A S l A â&#x20AC;&#x2122; S L E A D l N G m aga z l ne f o r t h e p las t l c s and r u b b e r l nd u s t r y
In this issue
Volume 28, No 201
publlshed slnce 1985
A S l A’ S L E A D l N G m aga z l ne f o r the plastlcs and rubber lndustry
Features 焦 點 內 容 20 有機及印刷電子產品:有機/印刷電路的革命性微電子 22 Front Cover Feature
Italian extrusion machinery maker Omipa celebrates its 50th anniversary and highlights its progress to date
26 Green Packaging
PRA, together with Tara Media & Communications, organise the third Green Packaging conference in Jakarta, Indonesia, on 21 November
28 German Machinery & Technology
Associate Publisher/Editor Tej Fernandez Tel: +60 3 4260 4575 Email: email@example.com Editorial/Production Coordinator Angelica Buan Email: firstname.lastname@example.org
German machinery makers and technology providers will occupy the largest space in the K2013 show; we provide some updates in this issue
Chinese Editor Koh Bee Ling
32 Extrusion/Converting/Compounding Machinery
Circulation Abril Castro Email: email@example.com
A round-up on what to expect from the machinery sectors at the K2013
Highlights on exhibits of compounders; additives, pigments and masterbatch suppliers at the K2013
44 Organic and Printed Electronics
Plastics can be used as electrical conductors to serve as components of organic/printed electronics
MCI (P) 029/08/2013 Printer KHL Printing Co Pte Ltd
10 Materials News 12 Composites News
is published 8 times a year in Mandarin and English by Kenter & Co Publishers’ Representatives BV.
Supplements 副 刊 Injection moulding technology will be one of the showcases at the K2013 Rubber is the small k at the K2013; with a dedicated Rubber Street
A S l A’ S L E A D l N G M A G A Z l N E F O R THE PLASTlCS AND RUBBER lNDUSTRY
Omipa thanks its customers and invites them to the booth (Hall 17, Stand 17A42) at the K2013 show in Düsseldorf, Germany, from 16-23 October
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Whilst every effort is made to ensure that the information contained in this publication is correct, the publisher makes no warranty, expressed or implied, as to the nature or accuracy of such material to the extent permitted by applicable law. © 2013 Kenter & Co Publishers’ Representatives BV No part of this publication may be reproduced, stored or used in any form, or by any means, without specific prior permission from the publisher. PRA is circulated free to trade readers in the plastics and rubber industry. Airmail subscriptions are available at US$160 within Asia and US$250 to all other countries outside Asia.
On the Cover
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4 Industry News
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Latest M&As and Tie-ups • Lanxess is expanding its portfolio of phosphorus-based chemicals by taking over the business operations belonging to the French subsidiary of the insolvent Dutch company ThermPhos International BV, which makes phosphorus pentoxide and polyphosphoric acid at a facility in South France. Both products can be used as chemical intermediates including flame retardants and pharmaceuticals. • US public-listed chemicals firm Huntsman is acquiring Rockwood Holding’s Performance Additives and Titanium Dioxide (TiO2) businesses at US$1.1 billion in cash and unfunded pension liabilities of US$225 million, with the deal expected to close next June. Through this acquisition, Huntsman will become the second largest global producer of TiO2 and inorganic colour pigments (after DuPont), with a global capacity of 16%, up from its current 10%. The other businesses that Huntsman is buying include the thermoplastic (plastics and PU) and rubber compounding unit that sells primarily to the European automotive market. Another two businesses being acquired by Huntsman
are on timber treatment chemicals and water chemistry. It will also buy Rockwood’s sulphate process for TiO2, which is a lower cost alternative to using chloride to produce the pigments. • Effective 1 October, K-Tron, a supplier of feeding, dosing, and pneumatic conveying equipment and systems, will operate as Coperion K-Tron. German firm Coperion was acquired by US-based Hillenbrand in December 2012. K-Tron has been a part of Hillenbrand’s Process Equipment Group since 2010. Hillenbrand is a global diversified industrial company that makes and sells premium business-to-business products and services for a wide variety of industries. • US firm Nordson Corporation has completed its acquisition of German Kreyenborg Group's Kreyenborg GmbH and BKG companies. Managing Directors Jan-Udo Kreyenborg and Theodor Bruckmann sold their shares of Kreyenborg GmbH, that manufactures screen changers and melt filters, and of BKG Bruckmann & Kreyenborg GmbH, which offers special processing technology to produce pellets. • UK-based Croda International has received Chinese
regulatory approval to acquire a 65% equity interest in Sichuan Sipo Chemical, a non-listed natural speciality chemicals manufacturer based in Mianyang City, Sichuan Province. Sipo was established in 1993 and makes speciality derivatives from natural raw materials, including primary amides, novel fatty acids and speciality esters. • US compounder A. Schulman has purchased the Perrite Group, a thermoplastics manufacturing business with operations in Malaysia, the UK and France, for US$52 million from Vita Group. The acquisition is expected to increase revenues in A. Schulman’s Asia Pacific (APAC) segment by 35% and will double the size of its existing Engineered Plastics business in the region. Perrite has manufactured thermoplastic compounds for the electrical, automotive and industrial markets for more than 35 years and recorded revenue of US$140 million in fiscal 2012. • Singapore-based moulder Flextronics is acquiring Swiss family-owned RIWISA, which moulds medical, consumer packaging and industrial products. RIWISA
is given access to the world market through Flextronics operations in more than 30 countries and global customer base. For the year that ended in March 2013, Flextronics reported a profit of US$270 million and sales of US$23.6 billion. • US-based conglomerate Koch Industries is acquiring Molex Incorporated, which is involved in the moulding of connectors, sockets and cable assemblies, for US$7.2 billion. Molex also developed a proprietary platedplastic technology that provides shielding in applications such as mobile phone antennas. The US$115 billion Koch, run by billionaire brothers Charles and David, also owns an oil refinery and chemicals company, amongst other companies. • Dow Chemical is no longer considering the sale of its additives business due to low offers from bidders, with Chairman/ CEO Andrew Liveris saying that the firm is “quite comfortable” continuing to run the additives business for cash. Without revealing the bidding offers, Liveris said the sale was being “taken off the table.” The additives unit was part of the US$1.5 billion proposed divestitures of a fumigants and PP licensing and catalysts units outlined in March this year.
INDUSTRY NEWS • US-based C. R. Bard, a maker and marketer of vascular, urology, oncology and surgical speciality products, is acquiring silicone urinary incontinence and urine drainage products supplier Rochester Medical Corporation for US$262 million. This acquisition represents a compelling strategic fit for Bard and enhances its position in the US$930 million global urology homecare market. • ZF Friedrichshafen, Germany’s third largest, and among the world's top ten automotive suppliers, is in the early stages of discussions to sell its rubber and plastics (R&P) unit. ZF says it has been approached by a Chinese railway products company Zhuzhou Times New Material
Technology, adding that discussions are still at an early stage. ZF’s rubber and plastics unit employs some 3,400 staff globally and had sales of EUR718 million last year. • Russian petrochemicals company Sibur has signed a long-term supply agreement with German chemicals giant BASF to supply additives used for production of PP, PE, synthetic rubber, TPEs and ABS at Sibur’s production facilities, with BASF also ensuring technical support. Both companies will also look at developing new, advanced materials, with a view to improving properties of elastomers and TPEs. In addition, Sibur and BASF are developing a new PP, to boost efficiency and consistency, for nonwoven fabrics.
Italian machinery exports down
talian machinery association Assocomaplast says Italy’s exports of plastics and rubber machinery in the first half of 2013 held “relatively firm”, dropping by 1.7% to EUR1.2 billion. And exports to China, its sixth largest export market this year, had the biggest drop, accounting for 4% of the total exports, compared to 5.1% last year. Exports to Germany (up 0.2% to 14.9%), the US (up 0.5% to 6%) and France (down 0.3% to 6%), the top three destinations, fluctuated marginally. In fact, the Polish market has taken over the Chinese market’s slot of fifth largest export market, with an increase of 5.5%, compared to 4.2% last year. In terms of machinery exported, the biggest drop was in thermoforming machines (down 15.8%), blow moulding machines (down 7.4%) and extruders/extrusion lines (down 4.9%) while exports of injection moulding machines increased by 23.8%. Against the backdrop of the
domestic market situation, the association says that maintaining exports at essentially the same level as in the previous year “can be regarded as an achievement.” Imports, meanwhile, dropped by 6.2% to EUR280 million, with the association pointing out that the downturn is an indicator that the domestic market is still struggling to recover. The biggest drop in imports was in thermoforming machines (down 61%), extruders/extrusion lines (down 44.1%) and blow moulding machines (down 38.5%), while imports of flexographic printers increased by a whopping 51.7%. Nevertheless, the association says that Italy’s GDP is expected to grow slightly (+0.3%) in the last quarter while a survey it conducted at the start of September reveals “a certain degree of optimism”, with processors’ order books up compared to the previous month and favourable projections for the next four months.
Plant/Office set-ups • Dow Elastomers, a business unit of Dow Chemical, will begin the production of Affinity GA polyolefin elastomers (POEs) for hot melt adhesives in Tarragona, Spain. It is expected to come on-line in the first quarter of 2014, adding to existing production in Freeport, Texas. Dow is the largest global producer of POEs with a variety of application and market segments, including transportation, packaging, adhesives, waterproofing membranes, health and hygiene, nonwovens, footwear and consumer solutions. • As part of its investment strategy on the US Gulf Coast to integrate advantaged shale gas, Dow Chemical will expand capacity in Texas for its Elite PE and high melt index Affinity polyolefin plastomers, while in Louisiana it will increase capacity for its Agility LDPE and Nordel metallocene EPDM, to drive strong revenue growth and generate US$2.5 billion in EBITDA once fully operational. Construction is scheduled to begin soon.
• Japanese firm Asahi Kasei Chemicals is constructing a 3,000tonne/year plant in China for Duranol polycarbonatediol (PCD), an intermediate for high-performance polyurethanes (PUs). It will start up in early 2015 and be operated by local affiliate Asahi Kasei Performance Chemicals. Demand for PCD is forecast to continue to grow briskly throughout Asia and especially in China, since it is a major centre for manufacturing automobiles and consumer electronics. Asahi currently produces Duranol at a plant in Japan. • US-based Gevo, the world's only commercial producer of bio-isobutanol, has opened a facility to manufacture plastic feedstock paraxylene from biomass in Texas. Gevo is working with CocaCola and materials firm Toray to deliver a new technology for renewable paraxylene, a key building block for producing fully renewable PET for beverage bottles and polyester for packaging films and fibres used in textiles, clothing and other applications. • As of October 2013, US machinery maker Davis-Standard will begin an in-stock programme of its existing fast moving components for the product lines available in China at
its subsidiary’s plant in Suzhou. Some of the parts include bearings, gears, bolt, screw, screen mesh and thermocouples for immediate delivery. The firm has also established a tollfree 24-hour hotline for all service and general enquiries from customers. • Germany-based compounder Albis Plastic has opened its first facility in Changshu, China, with a capacity of 10,000 tonnes/year. The EUR10 million plant will supply the company’s Altech and Alcom products to the automotive, electrical, consumer products and appliance sectors. • Borealis and Borouge have launched Fibremod fibrebased compound PP compounds for the automotive and the appliance industry and also started up a new long glass fibre line in Monza, Italy. The Fibremod family of engineered short (SGF) and long glass fibre (LGF) compounds means that the Xmod and Nepol glass fibre brands will be discontinued. Austrian firm Borealis’s proprietary Borstar process technology enables the tailoring of the PP compounds to required stiffness aspects. PP-LGF is a group of long glass fibre reinforced products, which are produced in the new Monza plant by pultrusion to achieve
increased fibre length in both pellets and final parts. • German speciality chemicals firm Lanxess has completed the move of its Group headquarters from Leverkusen to Cologne. With its approximately 1,000 employees, the firm now occupies the Lanxess Tower at Kennedyplatz 1 in the district of Deutz and unites all of its central management functions under one roof for the first time. Construction work took three years. Meanwhile, Saltigo GmbH, a whollyowned subsidiary of Lanxess, will move its corporate headquarters from Langenfeld to Leverkusen, with its workforce of over 100, into what used to be Lanxess’s main building (K 10) at the Chempark site. • Swiss injection moulding machine maker NetstalMaschinen, which is a part of the German KraussMaffei (KM) Group, is discontinuing its machining works at its Näfels plant and will concentrate on R&D, final assembly and servicing instead at the plant. Machining and module preassembly will gradually be transferred to sister plants within the KM group in Germany and Slovakia.
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Asia to lead in caps/closures and engineering plastics
sia is a growth hub for the plastic caps/ closures market, amidst growth drivers such as increasing global population, rising standards of living and the shifting consumer behaviour, with the region to increase its world market share from 34% to 42% over the next eight years. Germany-based market research firm Ceresana’s latest report also says that by 2020, the global demand for caps/closures is expected to rise to more than 1.1 billion units. It says that the versatility of plastic as material for packaging is primarily driving this growth, replacing traditional materials such as aluminium, tinplate, glass or cork. In terms of sectors, Ceresana says that in 2012, about 62% of all caps/closures were processed for the Beverages sector,
with the remaining utilised for applications such as food containers, cosmetics, personal care products, perfumes, pharmaceuticals, and household detergents. But the cosmetics and pharmaceutical sectors are expected to undergo “a highly dynamic development”, increasing by 4.9% per year until 2020. The market is profiting substantially from an increasing use of PET-based disposable bottles, says the report. Plus, it will see further access into segments that traditionally use other materials, such as wine, beer, or liquid foodstuffs like sauces. Meanwhile, in engineering plastics, which have been generating higher growth rates than standard plastics, Ceresana expects global market value of engineering plastics
to increase to US$90 billion in 2020. “Given their physical and chemical properties, many industrial, electrical/electronic parts as well as everyday products are made from engineering plastics by now. Faced with an increasing demand for ever more efficient and lighter materials, this trend will continue to gather momentum,” says the market research firm. In terms of market sectors, the firm says that on a global level, electrical/electronic applications as well as consumer goods are among the most important sales markets for many engineering plastics, with almost 25% of global demand in each of the two sectors. The third largest market is the transportation sector, followed by construction. On a regional level, however, notable differences become
apparent. In Western Europe, for example, transportation is the largest sales market – Asia Pacific, on the other hand, mainly utilises engineering plastics in the production of consumer goods such as coffee machines, dishwashers, washing machines, toys, and sports utensils, processing almost 30% of regional demand in this sector. Also, individual products show distinct differences in regard to application areas. While transportation accounts for 35% of polyamide (PA) consumption, household and consumer goods are the major application area for acrylonitrile butadiene styrene (ABS). Ceresana’s study offers an analysis of the global market for eight engineering plastics: ABS, PC, PA, PMMA, POM, PBT, SAN, and fluoropolymers.
Exhibitions in Indonesia and India
reach 4 million tonnes/ year by 2020, more global industry players for both the plastics and rubber sectors are drawn to participating in this year’s Plastics & Rubber Indonesia and ProPak Indonesia. It will be held 20-23 November at the Jakarta International Expo Centre, Kemayoran, Jakarta. The exhibition will have a participation of 700 companies from 30 countries, spanning 21,500 sq m of space. It will host group pavilions from China,
Germany, France, Italy, South Korea, Singapore, Spain and Taiwan, according to the organiser, PT Pamerindo Indonesia. As the largest group pavilion, Taiwan will converge with over 32 companies. The organiser says that the strong presence of technology and solution companies is evidence that Indonesia has emerged as the strategic gateway for plastics and rubber processing in the Southeast Asian market.
