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ISSN 2053-7182

November/December 2013

K2013: HIGHLIGHTS FROM THE BIG SHOW WOOD PLASTICS MOVE INTO NEW MARKETS DEVELOPMENTS IN MATERIALS HANDLING EUROPE: POLYMER DEMAND DATA FOR 2013


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contents PAGE 5

05 Industry news JM Eagle liable for damages in whistleblower case; Turkey’s Oyak acquires Chemson; Baerlocher expands in Turkey and USA; PVC-O ‘most sustainable’

11 Taking stock from

2013

Among the many innovations at K2013 were new pipe grades, recycling concepts and methods to make multi-layer products. Lou Reade reports PAGE 11

COVER PHOTO: MESSE DÜSSELDORF

23 Surviving in a slow market The global downturn and Eurozone crisis hit Europe’s economy hard. AMI’s Carole Kluth looks at what that meant for polymer demand in 2013, and what the future holds

PAGE 23

29 Mixing with the best Dosing, conveying and many other vital materials handling technologies were in huge evidence at the recent K2013 exhibition

35 Treading the boards

PAGE 35

Machinery and materials innovations are helping to propel wood-plastic composites (WPCs) into new markets. Lou Reade reports

41 Taking the heat Projects like the Pier 15 Exploratorium in San Francisco show the full advantage of PEX pipe. Lou Reade reports

45 Technology: Materials PAGE 41

46 Technology: Machinery 48 Extruder of the month: Reddiplex 50 Dates for your diary

coming next issue ❙ Engineering plastics & composites ❙ PVC stabilisers ❙ Indian market trends ❙ Screenchangers/melt filtration ➤ Click here to make sure you get your copy

contact us Applied Market Information Ltd AMI House, 45-47 Stokes Croft, Bristol, BS1 3QP, United Kingdom Tel:+44 (0)117 924 9442 Fax:+44 (0)117 989 2128 www.amiplastics.com

Head of business publishing: Editor: Senior editor: Designer: Advertisement manager:

Andy Beevers Lou Reade Chris Smith Nicola Crane Claire Bishop

E-mail: abe@amiplastics.com E-mail: lou@pipeandprofile.com E-mail: cs@amiplastics.com E-mail: claire@amimagazines.com Direct tel: +44 (0)20 8686 8139

© Copyright Applied Market Information. No part may be reproduced without the prior written permission of the publisher. www.pipeandprofile.com

November/December 2013 | PIPE & PROFILE EXTRUSION

3


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news

Agiplast to recycle Solvay PVDF

Jury finds JM Eagle liable in ‘whistleblower’ trial

Solvay Specialty Polymers

Plastic pipes manufacturer JM

questioning the validity of test

win up to 30% of the final

has teamed up with French

Eagle may be liable for billions

data. JM Eagle claims he was

payout.

engineering compounds

of dollars in damages, after a

dismissed for seeking

group Agiplast to develop a

jury decided that it deliberately

‘kickbacks’ from contractors.

range of recycled Solef

sold sub-standard products to

polyvinylidene fluoride

its customers.

Three US states and a

Part of JM Eagle’s appeal is likely to centre around test data – carried out on behalf of

number of city water authori-

the US Government – that

ties joined Hendrix as plaintiffs

exonerated the company’s

appeal the verdict. A new trial

in the case. A number of

pipe, yet was not presented to

from Solvay’s own produc-

will now begin to set the level

others – including several US

the jury.

tion processes and post-

of damages.

states and the US Government

(PVDF) resin formulations. Based on PVDF recycled

moulding scrap from

The company plans to

The case, first filed in 2006,

Before the jury retired to

– declined to get involved in

deliberate, JM Eagle’s former

customers, the new

has been tried in the District

the case, but may still be

parent company Formosa

Fluorloop grades allow

Court of Los Angeles over the

eligible for damages.

Plastics agreed to pay $22.5m

users of Solef PVDF resins

last two months. It was brought

to better manage processing

under the False Claims Act by

under ‘qui tam’ or ‘whistle-

legal fees.

waste and meet sustainabil-

former JM Eagle employee

blower’ legislation, which

● A longer report on the case

ity targets.

John Hendrix, who claimed he

allows private individuals to

will appear in the next issue of

❙ www.solvayspecialtypolymers.com ❙ www.agiplast.fr

was fired when he wrote a

sue companies on behalf of the

memo to senior managers

government. Hendrix stands to

Pipe & Profile Extrusion. ❙ www.jmeagle.com

The case was brought

in damages, plus $5.5m in

ECHA calls for DecaBDE input The European Chemicals Agency (ECHA) has issued a

retardants. The call for evidence is made

to be technically possible to substitute DecaBDE in most

needed to overcome obstacles. The deadline for submissions is 15 December and

call for evidence relating to the

as part of its preparation of an

plastics applications, but it is

substitution of decabromodi-

Annex XV restriction dossier.

not sure if challenges exist, or

details can be found at:

how much time would be

❙ http://bit.ly/ECHADec

phenylether (DecaBDE) flame

ECHA says it is understood

Turkey’s Oyak Group acquires Chemson Turkey’s Oyak Group has

integrated additives group with

acquired the Austrian-head-

clear world leadership in PVC

quartered polymer additives

stabilisers.

group Chemson from private

Chemson operates

equity firm Buy-Out Central

production sites in six

Europe II Beteiligungs-Invest.

locations in Europe, Asia and

Oyak, which posted sales of

the Americas, which together

US$15.5 billion in 2012, is one

have a total production

of the largest industrial

capacity of around 100,000

conglomerates in Turkey and is

tonnes a year. It offers a range

already active in the plastics

of PVC stabilizer packages for

market through its Akdeniz

applications such as pipes,

Kimya subsidiary. The company

profiles, cables and flooring.

Chemson is a leading supplier of PVC stabilizers for applications

says that the acquisition of

such as pipes

Chemson creates a backward-

❙ www.chemson.com ❙ www.oyak.com.tr

www.pipeandprofile.com

November/December 2013 | PIPE & PROFILE EXTRUSION

5


news

PVC-O leads the way in water piping A separate LCA study

concluded that PVC-O pipe

more than twice the energy to

are the most sustainable way

carried out by Edge Environ-

was “substantially the best

produce than PVC-O pipes. The

to deliver water, claims the

ment in 2009, commissioned

performer”.

force of gravity is also a major

PVC4Pipes industry group.

by the Plastics Industry Pipe

Oriented PVC (PVC-O) pipes

As well as the resistance to

environmental challenge: from

Steve Tan, spokesman for

Association (Pipa) of Australia,

corrosion of PVC-O pipes, Tan

truck to trench, their transpor-

PVC4Pipes, cites a recent study

compared identical functional

pointed to their much lighter

tation and handling leaves

by the independent Flemish

units of PVC-O with cement-

weight.

deep carbon footprints.”

