of providing adequate product
There are multiple approaches to extending
protection increases as package sizes decrease. The rate of gas ingress (or loss) is proportional to the surface area of a package, while the total amount of gas that can be allowed to enter or
the barrier properties of a PET package and the ultimate choice of the technology will be dictated by multiple factors, such as the level of required barrier improvement, the need to maintain PRA magazine 2017 yearender edition |
19
production flexibility, constraints placed by the
The coating is applied in a plasma treatment
logistics chain and, of course, the total cost to
following the blow moulding process. Silicon
produce.
oxide coating is clear and transparent, while amorphous carbon coating imparts a light yellow
The easiest solution to improving the barrier
tint to a clear package. The effectiveness of such
properties of a traditional PET package is to
coatings may be limited by the bottle creep,
blend PET at the injection system extruder with
which may disrupt its integrity and lower the net
one of the many barrier materials available on the
improvement of the barrier properties.
market. In contrast, the multi-layer co-injection barrier The resulting blend will have improved resistance
solution provides a greater package design
to gas permeation (passive barrier) or may even
freedom, since the package creep and deformation
actively trap oxygen molecules (active oxygen
levels are less critical or even inconsequential for
scavenger) in the polymer matrix. Not requiring
the barrier performance. It further allows the
any equipment changes other than the polymer
introduction of active oxygen scavenger materials,
dosing and mixing auxiliaries, this may be an
preventing oxygen ingress and lowering oxygen
appropriate solution in some situations.
content in the headspace.
At the same time, the simplest solution, as it
A multi-layer structure providing a barrier to
often happens, has serious limitations or even
light can also be created when required for the
penalties. The barrier improvement factor is
application.
directly proportional to the amount of barrier material added to the blend. As the additive
On the operational level, coatings are attractive
level is increased, the clarity and transparency of
due to a low cost of consumable materials. At the
a PET bottle typically suffers, placing a limit on
same time, a plasma coating system represents an
how much improvement can be reached while
additional process step between bottle blowing
maintaining the desired package appearance.
and filling, which can pose a challenge to preform moulders supplying multiple blowing sites.
Even more significant is the barrier material cost penalty of a blend solution and its potential impact
The choice of a system supplier is determined,
on recyclability when compared to a multi-layer
among other factors, by the type of the coating
package.
selected. Quality control of a barrier coating is accomplished through monitoring of the process
Bottle coating vs multi-layer technology
B
parameters. The silicon oxide coating itself can only
ottle coating, with a thin glass-like coating
be detected using laboratory grade instruments
on the internal surface of a bottle, is another
such as a scanning electron microscope.
available option to improve the resistance of a monolayer PET package to gas permeation.
Quality of the barrier layer distribution in a multilayer preform can be confirmed by both non-
20 | PRA magazine 2017 yearender edition
destructive and destructive inspection means.
runner, while the standard mould cold half can
A multi-layer preform is produced in a sequential
be interchanged between the monolayer and
injection or a simultaneous co-injection process.
the multi-layer systems, assuming the same hot
In both cases, the resulting preform contains a
runner pitch and nozzle interface is maintained.
distinct layer of the barrier material sandwiched between the inner and outer layers of PET. Even
While a co-injection system must be configured
though barrier materials are typically approved
with two injection units and a co-injection hot
for food and beverage applications, as an added
runner, as well as necessary auxiliaries and
benefit this results in only PET being in direct
control system, Husky Multi- Layer systems offer
contact with such products.
complete flexibility to run mono-layers tools (complete mould and hot runner) or to produce
Preform blowing and filling steps subsequent
monolayer preforms without switching tooling, if
to injection moulding do not require changes to
this becomes necessary due to changes in demand,
the existing production lines. This means that,
season or target markets.
when desirable, a producer is able to maintain the flexibility of operating a central injection
Both passive and active barrier materials are more
moulding facility supplying multiple blowing
effective when used in a concentrated layer in a
and filling locations.
multi-layer package, compared to a monolayer blend with PET.
Multi-layer technology
H
usky’s Multi-Layer Technology is a complete
The same barrier improvement factor (and the
integrated system solution building on the
resulting product shelf life) can be achieved in a
best-in-class monolayer preform performance
multi-layer barrier package using approximately
and reliability of the company’s HyPET HPP
50% or less of the blended barrier material. The
product line. Simultaneous co-injection results in
effect has been reported with co-injection systems
faster cycle times and the ability to inject thinwall
and confirmed in laboratory studies. This holds
preforms, since both PET and the barrier materials flow into the mould cavity through the gate at the same time. The multi-layer melt flow is formed in the nozzle of the co-injection hot Multi-Layer Barrier Technology combines the benefits of Husky’s proven HyPET HPP5 system with a revolutionary new hot runner to enable the most precise and controlled dosing of barrier material
PRA magazine 2017 yearender edition |
21
true for both the oxygen scavenger applications,
expensive opaque white additive that is needed.
where oxygen must be prevented from reaching the product, and for passive barrier applications,
The ability to provide uninterrupted barrier
where carbonation must be kept inside the
layer coverage through the preform dome
package, although the mechanism differs.
improves total package barrier performance and is especially important for oxygen and light
In the case of a passive barrier layer, the gas
sensitive applications.
permeation rate is reduced by creating a denser “fence� for gas molecules. In the case of an active
In particular, some food types (for example pasta
scavenger, the useful capacity of the scavenger
sauces) do not readily mix inside the package,
material is extended by ensuring only the oxygen
creating a potential for local oxidisation of the
molecules that reach the barrier layer are reacting
product in segments of the package not covered
with the scavenger and are trapped.
by the barrier layer, causing spoilage.
Even though light barrier applications do not
The Husky hot runner design and control system
involve gas diffusion mechanisms, similar material
allow moulding of the multi-layer preforms with
cost and package performance advantages are
either closed or open dome tips (with or without
derived from a multilayer technology.
barrier layer in the bottle base), in the former case providing outstanding control over the
Shelf life of dairy products (such as UHT
termination (trailing edge) or the barrier layer.
milk) processed for long shelf life at ambient temperature is limited, among other factors, by
In 2015, Husky began working with select early
the breakdown of riboflavin (vitamin B2) and
adopter customers to introduce their Multi-
oxidation of proteins and lipids triggered by
Layer Technology to the market. Customers have
exposure to light, leading to a loss in nutritional
since chosen to rely on this solution for a variety
value and off-flavors.
of applications, including for carbonated soft drinks, mineral waters, juices, sauces, and now
Monolayer preforms containing significantly
seeing expansion into dairy, beer and personal
above 12% of a TiO2 master batch (titanium oxide
care products.
commonly used to produce a strongly opaque white) are difficult and at some point impossible
An important factor to lowering the total cost
to stretch blow, thus limiting the extent of light
to produce is the ability to precisely dose and
barrier that can be achieved.
distribute just the right amount of barrier material for a given application while maintaining the
In contrast, multi-layer preforms containing a
robust productivity expected of Husky HyPET
black PET layer hidden within an opaque white
HPP systems.