Meanwhile, the triennial industry show, Plastivision India, returns this year in Mumbai from 12-16 December. It is expected to have a record-breaking participation with exhibitors from more than 46 countries over a 70,000 sq m exhibition space. According to its organiser, All India Plastics Manufacturers’ Association (AIPMA), the event will feature an Indo-US Business Summit, in coordination with US plastics association SPI.
here is still life after the K2013, with two prominent Asian shows in Indonesia and India taking place. Given the fact that Indonesia’s plastics sector is producing up to 70% of its total consumption and, likewise, the country is a top rubber producer, with production projected to
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Green Materials News – K2013 Round-Up
• Having made considerable investments in caprolactones, Perstorp will be launching its Capa thermoplastic products for bioplastics blends. The firm will also launch its new generation of Akestra co-polyesters, which are developed together with Mitsubishi Gas Chemical. The material is said to have unique properties as a replacement for heat resistant PS thin wall containers, a PC replacement for durable “dishwasher proof” transparent products and a glass replacement for hot-fill food containers. When used in co-extrusion sheets for thermoforming, Akestra bypasses PS heat resistance for hot-fill applications and, by using recycled PET, it can contribute to a more sustainable packaging solution. Perstorp's new co-polyester is an alternative to PC
• Dutch firm DSM will showcase new applications for its 70% biobased EcoPaXX PA 410 that include the engine cover of the new Mercedes-Benz A-Class as well as the engine crankshaft cover for Volkswagen. The crankshaft cover incorporates integral seals in PTFE and liquid silicone rubber (LSR),
DSM's material is used in this engine cover for VW
as well as various metal inserts. It will be used on Volkswagen's new MDB modular diesel engine platform, implemented across its Audi, Seat, Škoda and VW brands. Compared with covers made in aluminium, system costs for the PA 410 cover are said to be lower due to the integrated fully automated production cell for the parts made by KACO. It is also light weight since the EcoPaXX grade is 45% less dense than aluminium. Meanwhile, EcoPaXX cast films made by development partner MF Folien can be used in food packaging, medical, aviation and shipping, and building/construction. EcoPAXX is also promoted for thermal breaks in aluminium window profiles as an alternative to PA66. DSM will also announce a partnership with a distributor for a portfolio of glass-reinforced PA6 compounds containing more than 50% post-consumer recycled material from dependable sources. • German firm Lanxess will add on five new grades to its portfolio of green EPDM elastomers (Keltan Eco) before the end of 2013. The five new grades are “drop-in” variants of
conventional EPDM rubber grades from Lanxess that are already in use and contain 50% ethylene derived from Brazilian sugar cane. The company has also successfully converted biobased butanediol into PBT in a commercial scale plant utilising technology from sustainable chemicals company Genomatica. Meanwhile, Lanxess is also researching the use of Levapren EVM rubber as an impact-resistance modifier for PLA, to reduce its brittleness. EVM grades with a vinyl acetate content of around 50% have been found to be the best modifiers. • US firm Celanese will highlight applications for its biodegradable and compostable Clarifoil cast cellulose diacetate (renewably sourced from cotton or wood pulp) film. The company has been producing it since the 1940s and it is now also available as a thermoformed film for packaging as an alternative to PVC and PET. Produced in the UK, the film boasts high clarity and is able to dissipate moisture, thus is suitable for doughnut and muffin packaging. It has also been used for anti-fogging laminates in ski goggles. • The German Fraunhofer Institute for Process Engineering and Packaging IVV will present a new variant of its solventbased, patented CreaSolv process that allows metalplastic composites to be separated and recycled. The institute is also presenting two other variants of the process that target EPS and PLA. CreaSolv dissolves a polymer out of the waste mixture using a selective solvent formulation,
Green Materials News – K2013 Round-Up after which, the resulting polymer solution is cleaned - mechanically and by chemical extraction - and dried. The solvents are then returned to the cycle for reuse. • Colloids, a member of Israelbased Tosaf Group, will introduce Sustain biobased (corn starch or cane sugar) products, available in either universal or polymer-specific (PA, PE, PLA and polyester) masterbatches. It is fully recyclable and, unlike many biodegradable polymers, will not impact on the quality if mixed with fossil-derived polymers of the same type, says Colloids. • In the first quarter of 2013, over 370 million handheld devices were sold. DuPont
Performance Polymers’s Zytel RS HTN polyamide (derived from sebacic acid), that has grown four times since its introduction four years ago, is used for one such device. Stiffness, strength, low warpage and low moisture pick-up ensure thinner walls for sleek, light designs. A halogen-free, flame-retardant grade is also available for compliance with recycling of discarded electronics. Specific grades are also available that can withstand high-temperature circuit assembly methods, including those using leadfree solder. • German chemicals firm Wacker is launching different grades of Vinnex vinyl acetate-based binder system for bioplastics that
can be combined with one or more biopolyesters and fillers in a modular system. For example, PLA, PHA, PBS and starch can be used to create various polymer blends to improve the physical properties of biopolymers such as higher impact strength, flexibility or higher melting strength. Initial applications tests with PLA reveal that extremely thin PLA films can be produced and also welded more readily. Another plus is that Vinnex makes it possible to use combinations of incompatible biopolymers such as PLA and PBS. FDAapproved grades of Vinnex also enable thermoforming of bioplastics for hot filling applications like coffee cups and soup containers.
• UK-based Croda Polymer Additives has launched new Incroflo speciality additives for wood plastic composites (WPC) that act as lubricants to allow increased throughput, by increasing flow rate and dispersion. This allows for lower processing temperatures and pressures during manufacture. In addition, the additives act as a barrier between the WPC and the extruder to reduce wear, especially on screws; improves surface finish and reduces water absorption, which can lead to warping. • Germanybased Bayer MaterialScience has developed a material solution for window profiles, based on 80% fibre composite content with a tailored PU matrix, with a low thermal conductivity similar to that of wood and PVC. The composite materials are protected from weather elements, like rotting, with a suitable coating or by applying a laminating. The profiles are produced by a continuous process known as pultrusion. Working with PU systems generally enables higher production speeds than with alternative matrix materials such as polyester, vinyl
esters or epoxy resins. Further potential applications from transport and wind power sectors are possible. • A team of specialists from Ticona, the engineering polymers business of Celanese Corporation, Fraunhofer Institute for Chemical Technology (ICT) and the engineering company EDAG have pooled their resources to design a prototype commercial vehicle storage compartment flap. It involved using novel materials with the help of thermoplastic tape laying technology, PP was used as the matrix material and unidirectional oriented glass fibres (UD-GF) for the reinforcing inlay in the form of so-called UD-tapes. By processing the structure optimised in the 3D space in the 2D level, the partners were able to generate a flat inlay in the first process step using a tape laying machine; this was consolidated thermally and processed as a semi-finished product. UD-tapes are only laid in the component sections in which they are required; thus reducing the wastage. In the downstream thermoplastic shaping process, the consolidated inlay
is then heated in an infrared heater within the melting range of the matrix material and shaped in a mould to form the structural component. Subsequently, water jet cutters trim the component and make the assembly and function holes. The steel outer skin is then joined to the composite structure by roll hemming in the final assembly. The partners say that considerable weight savings are possible compared to the customary steel construction. • Thai chemical firm PTT Chemical and Japanese carbon fibre maker Mitsubishi Rayon are to jointly study the set up of a carbon fibre business in Asia. The firms anticipate up to 100 billion yen worth of sales in carbon fibre composites in the region by 2020. At the early stages, the joint collaboration will mainly focus on exploring automotive parts and pressure vessel demands, however, both companies believe that lowcost natural gas containers made of extremely strong and lightweight carbon fibre composites are a key technological breakthrough that will contribute to the transportation sector, unfolding the possibility of maximising fuel
efficiency globally. The companies expect to conclude the joint study by the end of 2013. • Teijin Group’s Toho Tenax, together with Sakai Ovex, has developed an ultra-lightweight Tenax carbon fibre fabric (0.06 mm thick) to fabricate a lightweight car body, which still has the stiffness and strength needed to withstand race conditions. GH Craft, also a Teijin company and a developer of CFRP structures for the automotive, rail and aerospace industries, was involved from the concept design stage in developing the solar car’s carbon fibre composite body. In addition to thermoset CFRP, Teijin is also developing thermoplastic CFRP at its Teijin Composites Innovation Centre in Japan.
Toho Tenax and GH Craft worked with Japan’s Kogakuin University to develop a CFRP solar car for the World Solar Challenge in October
• Netherlandsheadquartered TenCate Advanced Composites and Switzerland-based Kringlan Composites are to develop automotive parts
Composites NEWS using thermoplastic composites. A spinoff of the Swiss Federal Institute of Technology, Kringlan aims to produce lighter, stronger parts for the automotive sector and said it would work with TenCate's thermoplastic composite expertise. One such part will be composite wheels. Some 30-40% lighter, it is able to reduce fuel consumption. â&#x20AC;˘ Dutch firm DSM is launching a range of thermoplastic composites, based on its EcoPaXX PA410, Akulon PA6
and Stanyl PA46 resins with various fibre reinforcements initially aimed at the automotive industry. DSM is a partner in the four-year ENLIGHT (enhanced lightweight design) project, which also includes car companies Jaguar Cars, Renault, Volkswagen and Volvo. Part of the European Unionâ&#x20AC;&#x2122;s Seventh Framework Programme, ENLIGHT aims to accelerate the technological development of a portfolio of materials, to reduce weight in medium-tohigh volume electric
vehicles (EVs) that could reach the market between 2020 and 2025. DSM is also one of the founding partners in AZL, the Aachen Centre for Integrative Lightweight Production, along with suppliers such as Ashland and TenCate, and car manufacturers Opel and Toyota. â&#x20AC;˘ Germanyheadquartered Evonik Industries and SECAR Technologie of Austria have established a joint venture called LiteCon Advanced Composite Products
to focus on the mass production of composite components for the automotive and aviation industries. Evonik manufactures Rohacell structural foam core material, which is used in composite sandwich structures in aircraft, sports cars, wind turbine blades, X-ray tables for medical applications, and in sports equipment. SECAR is a manufacturer of carbon fibre reinforced plastic components for the automotive, aviation, and medical industries.
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Front Cover Feature
Omipa celebrates 50 years of business Italian extrusion machinery equipment firm Omipa is proud to have reached its 50th year in business. Omipa is owned by the Cazzani family who says that it would like to take this opportunity to thank its customers, past and present, for their constant trust and for having been an important part of their success over the 50 years.
Omipa’s factory in Morazzone
Asian market an important sector During the past few years, the Asian market has been very active for Omipa, in spite of the world economic and financial crisis and this has enabled Omipa to overcome this critical period. Furthermore, thanks to a highly specialised team of engineers and skilled operators, the firm has Gilberto Cazzani (right) and Fabio been able to develop new Cazzani, President and Managing machinery for innovative Director respectively lead the team at applications, in partnership Omipa with its clients, as well as enhance its already consolidated range of products, in order to improve the efficiency, both with regards to quality and output. The firm, which exports almost all its output, expects a stable year, especially since it offers high performance technology, said Managing Director Fabio Cazzani in an interview with PRA recently. “The global markets, especially China and Asia, are stable, compared to Europe,” he added. “Customers are still investing and growing, especially in the niche market of optical and display sheets,” he explained. Investing in R&D to enhance product lines Family-owned Omipa is continuously enhancing its equipment through research and development. The constant evolution of product applications and the presence of more sophisticated materials in the market have also led Omipa to develop new technology and equipment. With the aim of further improving and increasing its machinery's capabilities, the firm decided to further enhance the research and development field with new machinery and products. Enhancements include the following aspects: - Reduction in energy consumption of the equipment - Improvement of the quality of the installation and of the finished product - Improvement of the output and efficiency of the plants
Front Cover Feature New equipment for special profiles At the forthcoming K2013 exhibition, Omipa will present innovative equipment for the production of special profiles for the building industry. Omipa considers itself an important partner of the building industry, thanks to its large range of lines for hollow profiles in PC with different tailor-made profile geometries. These are especially useful for big coverings and infrastructures (stadiums, shopping centres, railway station coverings, logistics in general, etc).
cogging profiles, corrugated hollow profiles and “wing” panels. The hollow profiles can be produced with different designs for internal and external structures, hence covering a wide range and types of applications that include not only industrial roofing but also internal wall panels and roofing/wall panels for outdoor applications. These new panels offer the following advantages: a) Reduced use of energy consumption
b) Brighter environment
c) Reduction in the weight of building covering structures, yet maintaining the high mechanical characteristics
According to Omipa, all this is turning out to be much appreciated by customers, "since the final product, at reasonable prices, makes it possible to execute applications to existing buildings by modifying considerably their aspect, functionality and energy savings."
A special click profile
Clear sheet for high optical quality In the Asian countries, Omipa has installed several extrusion lines for the production of high optical quality sheet as well as foil and film, in thicknesses ranging from 0.3-30 mm in PMMA, PC, PET and PETG.
“Almost 40 years ago, we were the forerunners of the machinery for the extrusion of PC hollow profiles. Based on the experience built up with the PP hollow profile lines, in close partnership with our customers, we are now a world leader, with more than 120 complete extrusion lines delivered by us all over the world,” says Cazzani.
Clear sheet application as a roof covering
Recently, in the field of high optical quality sheet in PC-UVPC, the firm has delivered the largest installation it has manufactured to date. The machinery is used for the production of solid sheets, with a width of 2,700 mm.
Omipa is especially known for its machinery for special profiles in PC
In recent years, Omipa has developed a new range of machines for the production of innovative profiles, such as roofing panels, wall panels, clip profiles,
Extensive equipment range In addition, Omipa designs and manufactures complete extrusion lines for the production of a wide range of products. These include the following: • Complete extrusion lines for the production of hollow profiles with a width of up to 3,000 mm, and thicknesses from 2-40 mm in PP, HDPE, PC, PMMA, HIPMMA and PET. Special versions of the equipment are available for co-extruding up to five layers. OCTOBER 2013
Front Cover Feature Corrugated sheets
• Complete co-extrusion lines for the production of standard quality sheet (ABS, PS, HIPS, PP, PE, CA, SAN). Thicknesses range from 1-30 mm and widths are up to 3,000 mm.
• Complete extrusion lines for the production of co-extruded sheet and foil of up to seven layers and more. Thicknesses range from 0.15-10 mm (or more) and widths are up to 3,000 mm.
• Complete extrusion lines for the production of foil wound on reels (ABS, HIPS, PP, PE, PET). Thicknesses range from 0.1-3 mm and widths are up to 3,000 mm. • Special extrusion lines available upon requests.
environmental protection, without compromising the physical and mechanical characteristics of the finished product. Furthermore, the foaming process uses a neutral gas (nitrogen/CO2), which results in a reduction in production costs as well, compared to the chemical foaming process. Omipa is a strategic partner for the building industry, where its machines are used to produce corrugated hollow profiles
An absolute novelty is the new range of machines for the production of low shrinkage EVA, for the encapsulation of silicone cells for application in the field of photovoltaic panel production. Omipa employs skilled workers at its finishing operations
In the field of polypropylene (PP) hollow profiles, Omipa has developed the new Foam System. With this system, it is possible to reduce the final product weight by keeping unchanged the mechanical resistance features. Market applications include the packaging, printing, building, electronics and automotive sectors.
Finally, the company has tested with success the production of hollow profiles in ABS, a material which up to now has not been applied in these applications. Besides making it possible to replace the materials commonly used for heavy packaging, it guarantees excellent performance even when subjected to very low ambient temperatures.
This system for PP foam hollow profiles makes possible a reduction of 20-30% in raw material consumption, with consequent economic savings and
Visit Omipa at the K2013: Hall 17, Stand 17A42, where you will be most welcome to celebrate the company’s 50th Anniversary and get information as well as see the new range of special profiles Omipa will be exhibiting
Towards Sustainable Solutions
reen packaging is not without its challenges. A recent study reveals that consumers, while accepting the concept of green packaging, are not always agreeable to paying more for such packaging. Technology continues to unravel capabilities to enhance packaging with commonly available and easily accessed materials, as well as lower production costs. R&D on bio feedstocks/biobased materials surges on, to ensure that the materials that are diverted to green packaging do not compete with food sources for human consumption. Is green packaging worth the euphoria? Experts believe it is. It is a sector that is teeming with market opportunities and options for innovation. As a proponent for sustainability, PRA, together with Tara Media and Communications, will gather experts from relevant industries to tackle the various dynamic issues of green packaging. The third conference in the series of the Green Packaging conference, it will be held on 21 November at the Kemayoran Exhibition Centre in Jakarta, Indonesia. A CSR (Corporate Social Responsibility) event by PRA, there is no participation fee required. It will be moderated by Yoesoef Santo of the Indonesian Packaging Federation (IPF).
Speaker Lee Chee Kiong, Sales Director AsiaSorting Division, S&S Inspection Pte
Speaker Dr Phietoon Trivijitkasem, Honorary President (Charter), Thai Bioplastics Industry Association (TBIA)
Presentation Optical sensor-based automatic sorting systems to promote sustainability and increase profitability
Presentation Green packaging & total integrated waste management system
Bio-data Lee has been involved in the field of plastics packaging applications since 1997. The first 11 of the 16 years business development experience was involved in helping numerous customers in Asia Pacific acquire prudent investment and energy efficient material handling systems for the PET preform and PET sheet extrusion manufacturing industries. Realising the need to “close the loop” for the benefit of the environment, Lee has since 2008 been dedicating his time and energy in sharing the benefits of sensor-based automatic sorting technologies with the solid waste recycling industries. He is passionate about bringing highly effective automatic sorting technologies to the rigid plastic packaging recycling industries to improve efficiency and reduce costs. Lee has an Honours Degree in Mechanical Engineering from the California State University, Long Beach, US.