Institute for Technological

lined ductile iron pipes and

Research (Vito). Commissioned by the European Plastic Pipes and Fittings Association (Teppfa), Vito carried out life

“Ductile iron pipes require

● Wavin Overseas commissioned four new PVC-O

Gold standard

extrusion lines in 2013 – including its first to Asia. The line was sold to Wavin

cycle assessment (LCA) from

PVC-O was honoured with the top prize at the recent SolVin

Duta Jaya (WDJ) in Indonesia.

cradle to grave of PVC-O pipes

Awards for innovation in PVC. Molecor of Spain took the gold

The other three lines, which

manufactured in two separate

prize for its work on advanced PVC-O pipe technologies,

can manufacture pipes up to

wall thicknesses (1.8mm and

extending the diameter and market potential of such pipes. Its

500mm diameter, were sold to

2.7mm). It confirmed that both

larger PVC-O pipe, which measures 630mm in diameter, is

North and South America.

had a very low environmental

50% larger than previous versions, opening up new market

impact over a lifespan of 100

opportunities.

years. Tan said that the findings

Since 2000, the company has supplied 19 PVC-O

The judging panel for the awards included Andy Beevers, editor of PPE’s sister magazine Compounding World.

extrusion lines around the world. Its BiAxial process

should encourage more water

make socketed PVC-O pipe via

companies to favour PVC-O

a continuous process. PVC-O pipes have twice the

pipe systems. “For any water pipeline

Molecor

installation, the price of pipe is

scooped the top

only about 10% of the full cost

prize in the

of installation,” he said. “Water

Solvin Awards

companies are aware that

for its PVC-O

PVC-O pipes outlive and

technology

outperform their heavy rivals.”

strength of regular PVC-U pipes, but can be produced with a 50% saving in raw materials, says Wavin.

❙ www.pvc4pipes.com ❙ www.wavinoverseas.com ❙ www.solvinaward.com

Baerlocher to produce PVC stabilisers in Turkey Germany’s Baerlocher has

also include a technical

American industry with the

commenced construction of a

applications laboratory.

development of highly

new manufacturing facility for

“We clearly recognise that

customised additive systems.

the production of PVC

speed of response is critical in

The company has also started

stabilisers at Ashikar in the

these dynamic markets and

up a new 35,000 tonnes/year

Manisar district of Turkey.

this new investment will

stearic acid production plant in

enable us to provide custom-

Americana, Brazil. It said that

plant is expected to commence

ers with choices which they

this investment will ensure the

operation at the end of 2014

desire,” said Baerlocher CEO

supply of fatty acids to the

and will produce both calcium

Arne Schulle.

Latin American markets as

The 40,000 tonnes/year

and lead-based one-pack

In addition, Baerlocher is to

well as meeting in-house

products. Baerlocher said the

install a new laboratory in the

requirements for the produc-

facility is completely focused

USA alongside its production

tion of PVC stabilisers and

Arne Schulle: “Speed of

on meeting the needs of local

plant in Cincinnati, Ohio. This

metallic stearates.

response is critical in these

customers and to that end will

facility will support the

❙ www.baerlocher.com

dynamic markets”

6

PIPE & PROFILE EXTRUSION | November/December 2013

www.pipeandprofile.com


show review | News

K2013 hailed a success The K2013 exhibition has been deemed a resounding success by plastics industry organisations. Held in Düsseldorf, Germany, on 16-23 October, the event attracted approximately 218,000 visitors, with 58% coming from abroad. Germany’s VDMA Plastics and Rubber Machinery Association said that its members enjoyed great feedback and excellent business contacts from visitors through the world. Its chairman, Ulrich Reifenhäuser, reported that “demand from China, South-East Asia and the USA was extremely positive”.

Thousands of people from around the world converged on Düsseldorf last month for K2013

Reifenhäuser, who is also also praised K 2013, saying

Middle East. India accounted

Advisory Board for K2013,

which represents Germany’s

that expectations were fully

for the biggest share of this

added: “We had not expected

polymer producers, was equally

met and that it predicts that

total, and the show’s organiser

visitors’ willingness to invest to

enthusiastic. Its chairman Josef

order levels within the sector

reported that the number of

be this high. Many customers

Ertl said: “For plastics produc-

to be positively impacted as a

visitors from China, Indonesia,

are extending their capacities

ers it is true to say that firms

result.

Iran, Japan and Taiwan all rose

and are investing in new

exhibiting here meet exactly the

technologies to sharpen their

right visitors – ones with

heidt, president and CEO of

global competitive edge. We

technical know-how, decision-

Messe Düsseldorf, the

totalled approximately 8,100,

very confidently anticipate

making powers and a willing-

organiser of the event, said:

which was 1,300 more than at

strong post-fair business and

ness to invest in the future.”

“Once again it becomes very

K 2010. Some 11,000 people

clear that K is and remains the

came from Latin America, with

most important event in the

Brazil, Mexico, Argentina and

rubber and plastics industry!

Colombia accounting for the

This is where new technologies

largest share.

chairman of the Exhibitors

expect continuing growth in our sector.”

PlasticsEurope Deutschland,

Representing Germany’s plastics processors, the GKV

Continued coverage Following our extensive previews of the K 2013 exhibition in our September and October issues, we are continuing coverage in

are premiered... and this is

considerably. Visitors from North America

The Netherlands accounted

also where orders are placed

for the biggest share of visitors

for these innovations.”

from European countries

Messe Düsseldorf’s initial

outside Germany, with a total

the November/December issue. Go to page 11 to see our

estimate of 218,000 visitors to

of around 8,000. It was

coverage of some of the highlights of the show. Separate to

K 2013 is 2% down on the final

followed by France, Belgium,

this, some of the sections this month, such as Materials

figure of 222,486 visitors to the

the UK and Italy. Messe

Handling, are exclusively devoted to innovations from the show.

previous K in 2010. The

Düsseldorf also reported a

number of exhibitors is up by

noticeable rise in interest from

visiting countless companies and attending numerous press

over 3.4%, from 3,094 in 2010

Poland, the Czech republic and

conferences, receptions, parties and awards ceremonies over

to more than 3,200 in 2013.

Hungary.

We had a very successful and enjoyable show ourselves,

the eight days. We reported news as it happened on our

8

Werner Matthias Dornsc-

It is estimated that 126,000

The dates for the next K

@PlasticsWorld Twitter feed to our 5,500+ followers.

visitors came from outside

show have been announced as

❙ www.amiplastics.com

Germany with around 30,000

19 to 26 October 2016.

coming from Asia and the

❙ www.k-online.de

PIPE & PROFILE EXTRUSION | November/December 2013

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K2013 |

show review

Among the many innovations at K2013 were new pipe grades, recycling concepts and methods to make multi-layer products. Lou Reade reports

Taking stock from K2013 Everybody who heads to K goes there for a different

molecular weight. This combination already has high

Teknor Apex

reason. Here, we fillet through the mountain of material

temperature resistance. The catalyst forces a butene

has introduced

from the show to find some of the innovations that will

co-monomer away from the lower fraction and towards

be of interest to extruders of pipe and profile.

the higher fraction – which improves the toughness.

a UV-resistant vinyl compound

The end result is a pipe that is tough enough to be

for outdoor

a broad range of new pipe material grades, ranging

used outdoors and can withstand temperatures up to

applications

from polyethylene right the way through to engineering

80˚C says Schramm.