PET achieve signicantly lower light transmission, blocking up to 99.99% of light up to 650 nm
It is well known that material cost is a major
wavelength, while reducing the amount of
contributor to the total cost of a package. Barrier
22
| PRA magazine 2017 yearender edition
materials, while making up a relatively low
in the field, Husky customers have commented
(typically 2% to 15%) percentage of a package’s
on the barrier hot runner’s performance stability,
weight are substantially more expensive than
and this is without the need for unplanned
PET. This makes it critical to ensure the minimum
maintenance.
necessary amount of barrier material is delivered to each mould cavity and distributed in the most
When running temperature sensitive barrier
effective manner within the preform.
materials, purging both hot runner melt delivery systems with PET during system shut-down and
With Husky’s co-injection hot runner the two
re-start is a good practice that has been automated.
material delivery systems are thermally separated
Even the best maintenance practices may leave
and independently controlled by the embedded
room for unplanned events, such as contamination
Altanium control system, ensuring the barrier
of source resin by foreign material.
material is only subjected to the PET processing temperature when the two materials are combined
If a contamination particle finds its way into the
prior to the gate.
hot runner, the most likely area for a blockage is the hot runner nozzle, where melt passages
Injection moulders familiar with co-injection will
are smallest. It has historically been notoriously
recognise that in the attempt to improve hot runner
difficult to clean this area, often requiring
balance and ensure melt flow and temperature
complete hot runner disassembly.
rates are as uniform as possible across multiple gates, the hot runner may be melt-channels
The HyPET HPP5 barrier system features a
tuned by lowering and raising temperatures of
front removable nozzle design, which allows the
manifolds and nozzle tips.
maintenance or replacement of hot runner nozzles while in the press, by latching over the mold
Husky hot runners provide control flexibility through an increased number of manifold zones
and
controlled
individually
tips.
Traditional
temperature pneumatic
actuation of valve gates has been upgraded to an electric servo, plate actuated synchronous valve gate system. At the same time, the high level of balance means that the range of temperatures used in further tuning the performance is significantly reduced, further decreasing the maximum temperature experienced by barrier material.
Multi-Layer Technology for barrier is suitable for a variety of applications, including for carbonated soft drinks, mineral waters, juices, sauces, and now seeing expansion into dairy, beer and personal care products
Over millions of cycles of production use PRA magazine 2017 yearender edition | 23
cavity plate to expose the tips. While co-injection
was fully supported by Husky’s regional service
moulding is still more complex than traditional
engineers, as well as their Multi-Layer Barrier
mono-layer injection moulding, the operation of
subject matter experts who were present from
the complete system is facilitated by Husky’s
the company’s headquarters in Bolton, Ontario,
intelligent,
Canada.
preform-centric
control
system,
integrating all aspects of the injection moulding process and auxiliary equipment.
As part of the qualifying process, the system successfully completed uninterrupted production
Process setup for a new application begins with
runs for two Multi-Layer preform applications,
establishing a mono-layer process for preform
one being a 28 g preform for a carbonated water
quality. When barrier material injection is enabled,
bottle application and the other a 14 g preform
the control system automatically adjusts the PET
for a juice application. In fact, when comparing
injection profile based on the barrier content and
Husky’s new Multi-Layer Technology to their
generates the barrier injection profile, which can
existing co-injection barrier system, the customer
be further fine-tuned by the operator.
saw no change in performance after running the system for several months. In the past when testing
Early adopter customer sees success with
alternatives they had typically seen deterioration
Husky’s Multi- Layer Technology
in barrier performance after several weeks and
W
hen introducing its new Multi-Layer
that was not the case here.
Technology, Husky partnered with one
of Europe’s best known preform and PET bottle
They also saw significantly better control
manufacturers to test and validate the solution in
of the barrier weight. The accuracy and
the field. Having already established a proven
repeatability to control the barrier content in
track record of working together to validate
the preforms produced on the new Husky
new technologies, Husky knew this European
Multi-Layer Barrier system was significantly
customer would be a good fit as an early adopter
better than what they were currently achieving.
partner.
Both applications were produced with a tolerance on the barrier content within +/-0.5% of the
The two companies also shared a common goal of
total preform weight. This was achieved while
developing solutions that push the PET industry
realising a 40% faster cycle time.
forward, as well as grow the addressable PET market. It was also perfect timing for Husky’s
When measured against the existing competitor co-
customer, as they were experiencing maintenance,
injection system running the exact same application
service and stability issues with their existing co-
Husky’s Multi-Layer system ran more consistent-
injection barrier systems and were looking to find
ly for a longer period of time with no drop in per-
an upgraded solution.
formance and decreased hot runner maintenance.
The installation and start-up of the first Multi-
Today, this customer is continuing to work with
Layer system in the customer’s European facility
Husky on future Multi-Layer Barrier projects.
24
| PRA magazine 2017 yearender edition
Battenfeld-cincinnati China
Driven by innovation Austrian/German extrusion/thermoforming machine maker battenfeld-cincinnati’s new motto “driven by innovation” is the driving force behind the company’s equipment and services. Exhibiting at Chinaplas in May this year, battenfeld-cincinnati China presented energy and material-saving extrusion equipment in pipe and thermoforming sheet production. PRA caught up with Toni Bernards, CEO of battenfeld-cincinnati China, to learn more. PRA: Industry 4.0 is expected to become mainstream in industries, and in China, it is the “Made in China 2025”. How does battenfeld-cincinnati position itself in this developing trend, especially in China Bernards: Industry 4.0 offers every plastics processor the opportunity to run its extrusion equipment with maximum BCtouch-UX efficiency. For this reason, battenfeld-cincinnati has created a new control system, the BCtouch UX (UX stands for “user experience”). We first presented the control last year at K2016 in Germany. At Chinaplas 2017, we showed the BCtouch UX control in China for the first time. The BCtouch UX control system has advanced functions that support efficient production planning and preventive maintenance intervals. All process parameters are monitored centrally. Line operators can carry out energy monitoring and calculate energy diagrams over time, based on freely selectable production parameters. This makes it possible to find an operating point where the Bernards line can be run with optimal resource efficiency in terms of both material and
all line components are recorded in the control system. This supports necessary preventive maintenance actions, thus increasing line uptime and consequently overall efficiency.