Bio-data Dr Phietoon, a former deputy Dean of Science Faculty, Chulalongkorn University, obtained his DR.ING in Chemical Engineering from Trondheim University in Norway. He was also the Charter Chairman when the Thai Bioplastics Society (TBS) was founded in 2005. TBS later evolved to TBIA in 2007, where he is now the Honorary President (Charter). He is also ViceChairman of Biotech Industry Club, The Federation of Thai Industries (FTI), and an active speaker on bioplastics, green packaging and green reverse logistics. He has also been active in bioplastics development for applications and marketing innovation. He was appointed as the Chairperson for the drafting committee on Compostable Plastics Standard by the Ministry of Industry and a country working group member (ISO/sc 61 WG 22,23) on Bioplastics International Standard as well. Recently, he was awarded a fellowship for “Science towards the Excellence on Bioplastics” by the Royal Thai Senate.
Green Packaging Speaker Dr Pipat Weerathaworn, Vice-President for Growth Project Management, PTT Global Chemical Public Company Ltd/President, Thai Bioplastics Industry Association (TBIA) Presentation Policies, progress and direction of the bioplastics industry Bio-data Dr Pipat is an agricultural scientist with a Master’s Degree in agriculture from the Kasetsart University, Thailand, and a Doctorate from the Swiss Federal Institute of Technology, Zurich, Switzerland. He started his Thai stint with sugar research in 1992 and from 2001-2010, he was Vice-President for Research and Development at Mitr Phol Sugarcane Research Centre, Asia’s and Thailand’s biggest sugar and bioenergy producer. He has been with PTT Global Chemical Public Company from 2011 and the President of TBIA since 2010.
Speaker Geert Van Ballaer, Marketing Manager for Moulding and Film & Fibre, Borouge Singapore Presentation Life of Plastic Packaging Bio-data Van Ballaer has 30 years of experience in the plastics industry. Before joining Borealis in 2000, he took up various positions in Technical Services and Sales functions within the packaging industry (expanded foam applications), and as a Purchasing Manager in the automotive industry (fuel tanks and supply systems). From 2000 to 2005 he was strongly involved in the market development of moulding in Eastern Europe, and in 2006 he became Borealis Key Account Manager for the Healthcare and Caps & Closures segment. He joined Borouge in 2009, and in 2012, he assumed the responsibility of leading the Moulding and Technical Service Managers group of the firm. Van Ballaer has a Masters Degree in Electromechanical Engineering, and has received various trainings on Financial and Purchasing Management in IMD in Lausanne and on Advanced Marketing in INSEAD, Singapore.
Speaker Gilles Lefevre, Managing Director, Engel Thailand Presentation Tendency of the market: modularity and efficiency in packaging Bio-data Lefevre oversees the seven-man sales and service team at Engel Machinery, Thailand. Prior to joining Engel, from 2008-2011, Lefevre was Business Development Manager at Sumitomo Demag, Germany, and General Manager at Demag from 2006-2008.
Speaker Junaidi Zen, Principal Application Engineer, NatureWorks LLC Presentation Ingeo biopolymer as a sustainable solution for the packaging Industry Bio-data As Principal Application Engineer for NatureWorks, Junaidi supports customers in Asia Pacific in the area of technical and product development. Prior to joining NatureWorks in 2009, Junaidi held various positions at Ciba (now part of BASF) as Head of Chemical and Testing Laboratory, Technical Marketing Manager, Business Development Manager and Technical Support Manager from 2001-2008. Before that, he was employed for ten years at PT Tripolyta Indonesia, a PP manufacturing company. Junaidi has a Bachelor’s Degree in Chemistry from Andalas University, Padang, Indonesia, and a Graduate Diploma in Marketing Management from the Singapore Institute of Management.
Contact Details: For more information, kindly visit the event page at http://plasticsandrubberasia.com/gphome.html To sign up for the conference, contact: Winston Fernandez email@example.com Or Tean Arul firstname.lastname@example.org
German Machinery and Technology
German technology takes centre stage The triennially-held K2013 exhibition will be staged from 16-23 October in Düsseldorf, Germany. With the Germans (having booked 43% of the overall exhibition area of 170,000 sq m) making up a strong contingent in their home country, some of the highlights to be expected at the exhibition are showcased here.
Bayer MaterialScience has developed a concept for a futuristic cello using aliphatic polyurethanes
Materials companies raise the bar Frankfurt-headquartered Topas Advanced Polymers, a joint venture of Daicel Corporation and Polyplastics, both of Japan that operates the world’s largest cyclic olefin copolymer (COC) plant in Oberhausen, will showcase new grades with HDT nearing 200°C. The clarity and heat resistance of COC is driving use in touch screen and light distribution components of mobile devices while its fluoropolymer-like electrical properties are used to mould antennas. For the healthcare and packaging sectors, Topas will introduce the 7010F-600 film extrusion COC with heat stability and robust extrusion performance. It features a HDT of 100°C for multilayer food packaging in hot fill conditions. PMMA maker Evonik Industries will exhibit solutions for residential and urban construction, mobility and lifestyle. It will have a customised electro-powered Rinspeed microMax concept car at its booth. It is made of Plexiglas, making it 40-50% lighter than conventional glazing while the Tegomer anti-scratch additive prevents scratching in the interior. For greenhouse films, Evonik offers Sipernat 820A while the new, phthalate-free Elatur CH plasticiser is suitable for sensitive PVC applications. TPU specialist Huntsman will highlight materials for the wire and cable industry like Irogran A95 P 5003 that combines the mechanical benefits of TPU with fire retardancy. It is ideal for use in confined spaces where cables need to be tightly bunched together or where ventilation may be poor. Meanwhile, Bayer MaterialScience and its partners have developed a prototype interactive cello. The body is made of a crystal-clear cast aliphatic PU resin that can easily be moulded into the desired shape. Shortly before casting, the PU is prepared from two liquid, solvent-free components from the company’s Desmodur and Desmophen product lines. Depending on the components selected, the materials can be adapted to the specific requirements in terms of hardness and flexibility. All the technical components required for sound and visualisation are integrated into the neck and fingerboard. A tuning device or surfaces for video jockeying (VJing) can also be installed in the instrument. Bayer MaterialScience's Bayblend PC is already used for making the body and keys of saxophones while the Baydur rigid PU integral skin foam is used in pianos. Corresponding instruments made of transparent Makrolon PC will be introduced to the market soon. Electric blow moulding machines move up a notch Uniloy Milacron will be showing the UMS 20E.S all-electric blow moulding machine. It has an accessible clamp system fitted with a direct actuator drive transferring the force simultaneously via two rugged, deflection-free swivel joint arms onto both mould platens into the centre of the pinch-off areas. Once the mould is closed, no power is used. It is also fitted with an integrated post cooling station and flash separation including the handle flash, PWDS system and closed-loop controls for all machine movements. During the show, the machine will be producing 12 l stackable UN containers including a view stripe in a single-cavity mould. It claims power savings of up to 40%, in comparison to hydraulic machines. Additional accessories such as a Delta quality centre, including leak testing and weight control as well as an Eisbär blow air cooling system, are part of the full line set-up. Following the introduction of Bekum’s patented C-frame clamping unit (used on the 07 series of machines) at the last K show, it will present the Eblow 407D machine, equipped with a triple spiral mandrel extrusion head running a PP cosmetic bottle. Low-friction linear guides allow for efficient use of energy and low-wear operation, says Bekum. “Exact platen parallelism during the closing process and the uniform distribution of forces over the entire mould area promote flawless product weld lines and extended mould life,” it adds.
German Machinery and Technology Thermoformers aim for efficiency Thermoforming machinery manufacturer Illig will present automatic roll-fed (RDM-K) machines equipped with its new Intelligent Control (IC) technology that includes compatible control modules for optimising processes, with servomotor drives employed in all sections of the machines. One of the modules, ThermoLineControl, calls up and programmes all machine components of the production line centrally on the forming station. It will show the production of APET cups on an IC-RDM 54K machine, with a 520 x 300 sq mm forming area, 18-up tool and capacity of 50,000 cups/hour. PP hinged packs will be produced on an IC-RDKP 72 machine (forming area of 756 x 535 sq mm and six-up tool). Compatriot Kiefel will present its Best stacking system on its KTR 5 SPEED cup forming machine, with quicker removal and packaging or filling of formed parts. Since the cups are stacked vertically, it creates optimal conditions for the next automated steps such as sleeving and packaging, says the firm. The stacking station has been developed by Kiefel will showcase the production of Kiefel for the food industry. Another transparent PP cups with a stacking stacking system device will be showcased with the KMD 78 SPEED pressure forming machine. By means of a 16-up tool, PP biscuit trays will be produced. The horizontal stacking is rounded up with a conveyor belt for transporting the stacks out of the machine. Auxiliary equipment makers to showcase a wide range MTI Mischtechnik will present its Uni tec, Eco plus-line and redesigned Vent tec aspiration system. Designed as vertical-type systems, the Uni tec Universal Mixers are suitable for the preparation of plastics, with a single mixer combining multiple process steps. The Eco plus-line is an upgrade of the heating/cooling mixer combinations launched at K2010, to cater to the demand for doublebatch machines capable of mixing PVC-U for the volume production of pipes/profiles at over 10 tonnes/hour. Vent tec has a special emphasis on improved dehumidification performance under constant production conditions. The system adapts automatically to the different process phases in the mixing operation. Meanwhile, Motan will launch a new range of Luxor CA S small compressed air dryers with hopper volumes of 0.75, 1.5, 3 and 5 litres, for the production of small/ micro parts. The dryers take factory supplied compressed air and expand it to atmospheric pressure. This produces dry process air with a very low dew point, which is then heated to the required drying temperature. No desiccant
German Machinery and Technology is required. All models are equipped with a thermostat and low air flow safety switch to prevent overheating of the material in the event of insufficient air throughput. It will also highlight its Ultrablend gravimetric batch dosing and mixing equipment for medical applications. Due to its IntelliBlend technology, this silicone-free system offers high dosing and consistency, says Motan. It is also equipped with filterless conveying and electropolished stainless steel for a hygienic working environment. Meanwhile, the GRAVInet GP control system has been joined by a more compact GRAVInet GP light for up to two dosing modules. It is equipped with a new WEBpanel with a 12.1" TFT touchscreen and Ethernet connection. Antares is a new line of compact single-shaft shredders made by Lindner reSource, said to deliver up to one-third more throughput than previous machines but at the same price. Available in four design sizes and numerous equipment configurations, the units are suitable for recycling post-consumer materials, films, filaments, start-up lumps and sheets/plates. At the user's option, each machine can be equipped with a point-blade rotor or an energy-saving square blade rotor for hard plastics, with motor ratings from 37-110 kW and outputs of 500-2,500 kg/hour. Another innovation is the optional Skylight maintenance and service hatch, which is operated manually and permits a quick replacement of the blades and counterblades. ProTec Polymer Processing is focusing on its Somos systems for drying, conveying and dosing pellets and regrind, with a new BB 500 gravimetric batch dosing for up to four components and output of up to 500 kg/hour (at a bulk weight of 0.6 kg/l). The device is mounted directly on the material intake of the injection moulding machine – or on a frame next to the machine – and can be equipped with Somos suction conveyors for automatic filling of the material supply tanks. Up to 50 stored, individual mixture formulas can be called up. ProTec will also present the OHL process where washed/reclaimed PET bottle flakes can be reprocessed into rPET. It uses a continuous extrusion process and the discontinuous treatment of the extracted pellets in the OHL tumble reactor, which is a rotary reactor that can be heated and evacuated. During the PET reprocessing, the re-pellets are freed of volatile contaminations (decontaminated) and post condensation (increase of intrinsic viscosity IV) is simultaneously undertaken. The process is supported by upstream auxiliaries. Koch-Technik will present a new Graviko gravimetric dosing device that uses two load cells. Every filling is weighed and the dual weighing unit registers the Koch-Technik‘s Graviko GK 65 has an adapted device geometry and two precision load cells for gravimetric dosing
values and transfers them to the Koch control unit. This in turn compensates for fluctuations until the dosing recipe is reached accurately. Once all the values match, the dosed batch is emptied into the mixer below. Here a horizontal agitator homogenises the mixture before it is processed in the subsequent process. The Mcm-g Touch control unit from Koch-Technik is used to calculate and control the dosage values as stated in the recipe. Once the recipe has been entered, dosing takes place starting with the first cycle without the need for calibration. Because the Graviko devices are structured using Koch-Technik's modular system, the user can move, swivel away or fold up all device components for rapid material changes. Nordson Kreyenborg will display a hydraulic power unit with two pumps that overcomes resistance during slide plate or diverter valve operation. The volume flow pump draws on a larger volume of oil to provide fast movement when the level of resistances is low while the high-pressure pump uses less oil but generates a pressure build-up that overcomes high levels of resistance. The two pumps are controlled via an automatic switching valve that shuts either the pump on or off as required. The new system is said to eliminate costs associated with maintaining pressurised accumulators and safety inspections (Inspections must be carried out every one to two years in Belgium, for example, and every five years in Luxembourg and Germany.) In addition, the two pumps are supplied from a single oil reservoir and are driven by a single motor, simplifying the design and reducing the initial investment. In a conventional hydraulic system for slide plate screen changers, a pressurised accumulator is required to overcome the resistance caused by residual degraded or baked-on polymer, which can otherwise impede the movement of slide plate in a screen changer or of the bypass, start-up and switch-over valves used in processing applications. Screw/barrel maker Burgsmüller GmbH, a company of KraussMaffei Berstorff, will exhibit the successful use of nanoparticle layers that give high wear protection for components. The 140-year old company says the development of the new process for the application of hard-coating layers made of closed nanoparticles such as Burgsmüller will introduce screw elements with of tungsten carbide extends nanoparticle layers the life of screws and barrels, giving optimum resistance against corrosive, abrasive or adhesive wear. It says it is not necessary to treat the entire screw or barrel, treating only the zones that are exposed to intensive wear. Nanoparticle layers serve as wear protection when processing abrasive materials like WPC, standard and engineering plastics, biopolymers or substantially contaminated recycled material.
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Freedom has to be experienced!
ARBURG GmbH + Co KG Postfach 11 09 · 72286 Lossburg / Germany Tel.: +49 (0) 74 46 33-0 e-mail: email@example.com (CN) China: ARBURG (Shanghai) Co., Ltd. · Tel.: +86 (0)21 5488 8866 · e-mail: firstname.lastname@example.org | ARBURG Machine & Trading (Shenzhen) Co., Ltd. Tel.: +86 (0)755 8343 3750 · e-mail: email@example.com | (HK) Hong Kong: ARBURG Ltd. · Tel.: +852 2886 3007 · e-mail: firstname.lastname@example.org | (SG) Singapore: Tel.: +65 6778 8318 · e-mail: email@example.com | (TH) Thailand: ARBURG (Thailand) Co., Ltd. · Tel.: +66 (0) 2349 4062 e-mail: firstname.lastname@example.org | (ID) Indonesia: PT ARBURG · Tel.: +62 (0) 21 5830 3455 · e-mail: email@example.com | (MY) Malaysia: ARBURG Sdn Bhd Tel.: +6 (03) 5636 6213 · e-mail: firstname.lastname@example.org
2013 ldorf e Düss any m Ger
Extrusion/Converting/Compounding Machinery at the K2013 Extrusion • Canada-based Macro Engineering & Technology’s co-extrusion systems now feature a more compact design that allows more space in the extrusion area and simplifies installation. The C-series MacroPlast extruders are designed for up to 13 layers. All the controls are mounted to the frame of each extruder and can be configured in different positions to suit specific extruder layouts. Macro has incorporated the extruders into all multilayer, blown film, cast film and biaxially-oriented (bi-oriented) shrink film lines. An ideal application will be bi-oriented film lines for sausage casing and shrinkable bags where the downward extrusion configuration can become crowded.
Table 1 Blown film Assemblies Material conveying, blending and gsm control Complete Extruders with gear box and motors Die Air ring Automatic thickness control
Calibrating basket Oscillating haul-off Tower Winder Process control Rajoo’s supply
Hosokawa ALPINE’s supply
firms Plast-control, E+L and Softal provided the integrated supervisory touchscreen control, web guiding system and corona treater respectively.