Unsurprisingly, one of the highlights of the show was

plastics. Lyondell Basell has developed a new grade of

The material could be used to replace metal (which corrodes quickly), PVDF (which is 10 times more

material that claims to combine the high temperature

expensive) or cross-linked polyethylene (which is harder

benefits of PE-RT with the toughness of PE100 – allow-

to install).

ing the creation of outdoor pipes with greater temperature resistance. Hostalen CRP 100 RT black resin is derived from

such as tubing for algae farming

Potential uses include pipes for cooling power cables, removing industrial sewage waste or transferring fluid in biomass plants.

PE-RT type materials, but has sufficient sag resistance to make large diameter pipes. “We’ve brought PE-RT into the pressure pipe range,” said Detlef Schramm, marketing asset manager for pipe at the company. The key technology is the process catalyst, which creates a material with a combination of toughness and high temperature resistance. The material is made in three ‘fractions’, which have low, medium and high www.pipeandprofile.com

Water pipe breakthroughs Borealis introduced two new BorSafe products that exhibit higher resistance to chlorinated disinfectants. In some regions, the use of chlorinated disinfectants has been increased in an effort to guarantee the safety of drinking water, says Borealis. Pipes based on BorSafe ME3440-D and BorSafe HE3490-DS-H have shown in trials to last at least three November/December 2013 | PIPE & PROFILE EXTRUSION

11


show review | K2013

company. The materials are chemically modified PA610 and 612. Zytel RS LC 4000 is partially derived from non-food biomass. Both claim to offer high flexibility with minimal use of plasticiser for use in low-pressure hydraulic hose and low-pressure pneumatic/hydraulic tubing. Over time, the change in properties is negligible, even at temperatures up to 130°C. This is mainly because they also only use 5-7% plasticiser, compared to the incumbent materials that typically use 12-15%. Other benefits include low permeability, high yield stress/stiffness balance and a broad extrusion processing window, as well as a flexibility similar to PA12 but with better cold impact toughness. Molecor

times longer than conventional polyethylene (PE) pipes,

showcased its

it added.

Integrated Seal

The BorSafe family of PE pressure grades for

The materials have comparable (and sometimes superior) performance to PA11 and PA12 because of their modified polymer backbone. They are also suitable

System (ISS+),

infrastructure and pipe systems is based on the

for tie-layer-free adhesion to a variety of polymer

which allows

company’s Borstar bimodal technology. This gives them

classes including PA6, functionalised polyolefins and

PVC-O pipes to

robust mechanical properties that enable installation in

ethylene vinyl alcohol (EVA), so are suitable for multi-

be joined

difficult laying conditions.

layer constructions.

together

With one medium density (MD) PE80 – which is more

Enrico Simonato, marketing development consultant

adapted to small diameters – and one PE100, the two

at DuPont Performance Polymers, said: “The industrial

new grades cover the full range of pipe diameters.

hose and tube market is evolving with regard to

“The enhanced properties of these grades have been

customer demands, application demands and sustain-

developed at the request of our partners in the water

ability targets. The need to reduce weight, lower cost

distribution industry,” said Anton Wolfsberger, Borealis

and deliver performance are compounded by opera-

marketing manager for energy and infrastructure.

tional temperature increases – something that will start

The Kynar PVDF ‘E’ range of materials from Arkema is designed for potable water contact, and has been approved by KTW, the German agency for water and gas certification. A challenge for the industry is to select materials that have long service but do not release chemicals into the water. This range of materials has good processability and mechanical performance (with superior impact

to preclude the use of PA12 above 120°C.” DuPont is currently working to develop translucent versions of the grades. Celanese introduced its Hostaform PTX POM series of materials at K2013, which is used to make flexible pipes and tubes. “We developed the new series with a proprietary POM hybrid technology that improves the acetal copolymer coupling strength to modifiers and other

properties to equivalent PVDFs, says Arkema). The main Wacker’s

advantage is that Kynar uses no plasticiser, which

Elastosil R

lowers the amount of chemicals migrating into the

781/80 can

water. It also avoid the formation of a surface biofilm.

be easily

The range includes grades that can be processed by

magnetised

extrusion (for making pipes) and injection moulding (for fittings).

Fuelling innovation At the same time, DuPont Performance Polymers added two long chain polyamide (LCPA) grades for use in hoses and tubes. Zytel LC 7000 and Zytel RS LC 4000 both maintain impact strength at lower temperatures and offer better aging performance than PA11 or PA12, says the 12

PIPE & PROFILE EXTRUSION | November/December 2013

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show review | K2013

Teknor Apex introduced a rigid, UV-resistant vinyl compound for outdoor applications, such as tubing for algae farming and biofuel production. Apex RE 9118A is a transparent compound with less than 15% haze. The formulation reduces the harmful effects of ultraviolet radiation on the PVC while transmitting wavelengths that are essential in processes like algae farming. The tensile, flexural, and impact properties of the compound are comparable to those of standard general-purpose rigid vinyl, says Teknor Apex. “Rigid vinyl provides a superior cost-performance alternative to the glass piping used in ‘green energy’ applications, as well as to high-cost engineered Erema’s new

additives,” said Oliver Juenger, Hostaform POM product

thermoplastics such as polycarbonate,” said Michael

recycling

development at Celanese.

Renzi, business development manager for the com-

technology,

The series meets the fuel system requirements for

pany’s vinyl division. “Our compound withstands

called Intar-

flex fuels and highly aspirated engines. Celanese says

continued exposure to sunlight while allowing passage

ema, relies on

that the elastic mechanical properties of the range

of energy needed for bioprocessing.”

the company’s

provides an alternative to traditional thermoplastics –

patented

such as PA11 and PA12 – used in automotive fuel and

counter current

vapour lines, as it leaves no oligomer clogging sub-

technology

stance in the fuel. Grades in the series are suitable for both injection moulding and extrusion. They have similar mechanical characteristics to PA11 and PA12, with high toughness

The grade can also be used to make tough, high gloss weatherable profiles.

High profile But is wasn’t all about new pipe grades, as there were several new material for various types of profile. Bayer MaterialScience exhibited a window frame

and resilience. They are suitable for temperatures

made from polyurethane composite, which it claims is

between -40˚C to +65˚C, and have broad chemical

more energy efficient than those made from traditional

resistance and low moisture absorption.

materials such as metal, wood or PVC.

“We are excited with the opportunities, not just in

The composite, which comprises a polyurethane

automotive fuel and vapour lines but in pneumatics and

matrix filled with 80% glass fibre by weight, produces

paint line applications,” said Juenger.

profiles with high rigidity and dimensional stability.