Mobile operating terminal with the new BCtouch UX control was shown at the Chinaplas 2017
Fully in keeping with the industry 4.0 concept and the control system’s facilities for communicating with
other
units,
generally
described
as
“connectivity”, all line and process parameters included and evaluated in the system can be centrally tapped by an ERP system. For this purpose, the battenfeld-cincinnati OPCUA server provides a future-proof interface for vertical integration of the line at the customer’s plant. In addition to on-site operation, BCtouch UX also supports an alarm system via Internet or Intranet, with data of definable line statuses being transmitted to mobile units either by LAN/WIFI or by UMTS/LTE, according to the customer’s choice. PRA: The solEX 60-40-C extruder with the new BCtouch UX control is suitable for Industry 4.0 applications?
energy consumption. Maintenance intervals for PRA magazine 2017 yearender edition | 25
At first, we focused only on the Chinese market, but now we have export rates of around “We have a very broad customer base in China: about 90% of customers are small, local processors that want to gain a competitive advantage from advanced extrusion technology,� said Bernards Bernards: The BCtouch UX control offers the features needed to be used for industry 4.0 applications. The control has a large 21.5� multi-touch display in landscape format, with the solEX60-40 well-known swivel-and-tilt functionality from battenfeld-cincinnati. It is easy to use with multitouch zoom, move and slide functions that users are familiar with from operating tablets or mobile phones. With the new cockpit view, the process status of the complete line can be viewed at a glance. The design of the overview page and the navigation through the menu are derived directly from the line configuration. Additional terminals can be integrated into the line as well. PRA: Please provide a round-up of the Chinese market growth for battenfeld-cincinnati in China since the setup of the company 21 years ago. Bernards: Since its foundation in 1996, battenfeldcincinnati China has developed very positively. Sales and order intake have continually increased. In 2016, for example, our order intake increased by 35% compared to 2015. Today, we have 130 employees and contribute about 25% to the sales of the battenfeld-cincinnati group of companies. 26 | PRA magazine 2017 yearender edition
30% per year. The main export markets are Vietnam, Indonesia, Malaysia and Thailand. Over the past few years, the market for extruded products has developed significantly, both in terms of volume and of quality. In the beginning, we focused on the small, high-quality segment, but now there is growing demand for high-quality pipes and profiles in China and thus for the right equipment to produce it. We have therefore adapted our machine portfolio continuously to market needs over the years. We have a very broad customer base in China: about 90% of customers are small, local processors that want to gain a competitive advantage from advanced extrusion technology. The remaining 10% of customers are companies operating on a global scale that are often already familiar with the battenfeld-cincinnati brand. PRA: Apart from the solEX 60-40 extruder shown at Chinaplas this year, what technologies are being offered by battenfeld-cincinnati in Asia, including China? What are the latest technologies developed? Bernards: We offer complete pipe extrusion lines for mono and multi-layer PO, PVC and PE-RT pipes, profile extrusion lines for window main profiles or small technical profiles and pelletising lines, as well as extrusion lines for thermoforming sheet production. The latter are offered as hybrid lines, for which some components are supplied from Europe.
Our proven product range includes solEX, uniEX
the growth industry for the future?
and leanEX single screw extruders, helix PO pipe heads, twinEX LeanEX-C1-60-30-extruder
Bernards: We still see growth potential in the
and conEX twin screw extruders, spider PVC
infrastructure and construction segment for pipes
pipe heads, as well as complete downstream
and profiles.
equipment and state-ofthe- art controls. The requirements for these products have At this year’s Chinaplas, we premiered the first
increased steadily both in terms of the quality
leanEX twin screw extruder for pipe at an Open
and the complexity of the product.
House at our factory. The leanEX name is assigned to our turnkey extruders and lines for standard
There are higher standards for materials,
pipe extrusion. These feature high outputs, high
production and endproducts, and more demand
line speeds and a high degree of automation.
for multi-layer applications that offer better properties thanks to additional functional layers.
The new leanEX 2-93R-28-CL with 28 L/D has an extremely robust design and energy-efficient
We also see a growth in the packaging market
components. The heart of the extruder, the screw,
that is currently booming all over the world. The
is made in Europe. Outputs range from 200-580
demand is for high-quality packaging that offers
kg/ hour.
protection and long shelf life for the packaged goods. High-quality food packaging offers
The leanEX 2-93R-28-CL extruder comes with
protection, long shelf life and easier transportation
a “BC compact” control. This control offers all
for packaged goods.
standard functions and has an intuitive 12” touch screen with a modern screen design. It can also be
Battenfeld-cincinnati also offers equipment for
integrated into MES/ERP systems.
this demanding market. The combination of highspeed extruders and the innovative Multi-
One further new development shown at our
Touch roll stack is ideal for excellent product
Open House was a production line for three-
quality despite high line speeds.
layer glassfibre- reinforced PP-R pipes. These pipes are used for hot and cold water transport.
Due to their high outputs, one of these lines can
We extruded them with an output of 350 kg/hour
replace several conventional lines, saving space,
and a line speed of 3.95 m/min.
operating and maintenance costs.
We also showcased our uniEX single screw
High-speed extruders offer 15-25% energy savings
extruders and a helix 3-layer pipe head, as well as
compared to conventional systems as well as lower
a standalone BMCtouch control terminal.
material consumption and increased production times. Multi- Touch roll stacks ensure perfectly
PRA: What is your forecast of industries/ markets/
flat, stress-free sheet and a high transparency,
applications poised to become (or will continue to be)
particularly for PP products. PRA magazine 2017 yearender edition |
27
IKO Polymeric
Innovative solution for energy-efficient production of flexible PVC
I
KO Group is a global manufacturer of highgrade roofing systems. Its subsidiary, IKO
Polymeric, whose headquarters are in Chesterfield, Great Britain, was founded in 2005 in order to promote single-layer ply roofing membranes for flat roofs. Since it was first founded, the division has grown from three employees to 80 and it is now the market leader in Great Britain.