Macro’s compact extruders for multi-layer film extrusion
• India-based Rajoo Engineers has categorised its blown film lines as Economical, Balanced and Advanced (see Table 1) to help processors pick the right machine to fit their needs. It adds that though the features come at a price, film quality is not affected by the economics of the options. The Balanced model is a hybrid of localised manufacture with critical components sourced from Hosokawa Alpine, Germany. The Advanced model, meanwhile, is fully-sourced from Hosokawa Alpine. Balanced and Advanced models are offered in India, Bangladesh, Nepal, Nigeria, Kenya, Ghana and Tanzania. The locally produced Economical model provides the best value proposition, with the firm stating that 80% of films can be produced on the model. This line will be shown at the K. With an output of 350 kg/hour, it has a 60/40/40/40/60 extruder configuration with barrier screw and special mixing section for homogeneous melt and direct coupled motor to reduce transmission losses; specially designed five-layer CSD (Cylindrical Spiral Die) 400 mm die head with rheologically optimised melt flow path; IBC with three ultrasonic sensors; 360 degree oscillating haul-off with dynamically balanced turning bar and roller width of 1,600 mm. Meanwhile German
• A highlight at German firm Extrudex’s booth will be the VR-3 control unit, producing automatically a consistent vacuum in the calibration bath of an extrusion line, and the Helibar single-screw extruder, with 10% improved energy savings. By retrofitting older machines with a new screw/cylinder and keeping the existing gear system/motor, it can render 20% improvements and reportedly up to 60%, by replacing for instance, a 90 mm extruder with a 60 mm Helibar. These exhibits are design components of a five-layer pipe extrusion plant, developed by Extrudex. • Austria-based Battenfeld-Cincinnati will present the helix-63-5 VSI five-layer pipe die, in a new size for pipes up to 63 mm in diameter. The firm plans to add a new die in the future for pipe diameters of up to 125 mm. In the production of five-layer pipes,
Battenfeld-Cincinnati five-layer pipe die
Extrusion/Converting/Compounding Machinery at the K2013 EVOH processing constitutes a special challenge, hence the short dwell time is required inside the die and optimal distribution of thin layers with narrow tolerances. The modular design of the die facilitates its conversion for the production of three-layer pipes, as well as disassembly for cleaning. It will also show the RTA 250+ pipe cutter, which enables the cutting of both PVC (machined) and PE pipes (nonmachined), as well as process pipes of different sizes, ranging from 32-250 mm in diameter, and use of up to six cutting tools, depending on the material. • Beta LaserMike will display a range of measurement technologies for pipe and tubing including the UltraScan system, an ultrasonic gauge that provides non-contact precision measurement of product wall thickness, diameter and ovality. It will also show the latest AccuScan 5000 series of high-speed diameter and ovality gauges and LaserSpeed noncontact gauge for measuring the length and speed of products. This measurement solution delivers better than ±0.02% repeatable accuracy, recommending it for replacing error-prone, highmaintenance contact tachometers. The latest version of this gauge, the LaserSpeed 9000, detects both forward and reverse directions as well as zero speed (non-moving product). • Austrian Starlinger is presenting a new web lamination concept, a follow up to its stacoTEC lamination lines, of which it sells 30 lines/year globally. • Nordson Extrusion Dies Industries will show a new generation Contour cast film die that now incorporates an internal deckle. Compared to dies with “coathanger” manifolds, less time is needed to achieve
on-spec product and to purge between product runs and it allows for up to 25% improvement in crossdirectional product uniformity, along with a reduction in gel formation. The firm designed a coathangershaped manifold with a streamlined melt flow, with a “sculpted” configuration that is smaller and tapered at the ends, unlike the block-like shape of traditional coathanger dies.
Rethinking Precision Imagine if you could produce the best sheet ever, again and again.
Wouldn’t it be perfect if polishing stacks worked with the precision of upto-date machine tools? We think it would. With the innovative Mirex MT polishing stack you will immediately be able to adjust the polishing nip of your sheet extrusion line more precisely by a factor of 10, save setup time of at least 15 minutes, and reduce waste material by up to 75 percent. Adjustment is made fully automatically. This is how precision becomes reproducible. Find more information about us online on www.reifenhauser-csc.com You have questions? email@example.com
Nordson EDI’s new contour cast film die
See us at K show Hall 17, Booth C22 16 - 23 October 2013
Extrusion/Converting/Compounding Machinery at the K2013 Converting • UK-based Atlas Converting Equipment will show upgraded versions of its Atlas CW Series and Titan SR9 Series slitter rewinder technology for films and flexible packaging materials. The company launched its CW3600 and CW1040 series slitting and rewinding technology in 2012 and has recently introduced the CW5000 Series available in widths from 3,600-5,400 mm. Benefits include higher efficiency, increased productivity and reliability, higher quality rewind reels, reduced noise levels and operator-friendly control systems. Compared to a conventional primary film slitter running at 1,500 m/minute, producing rewind lengths of 8,000 m, the CW Series will have a faster rewind cycle, but at only 1,200 m/minute. It also features wireless rewind arm positioning, automatic knife positioning and direct-drive webpath rollers ensuring optimum web tension for films from 6-125 microns. Electrical cabinets are now integrated with the machines to reduce the space required for installation with under floor service trenches no longer required. • Rotary bag making machinery manufacturer CMD will launch the CMD 864 machine and winder. The system utilises the continuous-motion technology, which provides a wider processing window than traditional, intermittent-motion or shuttle-style bag machines. CMD rotary sealing allows for converters to adjust the dwell, or amount of time the heated seal bar is in contact with the film. This technology takes on sealing challenges, converting at up 138 m/minute bags made from bio-resins, post-consumer recycled content, or down-gauged films. • CMD will also exhibit the patented model 1270GDS draw tape bag making system with speeds up to 183 m/minute, space-saving footprint that is simple to thread up and operate; and optional print-to-seal registration for making printed bags. The system can be configured with the 0330HSW high-speed winder to produce drawstring style bags on “overlapped” rolls with one-at-a-time dispensing, banded for retail merchandising. The packaging automation system is designed by CMD and integrates a Yamaha YK600X SCARA robot with a PHD single-roll gripper assembly capable of handling over 1,650 rolls/hour. • Printing machine maker Apex Machine Company will debut the multi- colour S-11 for printing on flat components as well as the C-40 for printing on cylindrical and conical parts. The S-11 is capable of printing continuous webs such as plastic strapping at speeds of 120 m/minute/lane and the C-40 can print plastic or paper candy sticks at speeds of 2,000 parts/minute.
Maag’s new backflush screen changers
Compounding & Recycling • Swiss firm Maag presents the new CSC-BFX backflush screen changers for recycling rPET bottle flakes to films with just two screen pistons, in response to industry demands for backflush filters for direct processing without pelletising. The new screen changer stores the material in rheologically optimised conditions in an integrated melt accumulator and it, thus, cleans the contaminated screen surfaces. It incorporates two turn/lift cylinders for the complete filter function, compared to conventional eight hydraulic cylinders, allowing for a compact design. Control is via the maaxBFX for monitoring and visualisation of parameters when handling highly contaminated polymer melt. Standard extrusion sizes with active filter areas range from 250 sq cm-3,250 sq cm. • Starlinger will show the recoSTAR 65 VAC for recycling of washed household waste, agricultural films and printed material. It also features compounding capability for upgrading the final product. During the exhibition, it will process highly printed PE film, demonstrating the melt degassing and cleansing capacity needed for highquality regranulate that can be used in different applications. Furthermore, Starlinger viscotec will premiere the new deCON reactor to show the recently launched viscoSHEET PET sheet line, able to process up to 100% recycled PET, virgin PET and PIR (post-industrial regrind) at guaranteed IV levels, meeting FDA/EFSA levels for food-grade applications. • Nordson Kreyenborg’s new filter-media system for screen changers and melt filters prevents pressure loss and deformation of the steel filter fabric, or screen medium, and since it is sturdy is able to withstand the high mechanical stresses encountered during production start-up. Rheological optimisation of the cartridge design eliminates stagnation zones and makes possible 100% utilisation of the open filter area, prolonging filter life. The symmetrical structure of the filter cartridge facilitates secure and user-friendly handling and easy replacement of screen media without cleaning.
Extrusion/Converting/Compounding Machinery at the K2013 Nordson Kreyenborg says its new filter cartridge increases melt filtration output
It is an alternative to standard filter discs and candles where surface area is increased through pleating of the filter fabric, making it susceptible to mechanical stresses and inefficency. Backflushing of the discs and candles in order to clean the filter medium is not possible because the reversed polymer flow can damage the medium.
• Germany-based Gneuss will show an extrusion line consisting of its Multi Rotation System (MRS) 130 and two fully automatic filtration systems, the RSFgenius 200 and RSFgenius 250, with the capability to process up to 1,000 kg/hour of PET bottle flake directly into continuous filament. Gneuss will also unveil the SFXmagnus series of filters designed for applications with lower contamination levels, where frequent backflushing cycles are not necessary. Also on show will be the SFpvc filter for PVC processing and recycling. Gneuss Multi Rotation System MRS130
• Germany-based STF Group will debut its STF-LS Label Scrapper, designed for dry removal of bottle labels. The machine offers 95% removal of labels and full body sleeves from PET bottles with minimal damage to the bottle and without loss of necks or caps. • Coperion K-Tron’s new micro-ingredient feeder line has been expanded to include interchangeable MT12mm and MT16mm twin screw feeding modules or MS12mm and MS16mm single screw feeder modules. Overall feed rate capacity is from 0.02 dm³/ hour to 27 dm³/ hour. Also exhibited will be the Smart Flow Meter that is used in polyolefin production, where the main component is accurately and gently fed into the extruder. It is said to provide high accuracy feeding, at very high feed rates of up to 200,000 dm³/hour), offers lower maintenance costs and reduced headroom. Another highlight will be the Quick Change Feeder that is specially designed for applications requiring the maximum possible materials handling and changeover flexibility. The single screw feeding elements handle free flowing powders, granules, pellets and other free flowing materials. The twin screw elements are ideal for floodable powders and Smart flow more difficult, sticky or meter from hard-to-flow materials. Coperion K-Tron
• Also from Germany is Reduction Engineering’s upgraded Series E6 pelletiser, with single-side rotor bearings, available in working widths from 100-300 mm for easy, tool-less entry into the cutting chamber. The strand inlet chute is redesigned, for better strand guidance and smooth geometry for minimal dust deposits while the pelletiser discharge duct, which had been bolded to the base plate of the cutting chamber, is now easily removable for cleaning. • Austrian MAS Maschinen will show the largest model of its conical twin-screw extruders with co-rotating screws, the MAS 93. It will also show the largest model of its MAS-disc melt filter, featuring a rotating filtration disc made of hardened steel. The firm’s focus is on extruders for processing materials with low bulk density and those that are sensitive to shear and heat, such as PET or PLA regrind. • Buss’s third generation Quantec G3 compounder for processing PVC into high grade pellets features further improvements including a bigger processing window and higher output. Key features are the longer process section, now extended to 14 L/D, and the larger intake zone diameter. Smooth transition to the smaller mixing/kneading zone diameter is facilitated by tapered liners according to specific product requirements. Furthermore, the outer screw to shaft diameter ratio has been increased to 1.62, increasing volume at constant speed. Patented
Extrusion/Converting/Compounding Machinery at the K2013 Buss’s latest generation Quantec
lag time) cuts the connection to the screw in the event of a malfunction. The new drive system includes a variable three-phase motor. It can use a water cooling system, which is quieter than air cooling. It also uses JSW’s latest 64-bit RISC EXANET control system, featuring a 15” colour LCD touchscreen. It can also integrate auxiliary equipment from the feeding and mixing system downstream to the pelletising plant’s strand cutter.
screw flights feature optimised freeform surface geometry for a constant shear gap between the flights and kneading pins allowing for gentle kneading and mixing. • Automatik Plastics Machinery will display its Duro 2000 for drying of abrasive and sensitive compounds. The belt dryer is used primarily in underwater pelletising and is said to gently dry glass fibrereinforced products or high-fill mineral compounds to residual pellet moisture levels of less than 0.1%, with minimal dust. It is suitable for frequent product changes because it is quick and easy to clean with significantly lower operating costs because the design of its pelletcontacting components produces little wear. • Japanese firm JSW will be presenting the TEX 44 Alpha III co-rotating twin screw extruder for compounding, masterbatch production, devolatilising and underwater pelletising. The 36% higher torque is the key factor in the design of the new extruder, resulting from a new gear box, gears and bearings, allowing for a higher output on a smaller footprint. A mechanical torque limiter (no lead/
re:*the right o f e b t s be l a matter of l y * it´s a ilm Technolog Blown F
Hosokawa Alpine Blown Film Technology: - Blown film lines with up to 9 layers. - Patented X-dies for first-class film quality and shortest purging times. - MDO monoaxial film orientation lines.
Visit us at
K 2013 Düsseldorf hall 16, booth D06 HOSOKAWA ALPINE Aktiengesellschaft 86199 Augsburg, Germany firstname.lastname@example.org www.hosokawa-alpine.com JSW’s Alpha extruder for compounding OCTOBER 2013
Compounds/Masterbatches/Additives at the K2013 Compounds • UK-based Victrex Polymer Solutions (VPS) is presenting its latest PEEK 90GL30BLK EU that meets the current requirements of both the American and the European regulatory authorities, including the EU Commission Regulation10/2011 (Plastics Implementation Measure, PIM), which will be fully implemented by end 2015. Meanwhile, PEEK 90HMF40 was recently qualified by Airbus, permitting weight savings of up to 40% versus aluminium. In automotive construction, components made of WGT polymers with optimised slip/friction properties extend the service life and raise the efficiency of electric pumps, for example. Victrex’s PAEK is used in various applications including metal replacement
• US-headquartered Teknor Apex is restructuring its TPEs to serve as a single source of multiple compounds for European processors in the automotive, medical, consumer products and wire and cable industries. It wlll produce compounds spanning the entire range at its plants in Belgium and the UK. Included are many Teknor Apex TPEs developed in the US and previously unavailable in Europe. For example, the Sarlink brand once consisted exclusively of thermoplastic vulcanisate (TPV) compounds but has been expanded to include styrenic and olefinic blends, until now produced only in the US.
For automotive window sealing applications, Teknor Apex can supply Sarlink TPV or styrenic TPE compounds
• Swedish Hexpol TPE group will display its Lifocork flexible polymer compounds, which combine natural cork with thermoplastic raw materials, and a range of its Mediprene TPEs engineered to address the demands of medical device applications including IV systems, syringe plunger seals, tubing, face masks and medical packaging. • Dutch firm Polyscope, a producer of styrene maleic anhydride (SMA) copolymers, has added terpolymers consisting of styrene, maleic anhydride and N-phenylmaleimide, under the XIRAN IZ brand. Two new grades, XIRAN IZ1018M and XIRAN IZ0721M, were developed to meet the need for styrenic engineering plastics with high temperature resistance and low volatile residuals. The new grades exhibit a glass transition temperature (Tg) of 175˚C and can be exposed to higher processing temperatures with miscibility in ABS. Polyscope has upgraded its polymerisation process at its Netherlands facility to engineer the terpolymers. Also on show at its booth will be a large thermoplastic sunroof frame for the Citroen DS3 Cabrio, utilising XIRAN compounds to offer dimensional accuracy, low warpage, adhesion and a low density.
XIRAN thermoplastic sunroof frames for serial production of the Citroen DS3 Cabrio to be shown at Polyscope's booth
• US TPU specialist Huntsman will highlight its non-halogen Irogran A95 P 5003 material for the wire and cable industry. With a limited oxygen index (LOI) of more than 30, the product is said to exceed the performance of many competitor products. In the past, achieving a high LOI meant using halogenated additives. It can be processed using standard manufacturing equipment and is ideally suited to the creation of jackets for control cables, fibre optic cables, power system cables and leads for consumer devices,
Compounds/Masterbatches/Additives at the K2013 Huntsman will spotlight halogenfree cabling material
and minimal waste to improve production efficiency. Flexibility is achieved through easily interchangeable dosing pumps, transfer pumps and packaging types. New and improved packaging cassettes and pump connectors enable quick, spill-free product changeovers. When used in conjunction with ColorMatrix packaging, FlexCart reportedly delivers product recovery rates of up to 99%, reducing material waste.
such as mobile phones, computers and digital cameras.
• UK-based ColorMatrix, a subsidiary of PolyOne Corporation and supplier of liquid colour and additives, has launched the FlexCart proprietary liquid dosing system. It allows for clean and spill-free operation, enhanced metering accuracy
PREMIUM PREMIUM CORRUGATOR TECHNOLOGY
Masterbatch/Additives/Pigments • German supplier of antioxidants, light stabilisers and pigments BASF is the only supplier to have production and R&D sites in Asia, Europe, North America and the Middle East. The firm is also a world leader in CSBs, Customer Specific Blends, which represent pre-packaged blends of additives tailored to meet the individual needs of local customers. BASF has established the only global manufacturing footprint for CSBs in line with antioxidant production. This is why one of BASF's most recent investments has been set up for CSBs in Bahrain. It is based on patented technology in which BASF has invested a two-digit million euro amount, and with a capacity of 16,000 tonnes, it is one of the largest in the world. The firm is mainly producing CSBs based on extruded Irganox antioxidants for use in PE and PP. Meanwhile, its antioxidant production site in Singapore, a key site for the Asian market, is currently being expanded to produce Irganox 1010 in various product forms in the second half of 2013. This product sets the standard for low-volatility and low-discolouration phenolic antioxidants for a wide range of applications. Overall, BASF is investing several hundred million euros in expanding its additive production and R&D sites over the next five years.