Medical elastomer

insulation,” said Andreas Hoffmann, head of the project

Thermoplastic Biologic has chosen Versalloy HC, a

in the Europe, Middle East and Africa region. “It has low

“These composites are noted for their good thermal

medical grade thermoplastic elastomer from PolyOne, in its Pharm-A-Line peristaltic pump tubing. The material, made with Santoprene TPV thermoplastic vulcanisate from ExxonMobil Chemical, Two new Borsafe grades

“We developed Pharm-A-Line tubing with the objective of providing superior performance in peristal-

from Borealis

tic pump applictions, and Versalloy HC is critical in the

exhibit higher

outstanding results we’ve achieved,” said Robert

resistance to chlorinated disinfectants

Dupont, managing partner at Thermoplastic Biologic. “It helps us meet the most stringent cytotoxicity and extractability requirements for critical pharmaceutical process applications.” The material, certified under USP class VI and ISO 10993, combines the performance of thermosets with the processing advantages of thermoplastics to cut scrap rates and reduce energy use. It was found to withstand more than 1,000 hours of operation without detectable degradation.

14

PIPE & PROFILE EXTRUSION | November/December 2013

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Tecnomatic Srl | Bergamo | Italy | tel. +39 035 310375 | www.tecnomaticsrl.net


AMI’s 2013 INDIAN SUBCONTINENT PLASTICS INDUSTRY REPORT

What are the challenges faced by the plastics industry in the Indian sub-continent?

AMI’s 2013 INDIAN SUBCONTINENT PLASTICS INDUSTRY REPORT

2013 EDITION

LL/LDPE

Gilan

A complete market survey from Europe’s leading plastics industry consultants Figure 2.1: CAPACITY AND DEMAND FOR LL/LDPE IN THE INDIAN SUBCONTINENT 2007-2013

rapidly and consistently through the period 2007 to 2012, averaging growth of nearly 10% every year. Slower years were between 2010 and 2013 where the global recession, extended monsoon season and the eurozone crisis slightly curtailed growth. Generally, growth for LL/LDPE has been growing at 1.4 times that of the subcontinent’s GDP growth. 84% of the subcontinent’s demand is accounted for by India. LDPE is produced in dedicated plants whereas LLDPE can be produced in swing plants capable of producing both high density as well as linear grades. Swing plants in the region have tended to favour LLDPE grades however the ability to swing between grades makes calculating capacity problematic. All subcontinent LL/LDPE production comes from India. Production has been consistently lower than local demand and hence the region has become increasingly dependent on imports. In 2011 Indian imports were 625,000 tonnes but this increased to over 785,000 tonnes in 2012 (50% of demand). To cope with fast growth in demand there will be a number of new Indian plants coming on stream in 2013-2015. BCPL, % change Reliance, GAIL and OPaL will be investing in HD/LLDPE swing plants whilst Reliance Industries also plans a 400,000 tonnes/year LDPE plant as part of its USD12 billion capacity 2011-2012 2012-2013 investment programme. While capacity is expected to exceed regional demand by 2015 overall the subcontinent will continue to rely on imports although India is expected to become 10.0% 8.4% a net exporter before 2016.

Bangladesh

Demand for thermoplastics in Bangladesh 2011-2013

2011

2012

20131

LL/LDPE

67

74

80

HDPE

49

50

52

3.5%

PP

41

44

49

9.1%

PVC

32

34

35

4.4%

GP-HI PS

11

12

13

5.3%

EPS

5

6

6

1.9%

PET

41

47

53

15.6%

246

266

286

8.3%

ABS/ SAN

1

1

1

12.8%

11.4%

PBT

0

0

0

22.2%

15.2% 9.6%

Units: 000 Tonnes

3.2%

Table 2.1 SUPPLY/ 9.2%DEMAND FOR LL/ LDPE IN THE INDIAN SUBCONTINENT 2007-2013 2007

2008

2009

2010

2011

2012

20131

Capacity

595

620

635

910

1,020

1,020

1,130

Production

479

501

534

750

878

856

915

3.6% Demand

1,203

1,356

1,491

1,628

1,752

1,908

2,078

12.8%

9.9%

9.2%

7.6%

8.9%

8.9%

Units: 000 Tonnes 3.9%

6.3%

% demand 12.2%change 1

Sub-total commodity

Forecast

7.5%

PA

2

2

2

15.1%

PC

3

3

3

7.1%

6.7%

Acetals

0

0

0

10.0%

9.1%

PMMA

0

0

0

7.1%

6.7%

Sub-total engineering

6

6

7

10.9%

8.7%

252

273

293

8.4%

7.5%

TOTAL POLYMER DEMAND 1

Forecast

31

Click here to view sample pages or to order

A new statistical market survey reveals all END USE APPLICATIONS FOR THERMOPLASTICS IN BANGLADESH 2013 167

Included in this report: All commodity and engineering thermoplastics Analyses trends from 2007 up to 2017 Gives forecast through to 2017 Covers all Indian subcontinent countries Provides analysis by processing sectors Includes statistical data of country demand

APPLIED MARKET INFORMATION LTD.

Vital strategic market intelligence giving you the edge over your competitors.

www.ami-publishing.com


K2013 |

show review

thermal conductivity similar to that of wood or PVC.” The material is protected from the weather by a coating or a laminated film, which reduces the risk of rotting or embrittlement. The profiles are produced by pultrusion. At K2013, Wacker presented Elastosil R 781/80, a silicone rubber filled with tiny magnetic particles. The compounds can be magnetised in the presence of a strong magnetic or electromagnetic field. The compound can be used to make magnetic profiles that stick to flat and curved or rounded metallic surfaces. Such profiles could be used by kitchen appliance makers, who tend to equip their products with magnetic seals. These seals can be costly to make, especially as the magnets must be incorporated into the rubber gasket by hand. Profiles made of Elastosil R 781/80 would be easier and more efficient to produce, and would retain their elasticity and flexibility at low temperature.

Obo Bettermann, a German manufacturer of plastic security switches, began using Polysecure to tag its

BattenfeldCincinnati’s

products – to ensure that they would not be blamed in

new pipe dies

incorporate as many magnetic particles as possible into

the event of an electrical fire caused by a counterfeit

can be used to

the elastomer while maintaining physical properties.

product. Chemical analysis can be used to detect the

make to make

While the elastomer contains 70% magnetite by weight,

tagging compound in ashes, he says.

One challenge in developing this material was to

multi-layer PVC pipe

it has an 80 Shore A hardness.

Oriented performance Added security

Molecor, the Spanish producer of oriented PVC (PVC-O)

And, working across the spectrum of all plastics

pipes, showcased its Integrated Seal System (ISS+) at

products, German start-up company Polysecure has

K2013. The system allows PVC-O pipes to be joined

developed fluorescent ‘tagging’ molecules to prevent

together.

counterfeiting. The ceramic molecules are derived from rare earth

This is usually achieved by independent couplings for plain end pipes, or with a socketing system with a

metals – or, at least, the ‘south side’ of the periodic

sealing of flexible material that allows the end of the

table, according to the company’s Freddy Schleihs.

pipe to be introduced into the socket.