This article by Alois Billigen, Division Manager Marketing/ Documentation of AZO GmbH + Co. KG, is a case study of systems installed by IKO Polymeric for the production of flexible PVC for roofing membranes. membranes at its own site in Chesterfield, provided it could achieve a high level of energy efficiency, the company had planned to invest in a manufacturing plant for flexible PVC. AZO was charged with developing and producing this plant, after winning over the contract against well-known rival firms. A crucial factor in awarding the contract to AZO was its many years of experience in raw materials handling and its technical expertise. Indeed, AZO notched up points with its custom solutions to satisfy the customer’s specific requirements. For instance, existing peripherals could be made use of and new plants designed exactly, to fit the existing building. The tasks AZO faced
A
ZO faced two major challenges:
• Adapting and integrating the plant to fit
in the existing buildings
An overview of the plant installed at IKO Roofing membranes from IKO Polymeric are used in both new buildings and in refurbishments. The company offers an extremely broad variety of products for high-performance flat roofing solutions. Since IKO Polymeric’s aim was to manufacture the flexible PVC needed to make the roofing 28 | PRA magazine 2017 yearender edition
•
Directly feeding the compounder/extruder
downstream from the heating mixer without a cooling stage, which meant no longer cooling the mixture before the extruder, as is otherwise done when manufacturing flexible PVC. AZO also had to meet the following requirements:
• Maximum process accuracy • Maximum versatility
• Consistently high product quality • Highly accurate weighing • Constant batch weights • A high degree of process transparency • Reliable documentation • Automation of all raw materials handling, for
in liquid and in powdered form. The wide variety of formulations meant that the plant had to be very flexible at the same time. The formulations contain large quantities of plasticisers, PVC, chalk and different additives.
both powdered and liquid raw materials.
Tracking and tracing of the entire production
Dispensing with the cooling stage resulted in
process, using barcode scanners at raw materials
particular challenges when feeding materials
feeding points, was a further requirement for the
to the extruder. It was necessary to maintain
new plant.
the mixture at a temperature of approximately 100°C,
while
simultaneously
stabilising
or
increasing homogeneity of the mixture. After the mixing process, the mixture is moistened, which
Implementation
C
ommissioning of the plant took place in 2014; and in 2017, the final phase in expansion of
increases the challenge yet further with regard to
the plant involved supplying an additional silo
homogeneity and consistent temperatures and
for PVC.
requires that the plant engineering firm has indepth knowledge of process engineering and
Feeding of raw materials and feeding the heating
extensive experience.
mixer
Reliable solutions for control engineering systems are required here: the buffer bin, which is designed
D
ue to the large number of different materials, feeding of raw materials is
broken down into liquid medium components,
as an insulated mixing vessel, is equipped with a
liquid components and into large, medium and
weighing device and a temperature-measuring
small powdered components.
instrument. The signals it sends are used to regulate filling levels and temperature to ensure
Liquid plasticisers are stored in four tanks and
maximum consistency in the properties of the
are pumped into gain-in-weight scales via micro
end products.
filters with pressure monitoring. The micro filters are designed as a bypass solution, so that there
Major savings in energy are achieved by
are no downtimes caused by the need to carry
dispensing with the processes of cooling the blend
out cleaning. The raw materials are conveyed
in the cooling mixer and of reheating it in the
completely from the scales into the heating
extruder, as these stages use substantial amounts
mixer.
of energy. The height of the building meant it was also possible to dispense with expensive
The liquid medium components are supplied
modifications such as extending the roof.
in two scale hoppers, which are connected in parallel. From there, they are then weighed
A further stipulation for materials handling was
into the heating mixer using the loss-inweight
to integrate a large number of raw materials, both
method. PRA magazine 2017 yearender edition | 29
Different types of PVC are stored in three silos
stage in the process. Failure to achieve this will
and are transported via a vacuum conveyor into
have negative consequences on the subsequent
the vacuum conveying scales situated above the
extrusion process and product quality.
heating mixer. In addition, the PVC can also be
AZODOS-units-dosing
transported into the vacuum conveying scales Homogenisation serves to stabilise or improve
from a big bag discharge station.
the quality of the mix. The hopper is equipped as Five medium components are weighed into Sack-
scales in order to monitor yields and keep check
tipping-stations a scale hopper via sack discharge
of the product temperature.
stations and volumetric dosing units. These five raw materials have minimum ignition energy
The extruder is fed continuously using differential
between 3 and 10 mJ. The medium components
dosing scales. In addition, two vacuum conveyors
are also conveyed in parallel into the same
and downstream differential dosing scales can be
vacuum conveying scales in the PVC line.
used to feed returning raw materials and various substances for dyeing the PVC.
The proportion of these components varies, depending on the formulation, up to 5% within
Filling of finished goods following the extruder
the PVC line into the vacuum conveying scales.
he finished products are discharged from
This leads to a premix of the different raw materials, which are discharged from the scales
T
the extruder into a hopper and conveyed
from there into a silo for intermediate storage.
into the heating mixer. Micro components can be added to the heating mixer using appropriate
The silo is fitted with load cells. The flexible PVC
methods of product feeding.
is filled into big bags either for interim storage or for selling. There is an option to expand the
Feeding the extruder with the mixture from the
plant with direct feeding to the next process
heating mixer
(calender).
A
special feature is that there is no cooling stage in the direct feeding of the compounder/
extruder after the heating mixer. This results in a huge advantage for the customer in terms of energy efficiency.
The AZO Group
T
he AZO Group delivers innovative concepts for automation from a single supplier:
plant engineering and construction, process engineering and process IT dovetail seamlessly. are
AZO provides everything – from the initial
extremely high for this solution. The heating
concept, from innovative individual components
mixer discharges into a homogeniser hopper via
for storage, discharge, screening, conveying,
a screw feeder. The screw feeder and hopper are
dosing and weighing of raw materials right
insulated in order to maintain the temperature
through to a turnkey solution.