Visit us at booth 16 D59
3 mm i.d. to 90 mm o.d.
the corrugator experts
» Medium 32 mm i.d. to 800 mm o.d.
200 mm i.d. to 2400 mm o.d.
Compounds/Masterbatches/Additives at the K2013 • German supplier Eckart will showcase Silvershine for a metallic/steel look to automotive parts, with 30% lower production costs. The aluminiumbased pigments reportedly have improved optical properties, hiding power and a distinctive flop. It will also introduce Energysave pigment, which absorbs less sunlight, reflecting up to 60% of solar radiation, for outdoor applications; Lasersafe for environmentally friendly laser marking, replacing heavy metal-based pigments, and Symic micabased pearlescent pigments for use in cosmetic packaging. • Swiss speciality chemicals firm Clariant will launch AddWorks, a new branding for its additives with Addworks ATR for automotive, or Addworks ELC for E&E. Furthermore, its montan waxes, such as Licomont NaV 101 and CaV 102, are said to significantly reduce cycle times and provide improved release and flow properties for moulded nylons and polyesters. Other products include phosphinate flame retardants with new tailor made synergistic formulations. These include Exolit OP 1400 for polyamides with special requirements and Exolit OP 1260 for polyesters. Clariant has also enhanced its liquid masterbatches with a new integrated system designed to enhance product properties and process parameters globally.
Clariant’s Addworks ELC for E&E will further contribute to expanding the features of engineering plastics in terms of polymer protection, process stabilisation, productivity improvement or energy savings
• UK maker of white, black and colour additives masterbatch Silvergate Plastics is developing a facility at its headquarters in North Wales with new equipment for small, specialist orders of multicomponent masterbatch and an increase in capacity of over 1,000 tonnes. Silvergate anticipates more than 40% growth in sales by the end of 2015. • Swiss calcium carbonate specialist Omya will introduce additions to its Omyacarb and Omyafilm ranges, specifically targeted at the packaging sector and for a variety of new applications, including film extrusion, caps and closures, sheet extrusion and extrusion coating. It will also showcase its direct addition technology for PVC extrusion applications, which involves directly adding calcium carbonate
at the extruder feed throat for a higher calcium carbonate content, higher operational flexibility and a more stable process, compared to standard dry blend mixing. Various products in the Hydrocarb range for vinyl extrusion for the building and construction industries will also be on show. • Huntsman will showcase its new ALTIRIS titanium dioxide-based infrared reflecting pigment. When mixed with coloured pigments the result is higher solar reflectance in dark and vibrant polymers. Benefits include tailored solar reflectance from a single additive and in almost any colour, which was not available before from the ALTIRIS pigment. • South Korean supplier Songwon will highlight its Hindered Amine Light Stabilisers (HALS), which will be supplied globally in cooperation with Italybased Sabo. In China, a joint venture with Tangshan Baifu Chemical is now capable of delivering 8,000 tonnes of Songnox Thioester Antioxidants, which are widely used in PE, PP, ABS, HIPS, polyester and polyamide, as well as other materials. Songnox OPS (One Pack Systems) is also growing strong. OPS combine a range of additives into a dust-free pellet form and for assurance to the compounding process, reducing quality control, eliminating over/ under-dosing as well as enabling a cleaner working environment. In 2012, Songwon invested in OPS technology in Greiz, Germany, and Houston, US. It will also start up an additional 7,000 tonnes in Kizad, Abu Dhabi, early in 2014. With REACH and other global environmental regulation initiatives becoming stricter and the replacement of Butyltin compounds accelerating, especially in the European market, Songwon is proactively reducing its DBTO (Di-n-Butyltin Oxide) capacity. However, to ensure that it can provide products that meet customers’ needs without compromising its environmental stewardship, it has embarked on a programme to expand DOTO (Dioctyl Tin Oxide) in South Korea. This has resulted in increased sales of tin intermediates as Songwon foresees Butyltin compounds will be replaced by Octyltin compounds by 2015. • French supplier Imerys Talc will be highlighting its natural mineral-based micro-lamellar and high aspect ratio talcs. The new Mistrocell nucleating agents are for new polyolefin-based foam composites used to produce lightweight materials with improved stiffness at lower densities. These talcs promote uniform bubble distribution and growth, with reduced specific gravity and increased rigidity and strength of foamed products. CrysTalc is a new, high brightness, micro-lamellar talc development for homopolymer and copolymer PP. Used at addition rates as low as 0.5%, it optimises rigidity, impact strength, heat resistance, crystallisation temperature and haze as well as
Compounds/Masterbatches/Additives at the K2013 machine output by 10-15%. New Mistroblock talc is based on bright micro-lamellar talc and lowers blocking force and coefficient of friction in PE film production, while providing clarity and haze. • Swiss additives supplier Addivant will introduce powder-free additive solutions that deliver improved physical properties for increased production up-time, improved health and safety, reduced maintenance and higher throughput in a variety of extrusion applications. New solutions include Anox and Lowinox phenolic antioxidants; Alkanox, Weston and Ultranox phosphite antioxidants. Others are the Octamine and Naugard amines and thioesters; Anox and NDB blends; Lowlite light stabilisers; Polybond and Royaltuf polymer modifiers. • US-based Great Lakes Solutions, a Chemtura business, will present new flame retardant solutions. Emerald Innovation is a replacement for decabromodiphenyl oxide and decabromodiphenyl ethane and is used in applications such as consumer electronics, automotive, textile back coating and construction materials. It is designed to replace commonly used flame retardants in polyolefin and styrenic resin systems. The Emerald Innovation 3000 flame retardant offers producers of expanded polystyrene and extruded polystyrene (EPS and XPS) a choice in the transition from hexabromocyclododecane (HBCD). Chemtura’s Organometallic Specialties business will launch Axion MAO activator technology, used in the catalyst systems of advanced elastomer production. It plans to further expand and debottleneck to meet growing demand. • UK firm Colloids will introduce the Pace series for engineering plastics that has been extended to include masterbatch based on solvent black (nigrosine) and/or carbon black, as well as formulations offering improvements in frictional properties or heat stabilisation. It has also enhanced its range of special effects for film, augmenting the colour palettes developed on a seasonal basis and doubled the grades of leadfree light and colour fast film, available in a wide spectrum of opacity level and approved for EU food contact applications. Furthermore, the firm recently invested EUR1 million in a new twinscrew extrusion line featuring high torque and high volume extrusion, multiple loss-in weight feeders and underwater strand pelletising (particularly suited to high temperature crystalline polymers). • US firm Emerald Performance Materials will spotlight its K-Flex non-phthalate plasticisers, based on advanced dibenzoate chemistry, with wear toughness, increased line speeds and fast fusion when compared to BBP, traditional
dibenzoate blends and other phthalates. Another growing platform is the Good-Rite line of speciality phenolic and aminic antioxidants for polyolefins, PU, PS systems and rubber, with Emerald’s predecessor company, B.F. Goodrich, having patented a non-discolouring additive in 1972. Emerald has continued to develop it to offer improved protection against high temperature degradation, light stability and resistance to water extraction. Biobased Solutions • Dutch supplier DSM has combined its expertise in nylons with Ravago Group’s recycling to develop a portfolio of glass reinforced recycled PA6 compounds. The materials will be offered by DSM and distributed by Ravago Group member Resinex, which already supplies DSM’s engineering plastics. The Akulon PAs contain more than 50% post-consumer resin from well-identified and dependable sources. DSM is supplying grades with 30% and 35% glass fibre reinforcement, suitable for automotive under-the-bonnet applications such as air intake manifolds and engine covers, as well as furniture applications, including structural parts in office chairs. • Colloids will introduce the biobased Sustain line, available in either universal or polymer-specific (polyamide, polyethylene and polyesters including PLA) masterbatch. The range is fully recyclable and will not impact on the quality if mixed with fossil-derived polymers of the same type, unlike biodegradable polymers. • Malaysia-headquartered Emery Oleochemicals, a natural-based chemicals producer, has set up the Eco-Friendly Polyols (EP) business unit to tap opportunities in the global polyol industry. It offers sustainable polyol solutions for use in the manufacturing of flexible and rigid polyurethane foam for transportation, construction, packaging, furniture and bedding, and many CASE (coatings, adhesives, sealants and elastomers) applications. Solutions include the EMEROX Renewable Polyols, made from renewable resources, and InfiGreen Recycle Polyols, made from recycled polyurethane scrap foam.The firm is also investing US$50 million in its Cincinnati facility expansion in the US to cater to the demand. • Imerys Talc’s Mistroblock talc is also targeted at biopolymer film production. The firm’s Steamic, Jetfine and HAR ranges make ideal reinforcing fillers and nucleating agents in renewable bioplastics. These ultra fine grades increase biopolymer stiffness and temperature resistance allowing their use for more demanding rigid applications such as durable packaging and automotive parts. OCTOBER 2013
The art of manufacturing rollsurface mould components Gary A. Jacobsen President/ Chief Engineer of Jacobsen Lenticular Tool & Cylinder Engraving Technologies Company (JacoTech) of Itasca, Illinois, US, says the firm provides scientific solutions for the development and production of opticallybased cylindrical polymer/ plastic materials processing, including the manufacturing of micro-structured opticalquality roll-surface mould components used for the management and control of light.
The engraved units can be relatively small to unusually large and heavy
he focus of JacoTech’s custom optical micro-machining business is the ultra-precision CNC diamond turning, milling, and fly-cutting of cylindrical drums, rolls and mandrels used to extrude/emboss/cast or calendar plastic and polymer-based sheet and roll films and materials. The engraved units can be relatively small to unusually large (1,060 mm outer diameter by 4,500 mm wide) and heavy weight (2,300 kg). These optical-grade engraved cylinder processing moulds can contain simple to complex geometrical patterns designed to perform a number of complicated light management control functions. Using its custom-designed, precision large-scaled diamond turning equipment, JacoTech engraves complex optical patterns into materials such as copper, aluminium, electrolytic and electroless nickel alloys, beryllium copper, brass, gold and more. JacoTech’s diamond-machined geometries can include plano, spherical, parabolic, general aspheric, toroidal, hyperbolic, elliptical, cylindrical shapes and more. Special custom JacoTech cylindrical diamond engraving machining features can also include concave (sunken) or convex (raised) optical lens structures (one example: three-sided microsized cubic corner pyramids); in addition to angular, skewed, and circular patterns (one example: radial Fresnel lens), and many more. A typical drum during the engraving process where the engraved portion is shown beyond the mirror-surfaced portion of the drum yet to be engraved
Best results from proper designs To obtain the best results from a wellmanufactured cylindrically-engraved mould, a proper optical lens design is required to enable optically-based sheet films and materials to perform optimally for a client’s chosen resin and final end product. JacoTech offers complete optical engineering and lens design services for lenticular lenses and other complex micro-structured plastic optical lenses, as well as lens system optimisation, diamond tool designing and full metrology. For over a decade, the company has concentrated on improving the industry’s quality of 3D-animated/motion lenticular, produced by rotary web and sheet fed, via: offset, flexo, gravure, letterpress print processes and for digitally-imaged display products used by lenticular speciality printers. In order to accomplish this, an improvement over prior optical lens designs, diamond tooling and lenticular engraved cylinder mould processing were required to meet the everincreasing requirements of world-class producers of extruded lenticular sheets. An example of such an improvement is JacoTech’s ability to provide superior, ultra-low surface-waviness lenticular lens in its engraved cylinder moulds as compared to standard manufactured engraved cylinders. A second example is customised shaping of the lenticular lens surface profile, which creates much sharper, clearer, lower crosstalk, and greater apparent depth 3D-animated/motion lenticular printed/imaged products.
Advertorial Moulds for non-imaging applications JacoTech also produces cylindrical moulds for nonimaging applications. Fabrication of these direct machined moulds is intricate and time consuming. The plastic processing industry continues to seek improvement in lowering its manufacturing costs and improving profit margins for high-volume plastic/polymer produced products such as retroreflective vehicle license plates and road/traffic signage using three-sided cornercube prismatic reflective materials. JacoTech created a unique method of direct engraving precision corner cubic pyramids into cylinders that can be used to create prismatic materials in web roll form at near full processing line speeds. The material manufacturing cost saving of using recent new advanced prismatic web roll production vs. prior art of costly and slow injection moulding and similar one-by-one piece production methods can be dramatically impressive. Representative engraving is shown here where the lands between the grooves are razor sharp, although the size of the lands can be sized as desired by the client
JacoTech’s products are highly competitive and arguably set the quality and performance standard for these types of moulds. Such highly specialised custom engraved cylinders require essentially defect-free engraving in materials that yield a long life cycle. The cost of the mould is not the dominant cost element for customers when compared to the entire processing cost that occurs downstream in facilities. For over a decade, company owner, chief engineer and CEO, Dr Gary A. Jacobsen and his optical colleague, Dr R Barry Johnson, have worked together closely with a variety of technology experts to elevate the myriad of manufacturing and processing technologies necessary to achieve the finest quality optical engraved cylindrical drums, made available for global wide market use. This includes new diamond tooling shapes and structures, new hybrid CNC micro-diamond machine turning/milling/fly-cutting techniques, and creation of JacoTech’s own custom specifications for optical based copper and nickel/alloy plating to enhance achievement of the critical precision necessary for optical engraved patterns. Once all the new unique elements were brought together, they were tested and approved for use by a US-based extrusion leader in lenticular sheet and roll production. As a result of the R&D efforts, several US patents have been granted and issued, and are practiced today, in addition to being used with closely guarded trade secrets. Today, JacoTech ships custom opticallybased engraved cylinders around the globe for application
in many different industries. These significant efforts and investments have resulted in the achievement of world-class quality and market acceptance by companies throughout the world. For those interested in learning more about recent advances in lenticular technology, suggested readings are: R. Barry Johnson and Gary A. Jacobsen, “Advances in Lenticular Lens Arrays for Visual Display,” Proc. SPIE, Vol. 5874, DOI: 10.1117/12.618082; “Current Developments in Lens Design and Optical Engineering VI”, Pantazis Z. Mouroulis; Warren Smith; R. Barry Johnson, Editors, 587408 (2005). For competition reasons and to gain more market share, JacoTech customers seek to offer their plastic processed sheet and roll products to their end customers at the best possible price. In today’s environment, clients pay close attention to the dynamic changes in raw resin prices, and often then the lenticular extruders ask JacoTech for new optical lens designs and engraved cylinders for process modification. Today, as example, many extruders are moving away from using PET and towards selecting lower-priced resins such as PVC or PP. JacoTech’s manufacturing facility is located in the suburban Chicago area with close proximity to Chicago O’Hare International Airport. The 22,000 sq ft facility is a secured closed shop, to do highly specialised and confidential projects that the company produces for government and high profile US and global corporate accounts. Since we are not a volume based production company, but a one-part-at-a-time custom mould producer, our capacity output is not a problem. Having several custom large size and weight capable diamond turning/milling/fly-cutting machining centres enables JacoTech adequate back up and production machine time to meet customer schedule requirements. To enable "value added" offers to our customers, we continually push the envelope to the limits of technology and pattern designs by way of our own internal testing with live production utilising small-scale JacoTech test engraving cylinders. This continual R&D development lets us keep up with the ever changing demands of international standards compliance for optical based light management matters. JacoTech is continually evolving and expanding yearto-year as a consequence of new emerging optically-based plastics market opportunities. Since JacoTech is proactive rather than being reactive, it has plans for machinery enhancements and custom machine additions; including a new advanced roll plating facility; and added plans for additional international sales offices to help better serve the speciality optical plastic processing industries. A four-sided pyramidal structure (1.25 mm height) made by JacoTech OCTOBER 2013
Organic and printed electronics
Organic/printed circuits revolutionising microelectronics With suitable molecular configuration, plastic materials can be used as electrical conductors and semiconductors (albeit with still limited mobility of the charge carriers), to serve as system components of “organic” and “printed” electronics. Innovations will also be on show at the Printed Electronics Products and Solutions Pavilion at K2013, in Düsseldorf, Germany.
lastics with modifiable material properties, dimensionally stable as thermoplastics, thermosets or elastomers, films or coatings, granular or expanded, are an indispensable part of our everyday lives – in anything from simple items of daily life to intricately designed structural elements in vehicles and buildings. Plastics’ structural diversity is now being augmented by a further dimension: with suitable molecular configuration, they can also be used as electrical conductors and semiconductors (albeit with still limited mobility of the charge carriers). They thus serve as system components of “organic” and “printed” electronics. “Organic” because their transistors, sensors and LEDS are not based on silicone or gallium arsenide, but on carbon derivatives. And “printed” because two-dimensional circuit patterns can be printed “from the reel” with structural fineness of just a few tens of micrometres onto flexible and also transparent substrates by using conventional mass printing processes (flexo, screen-printing, inkjet). Integration in objects This yields electronically or photonically functionalised surfaces, threedimensionally on all conceivable objects and even textiles. They form capacitive touch sensors, large-area luminous fields with OLEDs (organic light-emitting diodes), sensors and detectors for environmentally or medically important data such as temperature and humidity. They operate as organic solar cells. Or as flat, printed batteries for miniaturised devices. This facilitates new, exotic applications in “smart” objects and their networking in the “Internet of Things”. The latest (fifth) edition of the Roadmap of the OE-A (Organic and Printed Electronics Association), a work group of VDMA (German Engineering Federation) with over 220 members worldwide, illustrates the state of progress and trends in organic electronics for a ten-year period. OLED screens and displays, the first mass market The small OLED displays in mobile phones and smartphones have already developed into a mass market. As a result, sales with organic electronics came to roughly US$9 billion last year. This has been forecast to develop into a global annual market of US$200 billion by 2025. Colour-intensive and high-contrast OLED screens for 55 in. televisions are already available (e.g., from Samsung and LG), although they currently cost US$10,000.