Polysecure will prepare a different molecule for each

Parameters that are considered for automated pipe

customer, meaning that each product is uniquely

socketing are based on moulding and gasket position-

tagged.

ing. The main issue for PVC-O is the molecular

The molecules are incorporated into the plastic – at

orientation ratio. The temperature control that is

a loading of around 0.02% – before it is converted into

necessary to prevent variations in size mean that

finished products. The molecule is stable up to very high

automated seal insertion for this kind of pipe is very

temperatures, and inert – so will not affect physical

difficult in normal operation.

properties.

Molecor’s ISS system manufactures socketed biaxial

‘We call it the “dead dog” in the mix,’ says Schleihs.

oriented pipes with automated integration of the gasket

The technology uses a quantum effect called the

– retaining the orientation degree in the critical areas of

anti-Stokes effect. When the molecules are illuminated with infrared light, electrons are promoted through two

the pipe. A reinforced rubber gasket is introduced inside the

energy states. When these electrons decay, they emit

pipe straight after orientation, retaining the high

light of a specific wavelength, which can be easily

mechanical properties of the PVC-O pipe – especially in

detected.

the socket.

Schleihs demonstrated this by shining a small laser

The ‘full dry’ system allows the conformation in the

pen onto two pieces of plastic: the one with the tagging

mould – during orientation – of almost any shape, says

molecule showed a fluorescent effect on the surface.

Molecor. An ‘open mouth’ shape is designed, ensuring

The tags can be identified with more rigorous testing

that the accurate amount of orientation at any point is

too, such as X-ray analysis or chemical analysis.

provided. Any gasket profile can be easily introduced –

www.pipeandprofile.com

November/December 2013 | PIPE & PROFILE EXTRUSION

17


show review | K2013

used to make highly complex pipe for the automotive sector. “Today’s fuel lines are five layers as standard,” said Roos.

Pipe dies The demand for multi-layer pipes is growing, he adds. The company regularly delivers lines to make five-layer pipe, and has a concrete order for a six-layer line. “New waste gas standards will continue to drive these developments,” he said. The new pipehead, in combination with a coextruder like the KME 30-30 BR, will be used to make products that meet the demands of the automotive sector, he said. “If we can make seven layer, that means we can KraussMaffei Berstorff’s

whether they are rigid gaskets or restraining systems. KraussMaffei Berstorff has developed the KME

KME 60-41 B/R

60-41 B/R, a single-screw extruder with an L/D ratio of

single-screw

41 for the production of PE and PP pipe.

extruder has

“It is aimed at performance-oriented customers who

easily make six or five,” he added. The system’s modular design has between two and seven radial distributors, with various spiral inflows. “We can achieve the lowest possible tolerances in the production of each layer,” said Roos. Meanwhile, Battenfeld-Cincinnati has developed two

an L/D ratio of

are very cost sensitive,” said Peter Roos, president of

41 for the

the company’s extrusion technology segment. “We have

new models of its Spider series of pipe dies, to make

production of

not just made an existing extruder longer: we changed

multi-layer PVC pipe.

PE and PP pipe

it completely to give the optimum solution in terms of process engineering.” The main element in the new design is the geometry of the screw and barrel. “It was not about having the screw run faster, but

recycled material – in order to reduce pipe cost or weight, says the company. The two new pipe die models, Spider 200-3 and

changing it in order to improve throughput and melt

Spider 400-3, are suitable for pipe dimensions ranging

quality,” he added.

from 32-110mm and 200-400mm respectively and

He said that the machine boasts a 10-15% higher output than competitive products, while running 10-20˚C lower temperature. The screw is designed to exploit the full length of the barrel for melting and homogenising the polymer. This reduces the amount of stress on the polymer, which

throughputs of 350 to 1,200kg/h. As well as high capacity, the dies have accurate layer thickness distribution with narrow tolerances and short dwell times, thanks to short flow paths and compact tooling design. The main benefit is the middle layer distributor,

maintins material properties. At the same time, and

which allows a whole spectrum of materials to be

improved combination of heating and cooling means

processed without adaptation. The dies give the

that the barrel dissipates heat more effectively.

flexibility for processing foamed compounds or

A filling opening, which has been modified to

compounds with filler content, as well as compounds

accommodate the higher througput, guarantees linear

with a high proportion of regrind. Having a modular

throughput development across the whole speed range,

design, they can quickly and easily be converted into a

says the company.

two-layer pipe die.

The series is available with 45, 60, 75, 90, 105 and 125mm screw diameters. “We have incorporated elements from our 36D

Battenfeld-Cincinnati offers the matching extruders for production of PVC foam-core pipes. Its TwinEx parallel twin-screw extruder series are commonly used to

series, and combined these elements with a new

process a wide range of middle layer materials, while

processing concept,” said Roos. “It offers increased

its ConEx conical twin-screw extruders are recom-

throughput while maintaining low melt temperature and

mended for outer layers.

high product quality.” The company has also developed a pipehead to make seven-layer pipe. The KM-7L-RKW 01-32 is likely to be 18

Manufacturers are increasingly turning to multilayer pipe – which have a middle layer of foam core or

PIPE & PROFILE EXTRUSION | November/December 2013

In addition, the company used K2013 to introduce the Helix-63-5 VSI five-layer pipe die, which can make pipes of up to 63mm diameter. In the near future, it plans to www.pipeandprofile.com


CREATIVE MINDS AND PVC REACHED NEW FRONTIERS

Inno

In


show review | K2013

to such an extent that the extruder screw acts in the same way as a sharp cutting edge which now cuts the plastic. This helps the extruder to process more material in a shorter time and is more independent in terms of the pre-compacting level of the material. The inverse tangential configuration of the counter current system ensures that the extruder screw is filled virtually pressure-free with pre-heated material. “The screw basically takes what it needs,” said Michael Heitzinger, chief technology officer at Erema. “The extruder always has the ideal filling level and is never overfilled, which makes it much better to regulate.” Results from development trials (in cooperation with customers) with in-house waste from 30 micron LLDPE blown film show the effect of the new system on the increased process stability, productivity and flexibility of The KM-7L-

expand the range to make pipes up to 125mm diameter.