The
demands
on
control
engineering
at approximately 100°C. It is vital to avoid fluctuations in product temperature at this 30
| PRA magazine 2017 yearender edition
AZO is the specialist for automated handling of
raw materials and of processes; of large, medium
process-oriented approaches resulting in the ideal
and small components in granular, powder and
combination of innovation and reliability.
liquid form. AZO CONTROLS acts as a partner for many AZO SOLIDS is the expert when it comes to
renowned companies and, in addition to its own
efficient handling of bulk materials. It caters to
developments, it offers solutions that are based
reliable storage, discharge, screening, conveying,
on tools that are available commercially.
dosing and weighing Outdoor-silos of raw materials within fully automated processes. From
Hence, the AZO Group provides support for
the major ingredient down to micro quantities,
successful companies all over the world in
from the initial study concerning safety concepts
implementing innovative projects by using
and risk assessments through to the turnkey
the technologies of the future and through its
plant in its entirety, AZO combines what belongs
extensive network of production and sales
together.
companies. In this way, AZO is continuously enhancing its products and adapting them to the
Founded in 2008, AZO LIQUIDS provides for
future requirements of the market and customers’
mixing, dispersing and homogenising liquid
needs.
and semi-solid products. Its main target is the development of a new generation of batch and
With sales subsidiaries and service partners
continuous process plants with an innovative
the world over, customers are provided with
homogeniser for fully automatic feeding of raw
expert advice and service in line with market
materials.
requirements.
AZO CONTROLS is the expert for innovative
The success of AZO is based first and foremost on
process
Small-liquids-
the quality and reliability of the solutions and the
weighing-and-pumping automation solutions in
accumulated experience of 65 years in building
the production environment. From consulting to
automatic material handling systems.
IT
in
developing
implementation, from sensor technology to the commercial production planning level, this is
At the same time, AZO is open to new ideas and
where AZO will provide with reliable, joined-up
is not afraid to translate them into new innovative
solutions at each stage.
systems for dispersing, mixing and homogenising of liquid and semi-solid products.
For over 35 years, AZO CONTROLS, as a fullservice provider for automation, has delivered
AZO measures the quality of its services by
innovative
production
considering the customers benefit. The reliability
environment for the entire value chain. It
of the AZO system in combination with specifically
is backed by well-trained staff from a wide
configured and fine-tuned process control allows
variety of specialist fields, who offer extensive
the highest possible availability and therefore an
experience, in-depth knowledge of products and
excellent efficiency.
solutions
in
the
PRA magazine 2017 yearender edition |
31
Thailand
A tiger economy in an era of innovation
Thailand is relentlessly asserting its claim as Asia’s key technologyefficient manufacturing spot, with its latest laurel – a twostep leap to becoming the 32nd most competitive economy on the World Economic Forum’s (WEF) global competitiveness index. The T-Plas trade show, held in Bangkok in September, also highlighted Thailand’s strength as a manufacturing and market base. It was co-located with Pack Print International and featured six national pavilions.
T
he second largest economy in the ten-nation ASEAN, Thailand is
ardent in its pursuit to becoming, or shall we say, maintaining its Asian powerhouse standing. The Thailand 4.0 initiative, for example, where the manufacturing ecosystem will be hinged on technology and innovation, gives a worm’s eye view of the bigger, rosier economic picture Thailand is painting. The country’s economy is pillared on its strong sectors like automotive, electronics, consumer goods, building and
construction,
aerospace
and
more, with its economy growing 3.7% year-on-year in the second quarter of the year, from 3.3% during the first quarter. It has also seen an exponential growth in domestic spending in recent years, posting a growth of 3.3% year on year. 1 | PRA magazine 2017 yearender edition
Lucrative market for plastics
P
Barot of Mamata was enthusiastic about the Thai packaging sector
lastic products are one of Thailand’s top five exports, according to Gernot Ringling,
Managing Director of Singapore-based Messe
E x e c u t i ve
Düsseldorf Asia (MDA), which organised the
said
recently concluded T-Plas.
was “a harbinger for innovation and technological advances in the country”, thus the need for new technology. This was echoed by most of the exhibitors
at
the
show.
recycling
interest in the company’s blown film and converting lines. Romain Reyre, President for Southeast Asia of Austria-headquartered injection moulding machine maker Engel, told PRA that most visitors to the booth were from the packaging industry. He added, “We see that the packaging industry
A u s t r i a n machine
manufacturer Erema said the company Rehkopf says Reifenhäuser expects higher end lines to be was promoting new taken up in Thailand technology for the Thai market as was
is continuing to grow and there is strong interest for in-mould labelling (IML) and energy saving targets.” Engel showcased a fully electric e-mac 440/180, demonstrating the production of oval bowls for convenience meals, using a four-cavity mould with IML, running a 4.5
German extrusion machinery maker Reifenhäuser.
second-cycle time. “This
Managing Director of Reifenhäuser Singapore,
highly energy efficient
Juergen Rehkopf, said that the demand for plastic
machine can be used
products is prodding the upgrading of machinery.
for general applications
He added, “We notice there is a general trend for
across various industries,
more quality films, and more customers are now
such
considering five-layer PE structures (from the normal three-layers).” Rehkopf said there had lot of requests for new equipment”,
like the new Evolution Ultra Flat haul-off for better printability and lamination capability. Seeing trends in packaging and labelling xhibiting for the first time at T-Plas, India’s Mamata Machinery has an eye on the Thai
packaging sector. Abhishek Barot, Sr Sales
as
packaging,
medical and technical Reyre of Engel noted the growing interest for IML and energy saving targets
producing films with improved flatness, enabling
E
potential
customers had conveyed
Speaking at the opening ceremony, he said this
been “a
several
(Export),
moulding,”Reyre
said,
adding that Engel’s inject 4.0, is the company’s response to Thailand’s
imminent digital
transformation. As
well, Reyre said that while the medical industry is receiving a great deal of attention, he averred that this sector still needs time to grow. “Overall, the packaging industry should be more active than the others,” he opined. PRA magazine 2017 yearender edition |
33
In a similar vein,
slowly picked up. We expect demand for new
Jessie Hsu, Sales
machines in this sector to increase, to support the
Representative
anticipated increase in automotive production
Jessie-Hsu of
capacity.”
Chuan Lih Fa (CLF), Taiwanese
Meanwhile, German thermoforming machinery
injection
maker Geiss is upbeat. “The automotive and
moulding machinery supplier, said
Hsu of CLF expects sales to be challenging
aerospace markets are favourable, compared to those in the rest of Southeast Asia,” Ankit Kapoor, Regional Head of Geiss told PRA. “Almost half of
that visitors were
Geiss’s turnover is from the automotive sector,
swarming to the adjacent exhibition hall where
and considering that there are a number of major
printing and labelling machines were shown.