Flat batteries (Ni metal hydride) printed on film from the reel
Flexible displays for e-readers The e-readers from Amazon and Sony with “electronic paper” from E-Ink enjoy widespread popularity because of the energyefficient, bi-stable principle of their electrophoretic displays. They are essentially ideal for presenting static content such as book pages. The next development step will bring forth lighter, flexible and maybe even roll-up e-readers and tablets without the heavy cover glass. The most progress here has been made by British company Plastic Logic (founded by researchers from the Cavendish Laboratory at UK’s Cambridge University) that produces backplanes of organic thin film transistors (OTFT), i.e. the active matrix for individual pixel control.
Organic and printed electronics Flexible electrophoretic colour display for e-readers and tablets with a backplane of organic thin film transistors (OTFT)
The latest milestone along the way is a thin, easily flexible e-paper display with a 10.7 in. diagonal and with a resolution of 150 dpi (dots per inch) it comprises a matrix of 1280 x 960 TFTs, i.e. a total of 1.2 million pixels. In the organic sensor field, Plastic Logic in its cooperation with ISORG in France, an enterprise hived off from the large CEA-LITEN research complex in Grenoble, also clearly leads the field. The two of them recently unveiled a 4 x 4 cm image sensor with 8930 pixels on a thin plastics substrate. What is still hampering the development of organic photovoltaics and display technology is their hermetic encapsulation to provide protection from atmospheric water vapour that corrodes their electrodes and shortens their service life. So far, such encapsulation has only been possible with rigid cover glass. The solution for freely contourable solar cells and flexible displays is laminated barrier films, for which transparent layers of amorphous silicone dioxide appear to be very well suited. These are being collaboratively researched and developed at various locations including at the Fraunhofer Polymer Surface Alliance (Polo) and at the Japanese National Institute of Advanced Industrial Science and Technology (AIST). Application driving forces The driving forces in the development of applications can be found in the automotive, pharmaceutical, consumer electronics and “smart” packages for foods, medicines and other consumer items. With inexpensive printed, radio-frequency identification (RFID) tags, smart packages are capable of making merchandise management more efficient and, with dynamically updated display fields, of informing the consumer of the best-before date, drawing attention to gaps in the cooling chain for sensitive goods and guaranteeing the authenticity of high-grade articles by establishing links to traceable supply chains. Another current development includes some premium class cars that are already fitted with printed antennas as well as printed sensors for seat occupancy integrated in the seat covers to trigger the airbags as necessary. They also detect the weight in order to distinguish children from adults. OLED displays for reversing cameras instead of the traditional mirrors are also included in the cars’ equipment, as are the illumination of the instrument clusters on the dashboard and barely visible printed window de-icers. Next in line are organic displays and touch sensors in premium class cars as replacements for mechanical
indicators and switches. Then there are reversing lights with OLEDs, among other things at Audi, so that today’s LED lights can be replaced to save energy.
Smart package for medicine with a smartphone-readable data memory
OLED lighting, organic photovoltaics and batteries Of the four large fields of applications, OLED lighting, organic photovoltaics, electrophoretic (e-paper) and OLED displays, and electronic components as a complement to classical silicone-based microelectronics – the OLED light sources are competing with established LEDs and halogen lamps. They promise dynamically colour-controllable light emitted uniformly over a large area and can be attached in architecturally attractive ways to the surfaces even of familiar objects in the home. Organic photovoltaics (OPVs), developing in parallel with hybrid alternatives made of titanium oxide and dyesensitised solar cells and with purely organic (polymerbased cells), are already commercially available as local supply sources for mobile data and consumer devices. However, because of their relatively low efficiency, they are not intended for feeding power into the public grids, but as local supply sources (energy harvesting) and charging the batteries of mobile data and consumer devices and measuring stations. The long-term prospects include applications in the envelopes of vehicles and buildings (BIPVs or building-integrated photovoltaics). Available as system components are printed data memories – in the form of the ferroelectric, non-volatile memory films of Norwegian manufacturer Thinfilm. These can be combined with a transistor logic produced at contract researcher PARC in California to yield softwareaddressable memory modules. With a printed thermistor as a temperature sensor and a display field together with a printed battery, they can be extended into a complete measuring system. Printed, slim and flexible batteries are also a focus of system integration. At present, the market is dominated by single-use zinc-carbon batteries, while rechargeable, lithiumbased equivalents are still undergoing development. As an alternative, energy-rich supercapacitors are available for the temporary supply of power to devices. Their discharge behaviour comes close to that of batteries. Such power supplies can be integrated with display and luminous fields, touch sensors and solar cells in packages, textiles and other consumer items, elevating them to new levels of value and functionality. OCTOBER 2013
Injection Moulding Asia Technology at the K2013
Screw/barrel technology • US - b a se d N o rd s on Xaloy h a s i n n o v a t ed the first c o m pl e t e l y “c ool-to-thet o u c h ” h e a t i ng system f o r i n j e c t i o n barrels and m e l t p i p e s . The SmartHeat c o a t i n g c o n s ists of two l a y e r s o f p l asma-sprayed m e t a l l i se d c eram ic with a n i c h r o me w ire wrap sa n dw i c h e d in between a n d a t h e r mal in s ulation c o ve r . T h e sy s tem allows f o r h i g h e r t em p eratures , u n i f o r m i t y and lower e n e r g y u s e , compared to b a n d h e a t e r s. The thermal i n s u l a t i o n w rap over t h e c e r a m i c coating also e l i m i n a t e s h eat losses w h i l e t h e w irin g is ru n u n de r n e a t h t he th erm al i n su l a t i o n , t hus allowing f o r s a f e t y . When compared w i t h a n i n j e c tion p res s u s i n g c o n v e ntional band h e a t i n g , t h e Sm artH eat b r i n g s t h e f our zones to t h e sa m e t e mp eratu re w i t h i n 1 5 minutes , wh ile t h e s t a r t - u p with the band h e a t e r s t a k e s 23 minutes, s a y s t h e m a nufacturer. It a l s o c l a i m s 30-60% higher e f f i c i e n c y a nd can be used f o r p r o c e s s t emperatures u p t o 4 0 0 ° C . It is available w i t h n e w b a rrels or c an be retrofitted.
SmartHeat technology from Nordson Xaloy installed on an injection moulding line, with thermal insulation (green) and the strapping
M e a n h w i l e , i t s new X220 inlay for b arrels is an alloy of iron, boron, and chromium, with a content t h a t i s said to be 40% greater than a standard alloy w idely used in Europe. In acid immersion t est s, t he fi rm says the alloy exhibited a 46% improvement over t he European standard material in terms of sample weight loss in sulphuric acid, and a 31% improvement wit h hydrochloric acid. It, thus, has improved corrosion resistance, increased productivity, and enhanced c onsist ency of part s.
Hot Runners/Tooling • Canadian firm Mo ld-Master s will showcase t he product ion of HDPE closures, wit h an EVOH barrier in the centre, in a 16-cavity closure mould, Iris co-injection hot runner, an E-Multi secondary inject ion unit and E-Drive servodriven valve gate c ont rol, all int eg rat ed int o a sing le cont rol unit . I MD from Swit zerland will b e p roviding t est ing equipment that has the ability to detect the thickness and lo cat ions of clear b arriers in t he part s produced. This w ill b e supplement ed wit h IMDvist a INOX downst ream equipment for cooling , s o rt ing and pack ing of t he parts.
Mold-Masters, which celebrates its 50th anniversary, will showcase the Iris co-injection hot runner, with an E-Multi injection unit and E-Drive servodriven valve gate
• Iris t echnolog y w i l l a l so be shown mouldin g a t h i n w a l l cat food cont ainer a t S t o r k Plastics Machin e ry bo ot h , wit h a mould fr om V a n Den Br ink. Co- i n j e c t i o n eliminat es t he need t o use a multi-layer th e r m o f o r m e d structure with t i e l a y e r s a n d glues, thus allo w i n g f o r n o web scrap. Simul t a n eo us injection of a 3- 6 % b a r r i e r in each cavity i s a c h i e v e d wit h b alanced fi l l i n g. • Swit zerland-b ased K i s t l e r Gr o up has a ne w f i rmw a re upg rade V 2.4 for i t s CoMo injection p r o c e s s monit oring sy st em. Fea t ures include automa t i c m o u l d recog nit ion t hro ugh aut omat ic loadin g o f mould data dur i n g m o u l d chang es plus t h e M ul t i Fl ow automatic hot r u n n e r balancing funct i o n n o w allows finer cont rol of nozzle t ip t empera t ures. • G erman Zahora n s k y F o r m enbau will s h o w c a s e the new TIM Li g h t s y s t e m , describ ed as “t he l i t t l e brother” of its T I M ( T o t a l Int eg rat ed Man uf a c t uri n g) cub e mould con c ept . I t is touted as a lo w e r - c o s t version wit h t w o mo ul d halves and a ce n t r a l r o t a r y cub e, allowing t w o d i f f eren t part s t o b e made o n a si n gl e mould using co m m o n h o t runner adapter a n d e j e c t o r plat es. The sy stem i s l ess complex and re q u i r e s n o tie-bar extensio n , a l l o w i n g the use of stand a r d machines. • HR Sf lo w of It a l y w i l l sh o w the electrically a c t u a t e d h o t runner valve ga t e F L E X f l o w , which is t arg et e d a t l a rge Class A aut omo t i v e pa rt s and offers comp l e t e l y independent ma n a g e m e n t of each valve p i n ’ s p o s i t i o n , accelerat ion, vel o c i t y a n d
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Injection Moulding Asia st r o k e . P i n pos ition c an be set with accuracy of 0.01 mm, and the system can be monitored remotely via WiFi. • Canadian MHS-Mold Hotrunner Solutions’s Rheo-Pro VA4010 Black Box pneumatic valve-gate actuator is said to be an economical alternative to electric valve gates for clean rooms. It operates without elastomer seals or lubricants, delivering continuous operation at temperatures of 450°C, with the ability to mould high-temperature resins like PEEK, LCP, PSU, PEI, and PPS. • Foboha of Germany will display what it says is the first cube system with an all-electric drive on all its axes, from the ejector to the turning unit to parts removal. It will be running on a Ferromatik Milacron machine with an 8 x 8 mould producing a two-piece cap. • German mould components maker Hasco is introducing Z 57 and Z 571 support pillars for larger mould bases, a new thermal insulating sheet, components with DLC (diamond-like coating), new cooling hoses and couplings, and refined mounting tolerances for location elements. • Braunform from Germany will show a 96-cavity cleanroom mould with a 5-second cycle moulding a needle holder using German firm Hekuma’s automation and an Engel all-electric press. With core diameters of 0.3 mm and 0.5 mm, the modular tool has individually
centered modules and externally accessible demounting. The mould also features direct side gating with a hot runner system from Heitec, and uses conformal cooling to achieve short cycles, with vacuum brazing. • Another Braunform mould will run on a Ferromatik Milacron machine. The four-cavity mould’s hot half is used to produce two containers: the 1-ml Adapplicator as well as the 2-ml Adapplicator in a 9-second cycle. The modular construction means that the cavity plate nozzle side and the complete ejector side can be changed while the hot half remains in the machine. It also allows for replacing the mould inserts on the nozzle side. • Canadian firm StackTeck will feature capabilities for In-Mould Closing (IMC) of flip-top closures, to fold the part over a living hinge and close the flip-top part before releasing it from the mould. Key developments have focused on using multiple, separate motions of the closing arms, while optimising the control of closing force, for hig h c avity moulds. • Glarof o r m from Switz erland will show a two -cavit y mould for th inwall (11 g ) oval 500 m l food cont ainers in a fas t cy cle. Swiss firm Bec k Auto m atio n will add IML to the cell, ap p ly ing lab els in less th an 3 seconds using a s id e-ent ry rob ot . The tou c hscreen-cont rolled cell is supplemented by a vis ion inspect ion sy st em.
Injection Moulding Asia c orrosion inhib it or t o prevent sedimentation and p art icle cont aminat ion; use of part ial insert s and t he use of parallel cooling to improve cooling .
Camera inspection from Omron integrated by Beck Automation in the IML
T h e o t h e r pa rtn ers in th e sy st e m a r e E rn s t H. Fu rrer ( “ f r e e c o o l i ng” tec hnology), Vi a ppi a ni Printing from Italy (labels based on a 60 micron EUP orange peel film made by Treofan) and BFA Solutions (PiSolutions software). A camera inspection system from Omron is used for quality control of the manufactured containers. • G e r m a n t o o l m aker H o f m a nn T o ol M a nuf a c t ur i n g supplied 3 K t o o l s w i t h conformal c o o l i n g , a n ew c onc ep t i n t o o l ma k i ng, to iron m a k e r R o w e n ta (of the SEB G r o up) rec ently. It a l l o w s f o r l e ss assembly w o r k , b e t t e r functional i n t e g r a t i o n , better p arts q u a l i t y , a sh o rter c yc le tim e a n d l o w e r u nit costs. Other p l u s p o i n t s of conformal c o o l i n g a r e t h e us e of a
Dual reversing plate tool with iron handles from Hofmann
• A patented automation system for filter separation and assembly of medical pipette tips will be shown by Hekuma, with the assembly process reduced to just 5 seconds. The system can be scaled up to 96 pipettes per cycle or 1,100/minute, while comparable systems only render about 500/minute, the company says. The high performance is due to the compact footprint. • German Waldorf Technik will also present a compact Vario TIP system for pipette tips and blood-test tubes at the booth of Sumitomo (SHI) Demag. The 64-cavity system boasts “a world record-breaking cycle time of just 4.5 seconds” while reducing floor space by 50-75%. Operating costs are reduced since compressed air is eliminated, with the parts collected by a patented gripper and placed in a storage unit. Plus, the Vario TIP also avoids damaging parts by impact with the storage rack.
• Wittmann’s DRYMAX Aton2 is a further development of its segmented wheel dryer with thermal energy re-feed via the 3-Save Process. It takes only what’s needed from regeneration energy to dry the molecular sieve in the wheel’s segments. The firm will also present a complete drying battery that consists of a Drymax central dryer and Silmax drying hoppers with a capacity of 900 l. The hoppers come with SmartFlow activated air control flaps. Also making its debut is the MC 33 granulator for in-line recycling of sprues/runners and PET preforms, with capacity of 100-150 kg/hour.
• Austrian firm Wittmann has developed the W842 robot for machines of up to 800 tonnes. It features a rack and pinion drive for the vertical axis allowing it to handle 25 kg payload. The length of the horizontal axis can be up to a length of about 20 m. The robot can also be fitted with servo rotational axes, spare I/Omodules and vacuum and gripper circuits.
• US measuring/t e s t i n g equipment firm In s t ron will b e showcasi n g t h e new melt flow t e s t e r CEAST MF30 w i t h m a n u a l mass select or, a C E A S T 9050 pendulum i m p a c t tester and a CE A S T 9 3 5 0 drop weight tes t e r . I t will also show t h e n e w Aut oX750 Aut oma t i c Cont act ing Ext en somet er, the TrendTracke r software packag e f o r
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Injection Moulding Asia Bl u e h i l l S o f t w are, an d a n a u t o m a t e d carousel s y s t e m f o r t ensile testing t h a t f e a t u r e s a h igh pr e c i si o n meas uring sy st e m f o r determ in ing spe c i m e n t h ic knes s .
