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German machinery and technology

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Germany takes the lead in exports to China The plastics and rubber industries in China have maintained highspeed growth in the past decade. Reflecting this growth is the upcoming Chinaplas 2012 event, which is set to achieve a new high record of 100,000 visitors and 200,000 sq m floor space, a 33% increase over the last edition. Aside from the chemicals and machinery supply industries, German technology will be showcased at this event to be held 18-21 April in Shanghai.

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German machinery tops exports Innovation, optimal energy efficiency, internationalisation and technological leadership continue to be the primary selling points for Germany’s plastics and rubber machinery, says the trade association VDMA. A recent report says that the country’s machine industry is growing, thanks to strong demand from emerging countries such as Brazil, Russia, India and China. More than half of the forecast growth is expected to come from the Chinese market, where exports alone reached EUR766.4 million in 2011, a 30.5% increase from EUR587.2 million in 2010. This export value sets a new record, topping the previous peak of EUR593 million reached in 2004. Aside from strong preference to Germany-made machines, producers in China also import machines from Japan (27.5%), Taiwan (11.8%), South Korea (5.8%), Italy (5.1%) and the US (5%). With the high flow of German machinery to China, it is only apt that the country takes up one of the largest country pavilions with 132 exhibitors occupying 3,178 sq m. Drinking water TPE TPE maker Kraiburg will showcase its new materials such as the drinking water (DW) series as well as its adhesion compounds, for the first time in Asia. Highly regarded for its optimal adhesion properties on PA, ABS, and ABS/PC and elastic recovery, the TPEs allow for improved injection moulding at high or low temperatures thus reducing production cost. With a special formulation and smooth, dirt and lime scale-repellent surfaces, the DW compounds are suited for use in sanitary and drinking water applications. Kraiburg Kraiburg says its Thermoplast W TPE allows for a says that it is widely higher coefficient of friction for improved grip used in Europe, where drinking water standards are stringent. “Green” options for packaging production Film extrusion may not seem to be the perfect process for energy conservation but on closer inspection a lot can be improved if the technology is put to work properly, says machine maker Windmöller & Hölscher. It says its Varex blown film line operates on low energy of 0.3 to 0.35 kW/kg, making it 30% more energy-efficient than its closest competitor.


German machinery and technology – Chinaplas 2012 preview W&H says its Varex line does not need trimming when running flat film, even at a high output

The line features the Optifil P thickness profile control system allowing for improved film gauge with lower thickness tolerances for thinner films, without sacrificing mechanical strength. The Easy-Change module also eliminates the need to stop the line for size changes, thus saving around 100 kg/resin per changeover while the Profile Booster narrows down film thickness tolerances after line start-up, reducing both time needed to reach full production levels as well as waste generated by 60%. The company’s Aquarex blown film line addresses yet another environmental aspect. Multi-layer, high-clarity PVC film produced in the upside down water-quench process can be used for producing IV bags. But since countries like China have banned PVC IV bags to avoid health risks arising from the content of plasticisers, PP film can also be produced in the system. Another green option is the Filmex cast film line that allows thick PET laminated film to be substituted with 250 micron co-extruded PET film to save materials, especially in deep-draw tray applications. Brückner focuses on material savings In line with China’s move to green manufacturing, extrusion machinery maker Brückner will be focusing on lines for battery separator, biobased and biodegradable films. The 6.2 m width and 250 m/minute PET-G shrink film line is offered for labels. To support its clients in the country, the company recently established a 24x7 hotline with

Film stretching line from Brückner


German machinery and technology – Chinaplas 2012 preview a Chinese-speaking electrical specialist. Furthermore, the TRAVIS mentor remote service tool, a 10 in. industrial grade touch panel, is provided to speed up troubleshooting. Film inspection system for precise detection The in-line film inspection system from Dr Collin is often used for quality control during resin production and for evaluating the dispersion of pigments and additives. It can detect gel particles, impurities and pigment agglomerates. A camera records flaws as small as 10 micrometres in size and documents them. Ten different types of flaws can be defined by means of 14 different defect parameters. The software offers online as well as offline possibilities. Corona station for cast film AFS Corona will be presenting its corona station for cast films. It comes with a cartridge system with integrated ozone extraction with either five or eight electrodes for low thermal impact of the foil, ozone extraction and easy maintenance. The single and double-sided corona treater systems are said to be ideal for high power, high-line speed applications. According to the manufacturer, its ceramic high-voltage insulators prevent creepage discharges or incineration found in other plastic material insulators. New developments for pipes and profiles Sister company of Battenfeld Extrusiontechnik, Austria-based Battenfeld-Cincinati will present the MTV125E swarfless PVC profile cutter with a speed of 15 m/minute and a maximum cutting cross section of 140x100 mm. The servomotor-driven saw carriage is supported by AC motor-powered cutting tools. Another highlight will be the parallel twin-screw Argos 93 extruders with outputs of up to 350 kg/hour for PVC profiles and