Japanese companies in Thailand, we have gained
Nevertheless, she added, “Business in Thailand
quite a few customers,” he said, adding that
has been slow for the last three years, further
Thailand’s aerospace sector also shows potential
burdened by a stronger dollar and weaker baht.
as a high-growth niche market.
(This situation) has affected our opportunity to export, and some users buying machines from
The country’s air transportation sector is enjoying
Europe or Japan have made the last two to three
brisk business, owing to its bustling tourism
years challenging for us.”
industry, as well as air travel driven by a rise in disposable incomes and offers of affordable airfares.
Foray into automotive and aerospace, a boon
A
According to the Thai Board of Investments (BOI)
t the onset of the year, Thailand’s exports
August 2017 report, the country’s air traffic is to
in the automotive sector turned soft amid a
expand 3.4%/year for the next 20 years to reach
rattled economy. But the country, dubbed Detroit
7 billion passengers by 2034, thrice faster than
of the East, has bounced back. Citing the Thai
the global market. Meanwhile, Frost & Sullivan’s
Automotive Industry Association’s (TAIA) data,
Asia Pacific aerospace infographic shows that
domestic sales and exports in January were pegged
Thailand’s aircraft fleet is likely to increase to
at 57,254 units and 80,087 units, respectively;
more than 800 by 2037, growing at a CAGR of
falling against sales and exports of December
4.8%.
2016 totalling 86,858 and 86,120, respectively. By August 2017, TAIA said the country’s domestic vehicle (passenger and commercial) sales totalled 67,965 units and exports were 102,907 units, up
Sturdy ground for building and infrastructure
T
he WEF, in its recent survey of economies, underscored Thailand’s achievements on
from the previous month (July)’s 65,178 sold
infrastructure projects. The country’s Eastern
units and 90,015 exports.
Economic Corridor (EEC) initiative, which is expected to mould it into a trade
and
Engel’s Reyre noted the same view. “Thailand’s
manufacturing titan, is expected to be completed
automotive industry has been quiet but it has
by 2021. The EEC’s US$43 billion estimated
34 | PRA magazine 2017 yearender edition
allocation will cover four core areas: infrastructure;
company is already a stalwart in Thailand, and
business, industrial clusters and innovation hubs;
is ready to explore opportunities in other Asian
tourism; and new cities through smart urban
markets. “There is high demand for power and
planning. Evidently, the project will boost the
telecommunications cables used in building
building and infrastructure sectors.
and infrastructure in the Asian region. From Thailand, we are able to serve markets like
For first time exhibitor,
China and India. But we find that India has
Greiner, a supplier of
many local compounders, thus, it is difficult to
extrusion lines for profile
penetrate,” Chongcharoen said.
extrusion, it is at the right He added that Thailand’s wire/cable market
place and at the right time for a potential windfall from these sectors, said General Manager Oliver Schuerrer.
“We
are
Schuerrer of Greiner says thecompany expects to enjoy the spills of the growth from the construction sector
is
hinged
on
private
developments
like
condominiums and department stores; and government projects. “This year, investments in government projects have increased and this
currently growing our
augurs well, whereas, investments by the private
customer network, even though it is competitive,”
sector have slowed, making it a challenging time
he said, adding that the company will require an
for the building sector.” Nevertheless, he deems
estimated two years to achieve its target.
that this setback is temporary.
It also has a biotechnology and medical devices
Accessing opportunities in white goods
unit, Greiner Bio-One, located in Thailand. In Asia, the Austria-headquartered firm has offices
T
he booming property development and real estate markets, including condominiums
in South Korea, China, Japan, and India, which
and stand-alone housing, are bolstering demand
Schuerrer mentioned as a strong market, besides
for consumer appliances in Thailand, according to
a presence in Europe and
Euromonitor International’s 2016 country report.
the US.
Along with an increasing disposable income, political stability, and economic stimulus package
Meanwhile,Bangkok-
by the government, the advent of new property
headquartered
development are buoying consumer confidence.
petrochemical firm SCG Geiss’s Kapoor confirmed a potent opportunity
Chemicals’s Wire and Cable (W&C) division was exhibiting at the adjacent Wire and Tube Southeast Asia show,
Chongcharoen, SCG, says the company is marketing its compounds for Asian infrastructure sectors
for white goods, such as refrigerators and washing machines. “We have supplied more than 17 machines to a Thai customer that makes refrigerators,” he said.
also organised by MDA. Saksit Chongcharoen, SCG’s Domestic Sales
This was opined by another exhibitor, Austria-
Manager-PVC Compound, mentioned that the
headquartered machine manufacturer Wittmann PRA magazine 2017 yearender edition |
35
with our technical and specified equipment.”
Battenfeld, which has a Thai subsidiary that was set up in 2004. Herbst,
Positive outlook, sectors drive growth
Florian
Area
T
hough it all looks rosy in Thailand, it has
Sales
its flaws, too. The WEF report pointed out
Manager referred to the challenge of positioning
that the country’s competitiveness is marred
in
by several conditions including bureaucracy,
the
market
amid
insufficient capacity to innovate, lack of skilled
competition. “Over the last few years, it was a little tough but
Herbst of Wittmann Battenfeld said the company had to compete with Japanese machine makers in Thailand
workforce, and tax policies, to name few. Nevertheless, exhibitors interviewed at T-
we are getting hold of
Plas are willing to chance it. “Thailand is a
the market,” he said, alluding to a competitive
strong market,” said Corné Verstraten, CSO/
footing with Japanese machine suppliers.
Joint Partner of Germany-headquartered Dr Collin. The company, which develops pilot and
Japan established diplomatic
relations with
laboratory lines
Thailand in September 1887, and formed a Japan-
for processing
Thailand Economic Partnership Agreement in late
companies
2007, according to the Ministry of Foreign Affairs
as well as for
of Japan. Trade value from Japan amounted to
research institutes,
about 3 billion yen in 2016. Currently, there are
is tapping
over 4,500 Japanese companies in Thailand.
Thailand’s manoeuvre
Verstraten of Dr Collin says the company had a higher turnover this year in Thailand
“There are a number of Japanese firms in Thailand
towards
that prefer Japanese equipment, and this thus has
innovation. “Our
created stiff competition for European equipment.