Moulding machinery • MHS-Mold Hotrunner Solutions’s new M3 micromoulding machine is able to produce runnerless parts in a 32-cavity cycle with shot weights under 10 mg and in 5 seconds (150 million micro parts/ year). The all-electric, cleanroom system has a tiebarless magnetic clamp of 4 tonnes, which is a new type of clamping that uses embedded magnets. It also uses a patented injection system and non-traditional tooling consisting of four modular inserts, each with eight microcavities, thus allowing the moulding of eight different parts in each cycle. • Cyprus-based machine maker Cypet Technologies says its two all-electric single-stage PET processing machine models allow PET processors to produce any size of PET bottles up to 20 l and any size of PET jar up to 145 mm neck diameter, which it touts as a “world’s first”. The process was originally implemented using servo-hydraulic injection technology, with three machine models covering all sizes of PET bottles and jars. Now Cypet’s new all-electric machines will complement the three servo-hydraulic machine models.
• Fanuc R o bo m achine Deutschland will exhibit three electric Roboshot machines. A 100-t onne R oboshot S-2000i-100B w ill produce PP closure c aps for sy ring es in a 48-cavity medical mould in 8.1 seconds. Together w it h Otto Männer of Germany, it will show a tw o-component applicat ion on t he Rob oshot S-2000i150B, which has b een enhanced wit h a duo-män bo lt -on unit as a second injection system, mounted directly to the mould half of t he nozzle side. Using t he eig ht -cavit y 2K mould b y Schneider , two-colour felt -t ip pen caps will be produced in PP in a 17-second c ycle and deposit ed b y a handling unit. The third machine will produce four c omponent s of connect ors in PBT, wit h a shot w eig ht of 22 g and cy cle time of 12 seconds. Part removal is handled by a three-axes linear robot by s yst ems part ner Hi Tech Auto m atio n. • Japan Steel Works (JSW) and it s European s a les part ner Windsor Kunststo f f techno lo g ie will present two machines. The 140-tonne J140AD will mould a t echnical hollow
JSW’s J140AD machine will demonstrate the moulding of PP hollow profiles
part in PP in a c yc l e time of 60 secon d s . T w o geometrically d i f f e r i n g parts will be mo u l d e d simultaneously i n v a r y i n g cavit ies of t he moul d , part s assemb led a n d overmoulded w i t h P P , i n a sing le operat ion . T h e 3 5 0 t onne J350AD w i l l pro d uc e a transparent P P c o n t a i n e r with a weight o f 4 0 0 g i n 17 seconds, faster by 3 0 %. • G erman supplier P ri a mu s has developed a n ew volt ag e module w h i c h measures t he ana l o gue machine sig nals i n t h e cont rol cab inet of t h e moulding mach i n e . Here, t he analo gue signals are conv e r t e d into digital sign a l s a n d finally connecte d w i t h t he BlueLine de v i c es t hroug h a sing l e h ybri d b us cab le. Thus, pressure and t emperat ur e a mpl i f i ers or machine int e rf a c es for process cont ro l c a n b e complement e d a n d desig ned in any ord er. The device is ga l v a n i c a l l y isolated and als o d e s i g n e d to provide the r e q u i r e d supply voltage f o r independent sen so rs suc h as pressure tran s m i t t e r s . In case of confi n e d s p a c e s , the device can a l s o b e mounted outsid e t h e control cabinet i n a s e a l e d housing . • G erman clamping syst ems mak er R ö m held w i l l present new ma gn et i c rapid-clamping s y s t e m s , a force sensor w i t h connected smar t p h o n e a n d tablet PC as we l l a s a n e w cont rol unit for ma gn et i c clamping plates t h a t conforms to saf e t y f a c t o r s . A new tool-chan g i n g c a r t wit h aut omat ic d oc ki n g function will al s o b e o n show.
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Injection Moulding Asia Automotive
Moretto provides a complete system to IAC IAC Group, a global supplier for the automotive
and emptying, with a constant medium speed that increases the pump performance and the granule quantity. It is said to operate just like the cruise control mechanism in a car, which maintains constant speed, even when the car is going on a slope. Kruise Kontrol offsets possible inefficiencies as it checks each material’s cycle and when the suction unit is empty. At the same time, it reports either the need to clean the filters or a possible loss of vacuum, indicating where the loss is. Kruise Kontrol provides a solution for the feeding of different materials through a unique pipeline. The conventional method would be to base the dimensions of the feeding line on the most difficult material and to envisage the worst case scenario, but it is not possible to guarantee quality. Kruise Kontrol can be described as a “real gentleman for polymers”, since it invites the granule on board and carries it to its destination with the highest comfort.
sector, set up a new production site in Bals, Romania. Partners for this project were Germany-based machine supplier KraussMaffei that installed several injection moulding machines (500/600-tonne CX series and 650-tonne MX series) and Italian auxiliary equipment supplier Moretto that supplied all the equipment for storing, feeding, drying, material dosing as well as the integrated supervisory system.
Making it easy for operators or material supply/feeding, Moretto installed large external silos and pipelines, while for material storage it installed the OKTOMATIK integrated system, which is an automated emptying station. With the OKTOMATIK, the complete octabin is turned over by an automated lifting mechanism into a collection storage bin, with controlled storage filling of 12 tonnes/ hour of material. The handling of the octabins is undertaken by lift trucks (assisted or not) and the work phases are indicated by dedicated signalling. Moreover, a special barcode-recognition system, besides driving the operator during the managing sequence, prevents mistakes from occurring during the loading. Furthermore, the equipment, especially that in contact with glass fibres, is made of a sturdy material. Thus, stainless steel anti-wear bends as opposed to glass bends are utilised. Also the pipelines are assembled with TRILOCK fixing systems that give a perfect fit and avoid material stagnation and dust in the clefts.
Manifold plate Dolphin oretto has installed its automated manifold plate Dolphin to distribute the stored material to the respective injection moulding machines. This manifold plate stands out for its exclusive arm mechanism. The positioning speed is 1 second for both the arms at the material and mould side.
The automated Dolphin distributes materials to respective machines
Instead of motorised rotation, it uses a pneumatically-driven mechanism, which has been tested for a million cycles. Since it is a modular structure, it can be extended at the base without the need for any stoppages. Thanks to its seal rings, Dolphin assures a hermetic coupling of the arm, avoiding ambient air from contaminating dried materials and allowing for efficiency.
Material feeding with Kruise Kontrol recurring problem when feeding material through pipelines of varying lengths and when utilising soft materials like PP or PE is the formation of angel hairs. To solve this, material feeding is managed gently through a feeding pump controlled in frequency with Moretto’s Kruise Kontrol system. Based on respective specifications, each material is transported at its own feeding speed. The data is recorded in a centralised calculator. When the feeding has to travel over a long distance, the granules are carried through an empty and clean pipe. In a conventional pipe, the granule slows down and speeds up when it reaches the end. The inconsistent speed thus results in inefficiency. Moretto says its Kruise Kontrol automatically manages the three phases, flattening the speed peaks during filling
Optimal drying with OTX ne of the problems in a large plant is the correct sizing of a drying system. If it is too small, the high moisture level in the dried material could cause wastages. And if the drying system is too large it will not be energy efficient. Faced with this challenge, Moretto installed its OTX
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Injection Moulding Asia Automotive OTX installed on a mezzanine level
dosing units are placed directly on the injection moulding machine throat, thus saving floor space. This type of installation requires efficiency and precision during the dosing phase, and also needs to be vibration-free. Thus, Moretto installed the Gravix gravimetric dosing units that can dose up to four components, in a free-hanging load cell with digital process control. The dosing hoppers, with a patented eyelid discharge system, are said to be up to six times faster than conventional guillotine-slide gates and provide accurate dosing, with tolerances of about 0.001%. The airtight mixing cell prevents contact between polymers and ambient air, a vital point when dried materials are used, and also prevents dust from entering the machine.
(Original Thermal Exchanger) technology for drying hoppers. OTX has an internal geometry to solve material flow-down problems. The improved performance allows for 50% shorter drying time; 50% less process air and 50% reduced hopper volume. Plus, the payback of the system is 12 months. Furthermore, it uses a new stainless steel, shockresistant Spyro covering. The new air distribution technology combined with the internal section allows for improved temperature distribution, assuring a uniform and progressive thermal treatment of the granule inside the hopper. The modular X Max dryer produces the process air, assuring a constant airflow with a dewpoint of –65°C. The X Max is able to synchronise with the moulding process and thereby regulate the quantity of process air, taking into consideration the hourly production. Since the most amount of energy consumed in the drying system comes from the quantity of the process air to be heated, it saves on energy. Moreover, thanks to the modularity feature, it is possible to integrate other dryer modules with the existing assembly, thus avoiding costly investments. Integrated Drying system installed on a mezzanine level with the X Max is the Flowmatik automated system for air distribution. A dedicated measuring instrument for air consumption and two self-adjusting valves ensure that the correct amount of airflow goes to the granules being treated. Thus, all the parameters given by the polymer supplier are able to be complied with, preventing over drying or polymer degradation and controlling increases in viscosity. Regarding the preparation of the formulation, the
Installation of gravimetric dosing units
Finally, to allow an effective control of the systems, Moretto installed its Mowis supervisory system. Material management, material feeding with variable speed, drying and dosing are accessible by a PC. “It is not necessary for users to have particular skills because the Windows-based graphical user interface details the plant layout and, with object interfaces and texts, shows the actual conditions in the plant.” In cases of emergencies, remote control is possible via an optional Ethernet-based network. Furthermore, with the Windows-based Mowis, it is possible to connect to other applications such as ERP and management production systems. It also assures a simple management of all the data from the Moretto equipment or the other equipment in the plant. Though realised in a short period of time, the IAC project is still a work in progress. The next step involves the installation of six large tonnage injection moulding machines, equipped with the Mould Control identification system, with Infotouch touch screen panel control. The Mowis system, with the integrated process control module and RFID technology, controls all the functions, assuring a process without human error and a real time control. 6
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Rubber Journal Asia Industry News • French rubber injection moulding machinery maker REP International has acquired Watson Brown HSM in Berlin, Germany, its patented HSM devulcanisation technology as well as its devulcanisation centre. It is the seventh subsidiary of the REP group, the others being involved in the sales and after-sales of REP presses. REP also developed a technical and commercial partnership with Watson Brown to devulcanise rubber production scraps and reintroduce them into the production chain, which is the HSM process. REP is developing a devulcanisation machine for compounders and rubber processors, in addition to the existing devulcanisation service. • The United Steelworkers (USW) says that Cooper Tire and Rubber Co. cannot sell two of its factories in the US to India’s Apollo Tyres until a collective bargaining agreement is reached. The decision could delay Apollo’s plan to buy US-based Cooper in a debt-funded US$2.5 billion deal, which is already facing opposition at Cooper Chengshan Tire in China. Chengshan Group, the local partner in the joint venture, is also against the deal, and has filed a lawsuit against Cooper in a local court, seeking to dissolve the joint venture. • Germany-based online tyre trader Delticom is buying Berlin-based online tyre retailer Tirendo Holding and its subsidiaries for EUR50 million. Delticom set up ReifenDirekt.de, one of Germany’s first online tyre shops, in 2000. With more than 6 million customers in 42 countries and sales of EUR500 million/year, the company is the market leader in European online tyre sales. • Italian tyre retreading equipment maker Italmatic Group has formed a joint venture with
Tesco of America, an automotive and tyre industries firm, to focus on the distribution of Italmatic products in the US. • Industrial coatings firm Barrier Group has taken up a 49% stake in family-owned Aquaseal Rubber, which manufactures rubber coatings, tubes for road cleaning equipment and fenders for Remotely Operated Vehicles (ROVs), to assist the latter in business expansion and widen its market scope. • Swedish firm Trelleborg is acquiring the full manufacturing line for production and testing, patents, qualification and type approval for cryogenic hose systems from SBM Offshore, a leader in floating production and mooring systems. This will enable Trelleborg to accelerate and strengthen its offering in the supply of equipment for the growing floating liquefied natural gas (FLNG) market. Meanwhile, Trelleborg is also developing a cooling seawater suction hose system, also for the FLNG market, to be launched in 2014. • South Korean tyre company Hankook has officially opened its seventh global plant in Indonesia. Located in Lippo Cikarang, Bekasi, West Java, the plant will export 70% of its output to the US, Asia and Middle East markets, with a production capacity of up to 6 million passenger car tyres, Ultra-High Performance (UHP) tyres and light truck tyres. Hankook is also setting up its first plant in the US, its third largest market after China and Europe. The company controls 5% of the market for replacement tyres and 7-8% of originally equipped tyres in the US. It also plans to build a R&D centre in Sangju City, South Korea, with an investment of KRW240 million until 2020. Covering a total area of 132 ha, it will be the largest tyre proving
ground in the country to enable testing of UHP and truck and bus tyres. • Japanese supplier Toyoda Gosei has set up a new company in Mexico to produce fuel hoses and radiator hoses by February 2015, its third manufacturing base in the country. It will cater to Toyota in the US, Canada and Mexico, with expected sales of US$3.2 million for fiscal 2015. • US firm Tenneco, which manufactures clean air and ride performance products and systems for automotive and commercial OE vehicles, is closing its ride performance plant in Gijon, Spain, and in Sint-Truiden, Belgium, as the company continues to address the ongoing weak conditions in Europe. Both plants manufacture shock absorbers for vehicle manufacturers and the replacement market. The company also closed a facility in Vittaryd, Sweden, this August. These actions are part of Tenneco’s cost reduction initiative that is intended to reduce structural costs in Europe by US$60 million/ year with related costs of US$120 million. • Cabot Corporation and Risun Group have started up a US$140 million carbon black facility in Xingtai, China, with Cabot owning a 60% equity interest. Cabot brings its technology while Risun provides the feedstock and energy integration capabilities. The first phase will produce 130,000 tonnes/year of carbon black, increasing Cabot’s overall capacity in China by 25%. It will produce the firm’s Vulcan products for the tyre market. • South Korean tyre maker Kumho Tire will set up a US$200 million plant in the US state of Georgia. Kumho has also opened a new R&D centre in Seoul.
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Rubber Journal Asia Rubber at the K2013
The small k at the K2013 Once again the K2013 will have the Rubber Street, an initiative of German speciality chemicals firm Lanxess. It has been organised since 1983 with the aim of improving the presence of rubber at K and today it is the home of rubber and thermoplastic elastomers.
German rubber sector stable t a preview in July, Boris Engelhardt, Secretary-General of WDK, the German rubber industry association, said that he expects the German rubber industry to have a turnover of EUR12 million in 2013, roughly the same as last year. Nevertheless, the sector has had a slow start. “It was not so good in the first quarter due to the long winter, with lower sales of winter tyres and subsequently the sale of summer tyres were slow too. Furthermore, the automotive production in Europe is weak.” However, Engelhardt expects the general rubber goods sector to grow over Boris Engelhardt of WDK the next six months, adding expects the industry to be that “we are hoping for a stable this year better second half of the year.” He added that 75% of the sales of the industry are accounted for by the automotive/ tyre sectors, with Germany the top market for rubber products in Europe. The country accounts for 30% of the rubber goods sold in Europe, followed by France. Furthermore, he said that rubber at the K is “small but beautiful”, adding that kautschuk (German for rubber) is the small k in the K2013, but with a huge innovation potential.
Highlights at Elmet’s booth will be TOP3000 metering system in tandem arrangement as well as multi-cavity moulds for two-component UV-curing LSR and for the production of ultra-small parts (top right)
an injection-moulded multi-component part in a fully automated process in cooperation with Austrian machine maker Engel, using a mould supplied by Elmet. Traditionally, multicomponent designs utilising silicone rubbers were limited to the combination of heat stable resins such as PA or PBT due to the moulding temperatures that were required to vulcanise the silicone. Now, UV LSR can be combined with more affordable, lower melting point resins, such as PP or PMMA, to produce multi-material moulded products with hard-soft characteristics. With 35% of its sales turnover accounted for by silicones Wacker, the Munich-based chemical group, will introduce a majority of silicone elastomers. It will have 12 new products for seven different industries such as automotive, elastomers, healthcare, energy and mould making. It will launch three Elastosil products for the automotive sector. The Elastosil 416/70 high consistency silicone rubber is for turbocharged cooling hoses since it is able to cope with rising temperatures. The firm says, though hoses are made from EPDM, customers are changing over to silicones and hence it introduced this grade in response to more requests from customers. It has also broadened the spectrum in damping components, for reducing noise and vibrations in vehicles, with the launch of two new silicones (Elastosil R 752/30 and Elastosil R 752/70).