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The new swarfless MTV125E PVC profile cutter

up to 600 kg/hour for PVC pipe. The Talos 60 single-screw for pipe, profile and cable extrusion caters to outputs of up to 350 kg/hour. MRS extruders for recycled PET Since the last Chinaplas, Gneuss says its patented MRS (Multi Rotation System) extruder has been used for rPET processing, with more than 20 units already sold worldwide for film, fibre and repelletising applications. Another highlight is the RSFgenius and SFXmagnus Rotary Melt Filtration systems, which it says have been applied in China in

dryers that use a closed cycle to dry granules. Dehumidified air flows through the granule, absorbing moisture and taking it to the desiccant and when it is saturated, the air is redirected to an unsaturated desiccant on stand by. The saturated desiccant in the first container is regenerated with a heating system. A dew point energy saving programme cuts energy costs by up to 45%. Calibrated measuring instruments are used to measure the dew point and fitted as standard in models with over 300 cu m drying power. Mixing system for various media Sonderhoff Chemicals will present the DM404 machine, a fourcomponent semi/fully automatic mixing and dosing system for gasketing, glueing and potting of different types of components. The equipment processes PE, silicones, epoxy resins and other polymer reaction substances. The user interface operated by a touchscreen has a new multifunctional teach-in-box to simplify contour programming for parts to be processed. Parameters can be preset and controlled, thus allowing for fully automated sequences.

foam sheet and foam packaging film, thermoforming sheet, nonwoven fibres as well as in PET bottle flake recycling. With the worldwide trend for bigger lines, the company says it has sold larger systems in 200, 250, 330 and 400 sizes with sales having doubled in the last one year.

Cutter fit for the budget Precision and cutting speed without changing the properties of the material are the two main benefits from Expert Systemtechnik’s Cutexpert Minijet. Compared to mechanical cutting, the Minijet uses less water, decreases tool wear and minimal operating cost due to its hardwearing cutting base. It is designed for technical textiles and plastics and has a cutting speed of up to 70 m/minute and repeatability of +/-0.2 mm. The machine’s cutting surface measures 1,300 mm x 1,700 mm but can be customised to meet a customer’s request.

Granule dryer allows for energy savings Auxiliary equipment supplier Koch-Technik will exhibit its CKT

Pulveriser resists wear Maker of size reduction and pulverising equipment Herbold Meckesheim will be presenting

Gneuss will also showcase its pressure transducer for wood composite applications


German machinery and technology – Chinaplas 2012 preview its HV series plastocompactors for agglomeration and drying of powders, fibres, film and foam materials; re-crystallisation of PET flakes; and compounding of thermoplastics and fillers. The materials that can be processed include PC, PE, PP, PS, PA, PET, PVC and ABS. Herbold’s pulveriser

The continuous process because of the settings of feeding screw revolutions and disc separation allow for two setting parameters without the need of changing components. The wear costs are low, even in the case of abrasive materials and the screw-fitted kneading rails on the compactor can be easily replaced. Blow moulder delivers high output Blow moulding machine maker Bekum will exhibit its Xblow X07 machine series. The new single and double-station machines are equipped with platen widths of 350-700 mm and are available with all-electric (Eblow) as well as hydraulic (Hyblow) drives. Moreover, the machines come with Bekum-manufactured 5 and 10-parison BKZ extrusion heads for close wall thickness, internal thread diameters, article weight and volume tolerances. According to the company, with the fast parison injection rate and extrusion head/extruder bobbing function, the machines can reach an output of 179,400 articles/day. Dispensing cell for 2D/3D applications Specialising in casting