Thai agent LMS
Since our production is in Europe, our lead time
Instruments has generated a higher turnover of
is also longer.”
about 10%-12% (this year), which is quite good.” Japanese
Geiss’s Kapoor said that next to China, Thailand
counterpart has, Herbst said, “They have the
is a “very strong country in the entire region”,
‘Asian mind’ and that is their edge. But we are able
owing to its expansive industries.
When
asked
what
advantage
a
to offer a broad range of options and flexibility to build machinery according to customer
Engel’s Reyre conjured a bright market outlook
specifications.”
for Thailand. “In the coming years, we expect that GDP will improve and the automotive
added that with the trend for more
and packaging industries will grow,” he said,
sophisticated automated and technical machinery,
rounding off an overall favourable sentiment for
Europeans are able to “compensate (the setback)
the Thai market.
He
36 | PRA magazine 2017 yearender edition
Industry 4.0 takes production processes to a new level Industry 4.0 is one of the strongest growth drivers for machine makers, as seen in the presentations by companies at the recently concluded Fakuma 2017 show in Germany. Development of an interface
A
can be accessed by anyone. “Transparency is very
s one of the first industries, the European
important Fakuma-Arburg to us at this point to
injection moulding machine manufacturers,
gain a broad acceptance amongst the machine
led by German machine group VDMA, worked
manufacturers and the software providers, as
on an internationally uniform interface for the
well as the users,” says Dr. Harald Weber who
exchange of data between injection moulding
leads the technical Euromap working groups.
machines and master computers or MES, known as the Euromap 77. This was presented at the K
All
the
large
injection
moulding
machine
show in Düsseldorf last year. A demonstration
manufacturers were involved in the development
showed how several machines that were set up in
of the new interface in the European umbrella
different halls exchanged data with each other.
association Euromap. Besides Arburg, companies involved were Engel, Ferromatik Milacron,
Euromap 77 is based on the communications
KraussMaffei, Netstal, Negri Bossi, Sumitomo
standard OPC Unified Architecture (OPC-UA),
(SHI) Demag and Wittmann Battenfeld.
which has been established by the non-commercial OPC foundation and has already been used in
For MES manufacturers, Euromap 77 offers the big
many industries as the basis for the communication
benefit that a machine that supports the standard
between machines of different manufacturers. The
can be connected via plug-and-play and deliver
independent industry association also was involved
a reliable basic set of information with which the
as a consultant in the development of Euromap 77.
basic MES functions can be represented, according to Euromap.
“The big advantage of OPC UA is that it is manufacturer independent. It is a technology
Euromap 77 is just the beginning. It is already
that is available to everyone and is not dependent
being worked on a further interface – Euromap 79
on a control unit manufacturer. This is a main
to establish a secure connection between injection
reason why OPC UA is increasingly becoming
moulding machines and robots. The biggest
the standard of Industry 4.0,” said Jürgen
challenge there is to make some signals available
Peters, Head of the software development
in real-time, so that it does not come to collisions
department at German machine maker Arburg.
between the machine and the moving robot. Since OPC UA itself is not capable of real-time, it
In September 2017, Euromap 77 released a second
uses Time Sensitive Networks (TSN). However,
Release Candidate, i.e. a sort of beta version, which
it will not stop at Euromap 79. The connection of PRA magazine 2017 yearender edition |
37
periphery devices is already in the planning, for
four-cavity mould in accordance with the order.
material flow control and for extrusion facilities.
Handling was performed by a six-axis robot
The growing number of interfaces finally requires
housed within the installation area. The inserts
a uniform, superordinate structure. It is worked
were optionally overmoulded in hook/ hook,
on such a structure already, so that the interfaces
hook/eyelet or eyelet/eyelet combinations and
for different plastics and rubber machinery will
the finished tension strap then removed from the
follow a unified pattern.
system. In industrial practice, this kind of highvolume production with multiple variants is ideal for cable assembly in the automotive industry, for
Practical showcase of Industry 4.0
A
t the Fakuma show, of the ten exhibits at
example.
its booth and ten at other booths, machine
maker Arburg aligned itself to Industry 4.0, Digital
Arburg also presented numerous smart solutions
Transformation and Smart Factory with products
in the service area, such as condition monitoring,
such as the Arburg host computer system (ALS)
predictive maintenance, the remote maintenance
as well as the integration of IT solutions into the
tool for fast, efficient and reliable online support,
production process.
the new “Mobile Maintenance” ALS module for maintenance and repair and machine connectivity
As a third highlight, Arburg presented a new
via various OPC UA interfaces.
practical example of Industry 4.0 that was tailored specifically to the requirements of the injection
Companies roll out new solutions for
moulding sector. In this regard, customer
Industry 4.0
requirements were integrated into the running injection moulding process for multi-variant high-volume production.
M
achine maker KraussMaffei unveiled at Fakuma its MaXecution MES, specifically
designed for small injection moulding companies. The new software creates
A compact turnkey system featuring
more
a vertical Allrounder 375 V produced
production by means of
flexibly tension straps in various lengths,
productivity indicators,
colours and end piece combinations on
for example regarding
demand from shot-to-shot – without
the overall equipment
any need for conversion. Visitors could
effectiveness (OEE), the
enter the desired tension strap variant
management of moulds
directly at the terminal, causing the order to be transmitted directly to the central Selogica control system via the OPC UA communication protocol. The
In KraussMaffei’s MaXecution, the programme function for the graphic planning of manufacturing orders provides a better overview in production planning
tension strap was automatically cut to the
transparency
in
and resources and the statistics on machines and rejects. In total, using this software
means
better
capacity utilisation of the
selected length, both ends spliced by means of a
machinery pool, fewer rejects and higher overall
plasma process and placed in the cavities of the
equipment effectiveness, says the firm.
38
| PRA magazine 2017 yearender edition
The MaXecution system, which KraussMaffei
Supported by intelligent stability and productivity
designed in collaboration with German MES
ratios, the user can recognise negative trends or
developer MPDV Mikrolab, offers KraussMaffei
performance deviations of individual machines
customers a plugand- play solution that is
at a glance. Stability specifications of individual
tailored to their specific needs. Based on MPDV’s
machines or the entire production process
popular Hydra MES, MaXecution is offered in
involves a newly developed ratio based on an
three versions, so that processors can decide on
intelligent algorithm.
the basis of requirements how many functions of an MES they need.