New material grades omentive Performance Materials is showcasing a totally new approach to hardsoft combinations with its newly developed UV-curing liquid silicone rubber (LSR), producing
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Rubber Journal Asia Rubber at the K2013 It will also showcase a coolant-resistant LSR (LR 3022/60), an addition curing rubber with improved sealing properties, since it retains a low compression set, even under long-term load in direct contact with coolants. It can be used in the manufacture of moulded seals for engine cooling circuits and fulfils automotive standards of car manufacturers regarding glycol resistance. Making its debut will be a new generation of silicones (Elastosil R781/80) with magnetic properties that can be used for household appliances such as refrigerators and baking moulds. The new Lumisil LR 7600 product range consists of LSR grades that cure to form highly transparent elastomers, targeted at lenses and other optical elements in lighting technology. In the environment friendly range, it is introducing tin-free catalyst (Elastosil Catalyst NEO) for condensation-curing silicone rubber grades that can be processed normally and possesses the same mechanical properties as compounds cured with standard catalysts.
with a new compounding step in polychloroprene production to extend the range of applications for this rubber. Two new product families, Baypren HP and GF, have been innovated. Baypren HP includes products with properties that are not yet available on the market, says the firm, while the polyethylene-vinyl acetate (EVM) Levapren materials under development include a grade for impact resistance modification of PLA. The business unit has also invested in Asia, with a 30,000-tonne/year nitrile rubber plant opened in Nantong, China, in May 2012 in conjunction with a partner. CNT compounding improved hein Chemie Rheinau, a wholly owned subsidiary of Lanxess, will showcase a dispersion process for the manufacture of CarboElast carbon nanotube (CNT) masterbatches for NBR. The dust-free CNTs are easier to incorporate into a compound than Rhein Chemie’s Rhenogran CNT powder, allowing for improved mechanical reinforcement. Due to the low CNT proportions in the vulcanisate, the shear modulus is subject to a 30% lower dynamic mechanical loss than vulcanisates with conventional fillers and a comparable level of reinforcement (modulus 100%). With CNT masterbatches, it is therefore possible to produce high-strength compounds with excellent elasticity. The project was undertaken as part of publicly funded Innovation Alliance for Carbon Nanotubes, which receives public funding from Germany’s Federal Ministry of Education and Research (BMBF), together with Freudenberg Forschungsdienste and the German Institute of Rubber Technology.
Fresh appeal of EPDM and NBR grades erman speciality chemicals firm Lanxess is looking to capture new market share worldwide with its Keltan EPDM elastomers. Innovative ACE technology plays a key role in this, producing EPDM without the use of chlorine in a high-purity process and with a composition that can be controlled with a degree of detail that has not been possible in the past. The process enables the manufacture of new EPDM rubber grades, such as oil-extended EPDM and special high molecular weight EPDM The firm is investing EUR235 million in the world’s largest EPDM plant at Changzhou in China, with a capacity of up to 160,000 tonnes/ year. Start of production is scheduled for 2015. China is the world’s largest market for EPDM, driven above all by automotive and construction industries. The new plant will produce ten premium grades of EPDM tailored to Chinese customer needs. EPDM is used above all in the automotive industry as door sealants, hoses, belts or anti-vibration parts. The product is also used in the plastics modification, cable and wire, construction and oil additives industries. Its properties include low density, good resistance to heat, oxidation, chemicals and weathering as well as good electrical insulation properties. Furthermore, the High Performance Elastomers business unit is pursuing the development of nitrile-butadiene rubber (NBR) grades and new Baymod powder NBR grades,
Rubber chemicals and additives hein Chemie is also reintroducing Rhenogran Geniplex-70 as a co-accelerator, crosslinking activator for sulphur vulcanisation and blowing agent. It is an effective coagent for crosslinking weight-reduced elastomer components for automotive applications. It is ideal for use in EPDM and standard types of rubber, such as NR, SBR and NBR. It can be used in both expanded and solid rubber compounds. Meanwhile, Rhenoblend is Rhein Chemie’s new line of oil-extended mixtures of transpolynorbornene, which is capable of absorbing up to ten times its own weight in plasticisers as well as large quantities of inorganic fillers. These two properties make Rhenoblend unique and enable conflicting characteristics – excellent
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Rubber Journal Asia Rubber at the K2013 damping and high strength – to be combined in a single elastomer component. Available in five grades, it can be used for anti-vibration and damping elements, tyre treads, automotive and applications. It can be used on its own or as a blend component to modify technical elastomer properties. Another new product from Rhein Chemie is the Addonyl additive for manufacturing/ modifying cast polyamide for lightweight construction technologies in the automotive sector.
Rubber processing presents enormous challenges day in day out for rubber and tyre manufacturers. Accordingly, Uth has updated the roll-ex extruder systems. Roll-ex gear extruders are used when frequent compound changes are involved or coloured materials used. They can be cleaned quickly and thoroughly on account of their unique design. The modular roll-ex system can be combined with a two-roll feeder (TRF), a screw feeder, or a conical twin-screw extruder. Outputs range from 70 kg/hour to 10,000 kg/ hour for standard applications, while customerspecific solutions can also be realised. Precision extrusion is another primary application of roll-ex gear extruders and gear pumps, where high operating pressures (up to 800 bars) can be applied. Uth can supply, among other things, system solutions involving complete lines for the manufacture of rubbercoated wire, yarn, or fibre components.
New machinery makes processing easy highlight at Austrian Elmet Elastomere, which makes metering systems for LSR and multi-cavity LSR moulds, will be a new generation TOP 3000 two-component metering system, now available in front-loading or side loading versions, to make best use of floor space. Redesigned controls are said to be easier to use and allow production data to be extracted via USB interface in a format compliant with the ISO/TS 16949 automotive quality standard. Elmet will also show two mould concepts, one for making UV-curing two-component parts at Momentive’s booth, and the other for moulding of ultra-small parts measuring less than 2 mm and weighing under 1 mg with dimensional tolerances in the range of 10 microns at machine maker LWB’s booths. Elmet says it has overcome the drawbacks associated with processing two-component plastics and LSR. Since the curing reaction with these materials is triggered by cold light sources instead of high temperatures, there is no need to rely on high-melting (and hence, costly) thermoplastics any longer. Moreover, the use of rugged LED lamps helps to extend the mould life. Uth GmbH from Germany will present its roll-ex fine-mesh straining systems and extrusion systems. A highlight is the latest model from the roll-ex series, allowing for fine-mesh straining of rubber compounds in mixing lines with outputs of up to 10,000 kg/hour.
Rubber injection moulding erman supplier Desma will showcase the S3 series. New are the EcoSilence temperature control units, which reportedly save as much as 50% energy when used together with the EnergyControl software. Desma also offers the FlowControl cold runner systems.
Desma will showcase its new S3 machine
Another focus is set on process automation and it developed the MoVis mould surface scanner at the last K2010. The effective optimisation and control of machines and processes is being demonstrated with the extended Propter software controls. Jointly with RheinChemie, Desma will also present the BlendIn method, a concept for the continuous production of rubber compounds.
Uth’s Roll-ex DSE
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Rubber Journal Asia Rubber at the K2013 French rubber injection moulding machinery maker REP International will focus on its new generation G10 machine, featuring a new ergonomic design, with embedded intelligent wireless 3G technology to simplify remote diagnosis without going through the customer network and predictive maintenance. REP will also exhibit its flagship CMS, a compact multi-station injection machine, the economical RT9 range and the compression moulding machines of its Taiwanese partner Tung Yu. Another novelty to be presented in DĂźsseldorf is the HSM devulcanisation, which devulcanises rubber scraps. The patented HSM process applies to any kind of uncontaminated rubber production waste. Controlling the strain applied to the compound by the HSM machine causes the rubber to The V710 of the latest G10 series be devulcanised by to be shown by REP preserving properties that are said to be close to the virgin compound. This is a 100% thermo-mechanical process that does not require any chemical additives and is undertaken at a low temperature, to prevent the characteristics of the devulcanised rubber from being altered. REP has also acquired Watson Brown HSM in Berlin, its HSM devulcanisation technology as well as its devulcanisation centre. This centre is equipped with an operational devulcanisation line and a test laboratory operated by a team of six persons. REP says it will carry on with the development of the HSM technology and promote devulcanisation machines and service on the international market to compounders and processors. Watson Brown HSM is the seventh subsidiary of the REP group, the others being involved in the sales and after-sales of REP presses throughout the world.
Carousel is purported to offer zero defect production of O-rings
Carousel process chain for the production of O-rings and seals. It uses a FIFO injection moulding machine MHF700/300XL from Maplan Austria and a 4x54-fold mould from the Italian mould maker ORP Stampi with four-drop cold runner technology. A focus is the cold runner systems with direct gating of cavities to save material and optimise processes. The fournozzle cold runner mould (Cold Runner Block) is designed with open nozzles, quick opening device, temperature control and regulators for volume flow control. Maplanâ&#x20AC;&#x2122;s MHF series machine is used in the Carousel system The four nozzles fill each pad (containing 54 cavities) with an elastomer, allowing for an output of 216 seals/cycle. Compounder Mesgo supplied the orange NBR 65Sh A sealing material. Each part has a weight of about 0.25 g. The total shot weight of the four pads amounts to 420 g. Meanwhile, another partner GiBiTre instruments is tasked to plan the entire production process and to create production related work equipment for measurements and tests. From Gamma Stampi comes the punching machine for separating parts while the final inspection is carried out by devices from UTPVision, a manufacturer of ] intelligent inspection equipment. The task is two-fold: testing quality of parts and sorting out faulty parts. The inspection consists of an optical test installation. It checks the dimensional accuracy of the seals, surface finish and injection deviation.
Efficient solution for processing n elastomer engineering, processors demand efficient system solutions. Hence, six partner companies from Austria and Italy will display the
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Rubber Journal Asia Synthetic Polymers and Latex
New applications and developments to spur growth Synthetic polymers and latex have been widely used in an array of applications such as packaging and coatings, construction materials, consumer electronics, medical equipment and agriculture. The recently staged Latex and Synthetic Polymer Dispersions conference, held in Kuala Lumpur, Malaysia, highlighted development studies and innovations for a modestly growing sector that is banking on demand, according to Angelica Buan.
S research firm Kline & Company expects the synthetic latex polymers industry to grow by 10% this year. Based on its study, the European Union (EU) is the second largest consumer after the US, and in 2011, the combined consumption of the 27 states in the EU was close to 2.5 million dry tonnes of latex polymers, valued at over EUR6 billion. It adds that polymer dispersion consumption in Eastern Europe, Russia, and Turkey is significantly smaller than the major EU states, yet these regions show potential for growth. Demand will be spurred by applications for paper, paints and coatings as well as adhesives and sealants. Nonetheless, growth rates differ and in general, growth will be moderate over the next few years, says the Kline report.
Applications for paper, paints and coatings as well as adhesives and sealants will drive the demand for polymer and latex dispersions
Compliance with the REACH initiative has resulted in various modifications in the use of substances covered by the regulation. For instance, in Europe, water-based paints are replacing solventbased paints in the market, thus boosting favourable demand for synthetic latex polymers.
REACH a driving force hile in some cases, stringent regulations serve as obstacles for development, such is Latching on to advancements for future growth not the case with the implementation of Europeâ&#x20AC;&#x2122;s pplications for polymer dispersions and REACH (Registration, Evaluation, Authorisation and latices are varied. The water-based mixtures/ Restriction of Chemicals) programme for polymers. preparations are used as binder, primarily in paints, Also, the United Nations globally harmonised system surface coatings, adhesives, non-wovens, plasters (UN GHS) is used for classification and labelling of and carpet backing. They also find applications in chemicals in Europe. paper and textile sectors as The goal for the REACH â&#x20AC;&#x153;..the synthetic latex polymers finishing agents. initiative is to uplift and The 8th Smithers consolidate the knowledge industry will grow by 10% Rapra conference on Latex base of the European this year..â&#x20AC;? and Synthetic Polymer SME polymer industry, Dispersions, held in Kuala especially since the initiative Lumpur from 10-11 September, gave the 140+ encompasses application of novel techniques, delegates a broad picture of the industry. new technologies and innovative instruments Amongst the experts who shared technical and methods that offer environmental as well as insights on the various facets of the sector was economic advantages to the industry.
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Rubber Journal Asia Synthetic Polymers and Latex Professor Ho Chee Cheong, an adjunct professor at to produce rubber-like polyurethane from palm the University Tunku Abdul Rahman, Malaysia. He kernel oil. The innovation has been produced at described the scientific principles underlying latex UKM’s 500 kg/cycle-capacity pilot plant. dipping and the pre-requisites for a barrier device for She says that the rising cost of petrol in gloves, as part of his talk on the influence of surface Malaysia was one reason why the research phenomena on the latex dipping process for gloves. department was prompted to develop the He says that the essential part of gloves, which is alternative synthetic material from sustainable the latex (as the material), should be able to form a materials. And since palm oil is abundant in the continuous film and be resistant to any pathogens to country, her team utilised it for the project. Badri efficiently render a barrier device to the gloves. also said that the basic reactant, the palm-based “The material should be soft and conform to the ester, is already in a pre-commercialisation phase. contour of the hand,” he said, adding that it should Hardi Tamm of Estonia-based Korymbos, a also give a good working surface so that it can research and technology development company, provide the wearer with the necessary grip. touched on the allergenic potential of synthetic Ho emphasised the non-deformable requisite. “The latex gloves versus those dipped in natural rubber. material for the gloves must be mechanically strong Meanwhile, the use of gamma radiation enough for it to be stretched and elastic enough for it sterlisation from the onset of the glove making to return to its original shape,” he said. Furthermore, process, as a means of prevulcanisation, to the he said that the material should exhibit low surface end of the production process, was discussed by friction to enable the wearer’s hand to slide easily both Dr Rosamma Alex of the Rubber Research into the glove. An important aspect of Ho’s topic Institute of India (RRII) and Eric Beers of is that latex needs to be able to form a film, and Nordion, a Canadian company that provides thereby, the particles sterilisation of the latex must be “…..rising cost of petrol is prompting techniques. fused together to form a The versatility the development of alternative continuous film. of natural latex Another expert, Aik was demonstrated synthetic material from sustainable Hwee Eng of glove by Dr Azura A. maker Ansell, discussed Rashid of Universiti materials…” about the production of Sains Malaysia an antimicrobial glove via a modern dipping method. who explained how natural latex can be used for According to Joseph L. Keddie and Alexander cleaning compression moulds. Francis Routh in the paper titled “Fundamentals Innovative polymer synthesis in the of Latex Film Formation”, the processing of latex manufacture of latex dispersions was covered by film involves several steps “from dilution through Dr Joachim Storsberg, Head of the Department to concentrated dispersion into a packed array of Functional Medical Polymers of the German particles and eventually into a continuous polymer Fraunhofer Institute. In his presentation, he film.” The process is split into three steps: drying, explained that dispersions can be used to facilitate particle deformation and diffusion. modification of the surface properties of different The environmental side of the industry was materials. Furthermore, “synthesis and analysis covered by two presentations from the Malaysian are essential in respect to residues of reactive Rubber Board (MRB). Muhammad Syaarani reagents,” he said. Danya presented comparison works involving Sören Butz of synthetic latex emulsion resins complexometric titration (a form of volumetric maker Synthomer spoke about how more “clever” analysis in which the formation of a coloured chemistry could be used to tailor-make pressurecomplex is used to indicate the end point of a sensitive adhesives. titration) of magnesium content in field and Rounding up the presentations were David concentrated latices by using KCN (potassium Hill of David Hill and Associates who focused cyanide). He added that cyanide-free compound as on process validation of dipped condoms and masking agents can be used instead. gloves while Dr Bert Krutzer of Dutch polymers Also from MRB, Dr Devaraj Veerasamy maker Kraton provided a comparison between presented the use of ultrafiltration to process latex. the newest latex for dipping, polyisoprene latex, In a similar vein, Professor Khairah Haji Badri, with natural rubber. The conference ended with of the Universiti Kebangsaan Malaysia (UKM), RRII’s Dr Siby Varghese and Mahatma Gandhi showed how natural resources such as palm oil University’s Professor Sabu Thomas describing can be used to create useful polymers. She said the the latest advances and applications in the field of latest development in a pre-vulcanisation technique nanotechnology. 8 OCTOBER 2013
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SSELDORF THE K 2013 IN DU 16 –23, 2013, FROM OCTOBER 6B51 HA LL 6, BOOT H
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