Bekum’s latest blow moulding series

resins made of PU and foam gaskets, Rampf Giessharze will demonstrate the application of a Raku-Pur thixotropic soft integral foam on its DC-CNC lowpressure mixing and dispensing system with three-axis CNC carriage. Raku-Pur possesses good attributes such as low water absorption, mechanical strength and high heat resistance. The company notes that adhesion of the material can be finished in less than 3 minutes, ensuring a fast cycle time. Suited to 2D and 3D application of casting, sealing and adhesive systems, the DCCNC dispensing cell is equipped with an integrated control cabinet and two-component material conditioning system. Pelletising system for thermoplastics Automatik Plastics will present its Sphero underwater pelletiser, applicable for compounding, recycling and raw material manufacturing. With a capacity range of 100 kg/hour to several tonnes/hour, the system is applicable for all thermoplastics as well as hot melt adhesives. Sphero 50 caters to small production lots of masterbatches or compounds as well as for laboratory applications; Sphero 70/100/140 for output rates up to 8,600 kg/hour; and Sphero 220/350/560 for outputs up to 36,000 kg/hour.

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German machinery and technology – Chinaplas 2012 preview With its digital 3.8 kW motor, a torque measuring range of 200 Nm and a speed range from 0.2 to 150 minute, the Plastograph EC can be used for raw material and recipe development, material testing and QC parallel to production.

The X factor in dies Blown film extrusion systems supplier, Hosokawa Alpine will present its latest X Die. The compact die is said to eliminate the visual port lines in blown films and is suited for short purging times and fast material transitions. In addition to die heads, the company will also feature its five-layer blown film line. Extrusion line for optical sector The latest in extrusion processes can now produce film and sheet in the most cost-effective way, according to Breyer. The company will highlight the key developments of its extrusion line, which is suited for the production of clear, multiwall and technical sheet, film, cosmetic tubes as well as solar and battery films.

plastics. The system works with the gravimetric principle with a speed control system and course/ fine flow. Powder materials are discharged from the hopper by means of an agitator and fed into the double screws. The double dosing screw discharges the materials in defined quantities and the discharged quantity is measured and recorded by a weighing module.

Breyer’s lines have effective venting systems that are said to lower energy costs and melt pump control for faster start up of the line. These advantages give the user the possibility to produce film and sheet for sophisticated products.

Extrusion testing line OCS Optical Control Systems will be presenting its ME extrusion measuring line that can be connected to a chill roll and CR9/WU9 winding system, which creates a self-contained basis for connecting optical measuring equipment. The modular concept allows an application of different rheological, chemical, physical and optical testing systems. Available in three different barrel diameters of 20, 25 and 30 mm, the lines are intended for the production of narrow blown or cast films for the laboratory and small-batch production.

Dosing system maxes out accuracy Azo will showcase its dosing systems including product feeders and rotary valves. Its compact dosing Azodos system is designed for a variety of applications including food, pharmaceutical, chemicals and

Rheometer tester for simulations Instrument and equipment supplier, Brabender will be featuring its Plastograph EC, a table-top version of the universal torque rheometer. The machine is widely used for application investigations in laboratories and simulation.

Breyer is promoting its optical film line

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Azo offers a range of materials handling equipment for dosing and conveying

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Slitter for films Goebel Schneid-und Wickelsysteme’s Monoslit slitter for converting films (BOPP, BOPET, BOPA, OPP and CPP) comes with a rewinder that incorporates the latest advancements from the company’s BOPP film technology. Furthermore, it provides working widths up to 11,000 mm; unwinding diameter of up to 1,500 mm; rewinding diameter of up to 1,250 mm and running speed of up to 1, 500 m/minute. Flexible trimming machines Thermoplastics, glass, carbon fibre, wooden panelling and blow moulded parts, are a few of the many applications of Geiss’s trimming machine Ecoplus. It can be customised to suit requirements and is available in any nominal size and different versions. The smallest machine size provides the same productivity and rigidity as the big ones. The nominal size is equal to the block size trimmed with five axes in all machines. The machine measures 2,000 x 1,000 mm.

Geiss Ecoplus trimming machine

Visit PRA at Booth E4-B67


PRA April 2012 Issue Features