RKW 01-32

The pipes, which include an EVA oxygen barrier layer,

pipehead from

are typically used in floor heating systems and are now

sensitive recycling process is essential to ensure

KraussMaffei

required in larger sizes.

recycling rates of 100 % high-quality recyclate in virgin

the Intarema plant. “Besides extremely easy operation, a stable and

Berstorff is

And Conextru, an Austrian engineering company

likely to be

that specialises in pipe and profile extrusion technology,

used to make

is planning to start selling pipeheads via the internet.

highly complex

Josef Dobrowsky, who leads the company, says that he

process steps to run completely automatically. Staff at

multi-layer

will start with three sizes: up to 63mm, up to 160mm

the machine can operate it very easily by pressing just a

pipe for the

and up to 250mm.

few buttons – without having to think about the

automotive sector

One recent project saw the company develop a monolayer pipehead to make telecoms pipes, with low internal friction. “This can be realised due to low friction inner layers

material grade, particularly when processing clean in-house waste from production,” said Heitzinger. The new Smart Start concept allows many central

operating language, because it is based on a few clear, easy-to-understand symbols. A further technical innovation is the EcoSave technology (fitted as standard) which enables users to

or with linear or spiral ribs inside the pipe,” said the

reduce energy consumption by 10%, cut CO2 emissions

company.

and lower production costs. The efficient direct drive on

Conextru developed a tool for this, based on a radial

the Intarema extruder screw can boost extruder

distributor, that has a rotatable mandrel, whose speed

efficiency by around 3%, while a practical energy display

can be adjusted. The radial die design makes the

gives a constant overview of energy consumption.

pipehead very short in length, giving high melt distribution.

Recycling innovation Intarema is the name of the new core recycling technology from Erema. It is based on the company’s patented counter current technology, which Erema says combines flexibility and higher productivity with lower energy consumption. Inside a cutter/compactor, the rotation of the rotor disc that is equipped with tools forms a rotating spout so that material circulates the whole time. In the counter current system this spout now moves against the direction of the extruder. As a result, the relative speed of the material in the intake zone – when passing from the cutter/compactor to the extruder – increases 20

PIPE & PROFILE EXTRUSION | November/December 2013

Click on the links for more information:

❙ www.lyondellbasell.com ❙ www.borealisgroup.com ❙ www.dupont.com ❙ www.celanese.com ❙ www.polyone.com ❙ www.teknorapex.com ❙ www.bayermaterialscience.com ❙ www.wacker.com ❙ www.polysecure.eu ❙ www.molecor.com ❙ www.kraussmaffei.com ❙ www.battenfeld-cincinnati.com ❙ www.conextru.eu ❙ www.erema.at www.pipeandprofile.com


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European polymer demand | markets

The global downturn and Eurozone crisis hit Europe’s economy hard. AMI’s Carole Kluth provides this exclusive analysis of what that meant for polymer demand in 2013 and what the future holds

When AMI published its last review of the European plastics industry in 2011 the market was making a tentative recovery from the effects of the global downturn of 2008 and 2009. However, the modest recovery seen in 2010 and through the first half of 2011 was beginning to run out of steam by the last quarter of 2011 thanks to the emerging eurozone crisis and for 2012 growth in the industry stalled. The drop in demand over 2012 and 2013 has been far

European plastics demand: Surviving in a slow market

less severe than in 2008-2009 and polymer producers and processors alike have been much more savvy about

However, the levels of volatility - in terms of both

managing their inventories, not getting caught out as

pricing and demand patterns - continue to present chal-

they did in the sudden downturn of 2008. However, the

lenges to an industry that has also been grappling with

declines in government spending, manufacturing and

issues of market maturity, rising costs, increased global

consumer confidence resulted in an overall contraction

competition, environmental opposition and increased

of polymer demand of just over 1% in 2012 to 36.5

regulatory scrutiny. The market has been undoubtedly

million tonnes. That level of volume demand is expected

tough over the past five years, but most companies have

to be maintained through a subdued 2013. Overall, the

come through the downturn and continue to thrive and

industry shows no sign yet of returning to the levels of

grow through the use of innovative technologies,

volume growth seen pre-2007. It seems the European

material developments and new application gains. The

plastics industry is learning to cope in a low growth

discipline of the downturn has, it seems, made

environment.

companies cut costs, preserve cash and be judicious in

petrochemicals business, and with it polymer demand. www.pipeandprofile.com

their investments. Those that are surviving are increasingly thriving.

â–˛

Industry players are used to the cyclical nature of the

November/December 2013 | PIPE & PROFILE EXTRUSION

23


markets | European polymer demand

European

Where did it hurt?

expected to be 1.5 million tonnes less than it was in 2007.

polymer

Unsurprisingly the drop in polymer demand was most

The ongoing economic uncertainty across Europe

producers

severe in southern Europe, where the eurozone crisis

continues to deter investment in construction markets,

showed

has been at its most intense. Collectively polymer

which is particularly painful for PVC as 70% of its

effective

consumption in Spain, Italy and Greece contracted by

demand is accounted for by building-related applications

inventory

4% and these three countries have lost nearly 25% of

(most notably in the production of window frames, pipes,

management

their market in volume terms since 2007. Unfortunately,

cable, and flooring).

as demand

there seems little prospect of things changing anytime

weakened once

soon and these countries continue to see cutbacks in

weakened by an 8% fall in European car production in

again in 2012.

production throughout the value chain, from polymers

2012 that, twinned with weak demand from logistics

Photo: BASF

to finished manufactured goods.

and general manufacturing, led to a contraction in

Ludwigshafen

The downturn in Spain and Italy resulted in particularly steep falls in demand in the consumer goods and

Polymer demand from the automotive sector was

demand for polypropylene and several engineering polymers.

electrical appliances sector and in production of disposables. This pulled down polystyrene demand and

Reasons to be cheerful

contributed to the market for this material being the

Germany, which is the engine of the European economy

weakest of all the polymers in 2012. In addition to

and plays a similar leading and trend defining role in

reduced production in key end use segments for

the chemicals and plastic industry, has been the

polystyrene, the material also remains under pressure

strongest of the western European markets. Although

from PET and PP in food packaging applications.

demand was down marginally in 2012, current market

PVC is another material which seems to be in a process of long-term decline, with demand for 2013

demand is only fractionally off the levels of 2007. This tells us two things: firstly, that Germany didn’t experience the same level of decline as seen elsewhere; and

European polymer demand by resin, 2013. Total: 36.5 million tonnes

secondly, that it has done better than most other markets in clawing back what demand it had lost. The

LL/LDPE

Engineering Plastics

German plastics market has been sustained by the strength of its small and medium sized processors, HDPE

which have often developed leading roles in niche markets.

PET

The UK also had a better year than might be expected, given the weak state of plastics processing

EPS GP-HI PS

PP PVC

Source: AMI

24

in the country even before the downturn. Although UK market demand at just over 3 million tonnes is

PIPE & PROFILE EXTRUSION | November/December 2013

some 800,000 tonnes less than the country’s peak demand - which was way back in 2000 - the market appears to be stabilising. With the improvements in UK www.pipeandprofile.com


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to predict the future is to invent it


markets | European polymer demand

Million tonnes

substitution and new product development. PET bottles,

41

for example, can replace glass for the packaging of

40.4

alcoholic beverages, barrier sheet and multilayer rigid

40 39

38.7

38

38.0

37.8

37

36.5

36

36.5

36.5

Some of the engineering resins, most notably

36.8

polyamide and PBT, managed to maintain market

35.4

volumes despite the downturn in car manufacturing,

35

driven largely by developments in electrical and lighting applications.