Overall performance is detailed as a single percentage after taking into account ten crucial process parameters. In addition, the productivity coefficient determines the efficiency of overall production
and
individual
machines,
also
returning this as a percentage. Another possible option is continuous online monitoring of the power consumption per cycle. Netstal launched its e-service and the cloud-based production monitoring platform AnalytiX Sister company of KraussMaffei, Swiss machine maker Netstal, meanwhile, unveiled its e-service and the cloud-based production monitoring platform AnalytiX, both of which will be commercialised in the second quarter of 2018. Furthermore, Netstal machines can also be linked via standard Euromap interfaces to KraussMaffei’s new MaXecution MES system. Netstal’s cloud-based analysis tool AnalytiX is an
AnalytiX analyses over 60 different production parameters available for each individual machine. This enables, for example, the cycle times, metering stroke and injection time to be remotely monitored in real time and used for independent analyses. Customer portals from machine makers
E
ngel introduced its e-connect, the new customer portal, at Fakuma. Engel says it
will also integrate future service products for the smart factory into the customer portal.
integral component of the new e-service portal and will also be available as an independent app for smartphones and tablets running the iOS and Android operating systems. AnalytiX enables customers to monitor their machines at any time regardless of location and benefit from automated analysis of the processes and machine conditions, saving time and increasing employee efficiency.
Engel introduced its new e-connect customer portal at Fakuma PRA magazine 2017 yearender edition |
39
Meanwhile, the Austrian machine maker has also
their production from any location.
opened an inject 4.0 hotspot in its technology and automation centre in Hagen, Germany, “to very clearly communicate the new opportunities of digitalisation and networking,” and to offer live demos of all its inject 4.0 products.
Machine makers bask in glory of high sales
E
uropean machine makers had much to gloat about with most of the companies
participating at Fakuma scaling higher heights in terms of machine sales. For the fourth year
Sumitomo (SHI) Demag Plastics Machinery has
running, Arburg expects record sales, as well as
developed a web-based software solution to
projecting continued growth in 2017. “In 2017 we
provide its customers with a central platform for a
are set to exceed our 2016 consolidated turnover
wide range of services. The modular myConnect
of EUR636 million, breaking the record for the
system will open up access to a full range of online
fourth year in succession. For 2018, we expect
services from the injection moulding machinery
the level to be as good as 2017,” said Managing
manufacturer.
Director Sales Gerhard Böhm. From the second quarter
2018,
For Engel, Germany continues to be one of the
the
company
highest revenue markets in Europe, with sales
plans
to
deliver
having increased by 50% over the last five years.
machines
Dr Stefan Engleder, CEO of the Engel Group,
netw o r k -
also said, “In the current financial year, we are
c o m p a t i b l e
expecting revenues of approximately EUR1.5
The web-based software solution equipment, a n d myConnect provides its customers with also with t h e a central platform for a wide range option of wireless of services. connectivity.
billion. This is a significant increase as compared
all
of
its
with
The standard package of modular service
to the previous year’s revenue of EUR1.36 billion.” At 55%, Europe represents the lion’s share of revenue for the Austrian firm, followed by 24% in America and 20% in Asia.
products in myConnect contains five modules. These comprise online support for request help
KraussMaffei also anticipates another record
from Sumitomo (SHI) Demag at any time from the
year, as orders and sales for 2017 have upped by
machine’s control system, a PC or a mobile device’
10%, compared to the previous turnover in 2016.
myDocumentation that allows customers to call
Meanwhile, China, according to Group CEO Frank
up all the documentation about their machine at
Stieler, is the machine maker’s driver of growth.
the touch of a button; myPartsShop that allows
“China and other Asian markets will increasingly
customers to order spare parts online.
become more important for us in the future. Through our new owner ChemChina, we now
The last two are myLifeCycleLog: that records
have even better access to the markets than before.”
all key events and provides customers with a
In view of this, KraussMaffei has doubled
complete history of every single machine and
production volume at its plant in Haiyan, China,
myConnectApp that allows customers to track
and expects an additional increase in 2018.
40 | PRA magazine 2017 yearender edition
Meanwhile,
in
cooperation
with
an
international leasing group, KraussMaffei and Netstal are testing the waters in Germany to determine the feasibility of leasing rather than selling standard injection moulding machines. Customers can lease machines for four years, after which they can extend the lease, purchase the machine by paying its residual value or simply return it. KraussMaffei will offer its CX ClassiX machines for the programme.
PRA will be at these events in
2018
Plastindia
Gandhinagar, Gujarat 7-12 February
P&R Vietnam
Ho Chi Minh City 20-22 March
Chinaplas Sumitomo (SHI) Demag Plastics Machinery says it is set to achieve its highest-ever sales volume in 2017, with revenues to increase by 17% to EUR273 million, beating its previous record year of 2015. A 20% increase in orders is anticipated for the current year, it said. The main reason for this positive trend, it says, is the take up of its ElExis high-speed and InElect all-electric machines. Companies have also been investing in their facilities to meet demand growth. Wittmann Battenfeld’s EUR15 million expansion of its Kottingbrunn plant will be completed by December 2017, with further extensions expected in 2018. The company also expects the expansion of its Czech Republic facility to be completed in 2018, and will expand its facility in Nuremberg, Germany, next year, too. Engel
also
announced
comprehensive
investments into its worldwide production sites, the continued expansion of its sales and service teams, and the reinforcement of local application-technical, automation and industry expertise. Some of the EUR375 million expansions include a new facility in St Valentin, Austria, and the expansion of its Shanghai plant to commemorate its tenth anniversary of
Shanghai 24-27 April
PlastMilan
Milan, Italy, 29 May-1 June
Propak Asia
Bangkok, Thailand 13-16 June
Propak China Shanghai, China 11-13 July
M’sia-Plas
Kuala Lumpur, Malaysia, 19-22 July
Taipeiplas
Taipei, Taiwan 15-19 August
Medical Fair Asia Singapore 29-31 August
Indoplas
Jakarta, Indonesia, 19 - 22 September
Fakuma
Friedrichshafen, Germany 16-20 October
P&R Indonesia Jakarta, Indonesia 14-17 November
© Plastics and Rubber Asia (PRA) 2017 Yearender Edition Regional Office: SQ9, Block A, Menara Indah, Taman TAR, 68000 Ampang, Selangor, Malaysia Tel: +603 4260 4575 Fax: +603 4260 4576