34 33 32

cans, plastic one-piece closures are replacing twopiece closures and metal tops.

37.4

37.0

and flexible constructions may replace glass and tin

Moving forward 2007

2008

2009

2010

2011

2012

2013

2014

2015

2016

2017

Total European polymer demand (actual and estimated), 2007-2017 Source: AMI

Looking ahead, there is widespread uncertainty over just how quickly markets will recover from the downturn and to what extent polymer consumption will move back towards its pre-2007 levels.

car production, the outlook for plastics processing there is better than it has been for a decade. Central Europe also continues to show positive

For 2013, demand is expected to be largely unchanged on the previous year. The first half of the year continued the weak fundamentals from 2012, but this is

growth, even if some of the smaller countries remain

expected to be offset by improving demand in the

vulnerable to external shocks. Poland is the only

second half as confidence has been slowly recovering in

country in Europe which has not technically gone into

consumer markets. However, demand, pricing and raw

recession since 2007. While overall Polish polymer

material availability are all expected to remain volatile,

demand growth has weakened, the country still

so margins will continue to be challenging for raw

manages to show some positive trends in areas such as

material suppliers and buyers alike.

appliance manufacturing and consumer packaging

Nonetheless, AMI takes the view that polymer

markets. Automotive production in Poland in 2012

demand has bottomed-out and in the years to 2017

contracted substantially. However, automotive produc-

there will be modest annual growth. The recovery will,

tion has helped to sustain demand in other Central and

however, be slow as less stock is being held through the

Construction

East European countries, particularly Slovakia and to a

supply chain. Processors fearful of any sharp downturn

has been hit

lesser extent, Hungary.

in prices are much more cautious these days about

hard by weak

On an application level, packaging demand for

what stocks they hold and also about who they sell to.

European

polymers remained steady through 2012. The packaging

They are also focusing effort on controlling costs,

infrastructure

sector accounted for nearly half of all polymer pro-

preserving cash and optimising operations.

investment and

cessed in Europe but trends in downgauging, light-

that impacted

weighting and increased use of recyclate impacted on

back as strongly as might have been expected is that

polymer

overall demand for virgin resins. However, opportuni-

the downturn has focused companies’ activities on

markets

ties still exist in the packaging industry in material

maintaining margins rather than going for volume.

One reason that polymer demand has not bounced

Average order sizes have tended to shrink (which usually brings a premium). And processors buy to order and hold lower stocks despite, at times, erratic and tight availability of raw materials. While it is hard to see overall European polymer demand advancing at anything much above GDP rates going forward, expectations of where growth will occur have changed over the past two years. Germany and northern European (Benelux and the Nordic countries) recovered more strongly and are considered more economically sound, so will be the drivers for growth in Western Europe. Poland and other Central European countries are also still expected to show good growth, driven by ongoing investments in car production and 26

PIPE & PROFILE EXTRUSION | November/December 2013

www.pipeandprofile.com


European polymer demand | markets

electrical goods manufacturing, although the success of their plastics industry will be dependent on growth continuing in the more western European countries. However, the countries of Southern Europe are expected to continue to see shrinking market demand for some time yet. Given the modest outlook for polymer demand in the economies of the European continent, overall European demand is expected to average equally modest growth of just over 1% a year for the five-year period 2012-2017. Volume demand will mainly be driven by developments in Central Europe, where the market is expected to continue to grow at nearer 3% a year. In contrast, growth in western Europe will average less than 1% a year.

For more information

compound trends, as well as reviewing application

This article is based on AMI’s recently published

developments in key plastics markets, including film and

European Plastics Industry Report 2013, which provides

sheet and pipe and profile extrusion, injection and

a comprehensive analysis of key polymer supply and

blowmoulding. It provides information at a European and

demand across the continent. Now in its 12th edition, this

national market level, including actual and estimated

report examines commodity (L/LDPE, HDPE, PP, PVC, PS

market data for the period from 2007 to 2017. The report

production is

and PET) and engineering (ABS/SAN, PBT, PA, PC, PMMA

is available in print or PDF form. You can find out more or

strengthening

and POM) polymer supply and demand and thermoplastic

order a copy here http://bit.ly/EUdata.

ADDing

||DURABILITY||

European automotive polymer demand fell 8% in 2012 but car

once again

No Worries!

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Materials handling | machinery feature

Dosing, conveying and many other vital materials handling technologies were in huge evidence at the recent K2013 exhibition

Mixing with the best Materials handling equipment can be the ideal type of

we can offer processors a consistent, balanced

machinery to demonstrate at a trade show like K2013.

performance in their optical sorting.”

For products like conveying lines, transporting coloured

Several plastics customers, including

granules along transparent tubing lines can make for a

Deceuninck and ITW Poly Recyling, have already

very eye-catching display.

installed a full optical sorting station.

Of course, some aspects of materials handling – such as drying – are less picturesque, but were also

Dosing and drying

greatly in evidence at the show.

Motan used the show to introduce a number of ancillary products, from dosing to drying.

Sorting it out

Its Ultrablend gravimetric batch dosing and mixing

Bühler used K2013 to introduce its Optical Sorting

equipment is aimed at pharmaceutical, medical and

Station (OSS), which combines all the key elements of

cleanroom applications. IntelliBlend technology helps it

optical sorting – including plant engineering, sorting

to deliver high dosing precision and consistency. The

technology, pneumatic conveyors, pre-conditioners and

system is also equipped with filterless conveying.

auxiliary equipment – in a single system. It means that processors no longer need to source separate elements from multiple suppliers, and manage multiple relationships, said the company. For flake processing, an optical

At the same time, its GraviNet GP control system was joined by a smaller version, GraviNet GP light, a compact control system for up

Motan’s Ultrablend gravimetric batch dosing and mixing equipment is aimed at pharmaceutical, medical

to two dosing modules. It has been

and cleanroom

designed in a modular way. The

applications

operator interface has been

sorting station features a purifying,

retained, but now also includes a

refining, sizing and grading stage

WebPanel with a 12.1in TFT

The Graviko

which can include one or more

touchscreen. Connection to the

gravimetric

Sortex optical sorters. These

GraviNet GP light takes place via

dosing and

convey the product between stages

Ethernet.

mixing system

and, if required, reintroduce it into

In dryer technology, Motan has

from Koch-

the system for re-sorting. Flakes

extended the availability of its

Technik has a

can be fed into one end of the

ATTN automatic temperature and

throughput of up

station and collected at the other end, ready for bagging or further processing. Charith Gunawardena, head of optical sorting, said: “We want to help our customers achieve the most efficient sorting methods on plastic flake processing lines. By

dew point levelling system to the been developed for applications where drying of materials can only take place within a narrow dew point ‘window’. The dew point of the process air is constantly

taking care of the whole process, from

regulated and documented to ensure

engineering through to customer support,

regulation precision within 1°C. Motan says

www.pipeandprofile.com

to 2000kg/hour

entire Luxor A dryer range. ATTN has

November/December 2013 | PIPE & PROFILE EXTRUSION

29


machinery feature | Materials handling

conveying product manager at Conair. “Production supervisors and managers can change settings, respond to alarms, perform troubleshooting and other operations as if they were standing in front of the operator interface on the plant floor.”

Conveying confidence For central vacuum conveying, the company exhibited its FLX loading control, an entry-level system that has been expanded to handle up to 128 loaders and 40 vacuum conveying pumps. In-plant communications are handled by standard industrial Ethernet wiring, meaning it is easy and inexpensive to install and expand. A processor can start with a system to manage just eight loaders and two pumps (one primary pump and one back-up pump), Bühler’s

that ATTN helps to reduce the risk of over-drying plastic

then increase capacity and capabilities in increments by

Optical Sorting

granules at too low a dew point.

adding input and output cards. The system can include

Station

At the same time, US-based Conair exhibited its

high-level functions like first in/first out (FIFO) and

combines all

DC-T TouchView control, which an interface for

priority loading, multi-source/multi-destination loading,

the key

monitoring and controlling the polymer drying process.

ratio loading with purge, reverse conveying for regrind

elements of

It formed part of a drying cell that included a W300

recovery and loader fill sensing.

optical in a

Carousel Plus desiccant dryer and a four-hopper

single system

ResinWorks system. An 8in diagonal graphical touch-screen interface

automation in plastics processing. The patented system, which combines flexibility and ease of use, delivers

allows easy adjustment of parameters, showing current

accurate material distribution with zero residue in central

and historical temperature data and allows precise

conveyor systems, says the company.

It is also a gateway for controlling multi-hopper central drying cells, such as the ResinWorks system,

It can easily be integrated into existing material supply systems without modifying their basic design. Pneumatic sliders automatically move the required

which combines multiple hoppers with integral air

material and machine lines together and connect them.

manifolds, ducting and wiring on a single, sturdy

The advantage of the system is that the lines do not come

platform.

into contact with any other material, offering maximum

Each hopper can be equipped with a Drying Monitor TSM’s loss-in-

system from Koch-Technik – increases the level of

shows everything happening in the drying system and

dew-point control.

weight blender

Meanwhile, Navigator – a fully automatic material feed

probe that incorporates RTD sensors along its length. The probe measures the temperature at

protection against contamination and undesired mixing. The system can distribute up to 40

can dose up to

up to six different points in the bed of

different plastics to the processing

seven materi-

plastic material so that a temperature

machines in a single material supply

als at one time

profile can be created to verify that

system allows all data to be stored

maintained.

and output on standard interfaces.

Up to 15 hoppers can be linked to the DC-T for monitoring and duplicate control. All settings can

User-friendliness is increased with an operating status display and a self-diagnosis option. As an option it

be made, viewed and adjusted at the

can also be integrated in process

dryer. Data from individual Drying

monitoring visualisation software.

Monitor probes, including trending

Also, its Graviko gravimetric

graphs, can also be displayed on the

dosing and mixing system provides

monitor – or elsewhere, thanks to its

material throughput of 3-2000kg/

Internet connectivity.

hour. The recently unveiled GK 65 is

“Customers want these remote access options to maximise productivity,” said Doug Brewster, 30

system. The integrated control

conditions for proper drying are

PIPE & PROFILE EXTRUSION | November/December 2013

the latest addition to the series and provides a throughput up to 70kg/ hour of plastic. Alongside the main www.pipeandprofile.com


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machinery feature | Materials handling

mance balance for plastics manufacturers by allowing throughputs to be measured in real time. The product combines the benefits of TSM’s patented reverse auger technology with a fast, responsive throughput measurement. “The fast, responsive throughput measurements will benefit plastics producers by giving them real-time control,” said Declan Byrne, director of sales. “This will improve the accuracy and consistency of their end product, reduce waste and improve cost efficiency.” A new control algorithm, developed in conjunction with a UK university, delivers accurate control that allows performance to be maintained at lower setpoints. The small footprint makes the machine ideal for new or retrofit installations. The blender development came about in response to an industry need for highly responsive control systems. “Plastics producers are increasingly looking to use less raw materials to make more consistent end-product and decrease wastage,” said Byrne. At the same time, the company has developed a new Zeppelin

component, the basic version weighs up to three volume-

loss-in-weight blender which can dose up to seven

supplies a

trically added material components in its internal,

materials at one time and features optional cascade

range of

vibration-free weighing container. It is the first Graviko

mixing chambers, multiple augers for varying feed rates

pneumatic

product to have two synchronous precision load cells. Every

and easy hopper cleaning.

conveying

filling is weighed 100 times in succession. The dual

systems for

weighing unit registers the values and transfers them to

its Opti-Mix gain-in-weight batch blender series, with

plastics

the Koch control unit, which compensates for fluctuations

several new design features.

until the dosing recipe is reached accurately. Once all

In addition to these two system, TSM also displayed

Conair also highlighted blending technology at

values match, the dosed batch is emptied into the mixer

K2013. At the show, it networked a TrueBlend TB-250

below, where a horizontal agitator homogenises the

gravimetric blender, with throughputs as high as 431kg/

mixture before it is processed.

hr (950lbs/hr). The blenders are available with through-

Zeppelin Systems introduced a new concept in bulk material conveying. In partnership with Doppelmayr, it has developed a ropeway system to transport materials

puts up to 5443kg/hr (12,000lbs/hr) and are accurate to within 0.5% of set point on colorant and additive weights. The four hoppers on the blender were equipped with

over far longer distances than is possible using

access loaders and a filterless loader. Access loaders

conventional pneumatic conveying.

and receivers feature an angled hopper – making them

It has also updated the capacity of its Bolt-Tec

easier to clean and maintain – and an oversized

system – a silo design allowing silo sections to be

discharge opening to prevent material bridging.

bolted together rather than welded. This cuts shipping

Filterless loaders are designed to handle dusty,

costs by up to 30%.

problem materials like regrind and free-flowing

Bolt-Tec silo segments are transported in standard

powders that are 100 microns in diameter and larger. A

containers and assembled on site, which is much less

patented ‘filterless insert’ uses continuous reversal of

expensive than shipping a complete silo. This is of

air to separate incoming material from conveying air

particular benefit in regions with less developed

without filters or screens.

infrastructure, where conventional silos can be shipped by expensive wide load transport only. The silos were limited to sizes up to 500 cubic meters, but Zeppelin has doubled this to 1,000 cubic metres.

Blended to perfection Ireland’s TSM Controls introduced new blender technology at K2013, which aims to improve the cost/perfor32

PIPE & PROFILE EXTRUSION | November/December 2013

Click on the links for more information:

❙ www.buhlergroup.com ❙ www.motan-colortronic.com ❙ www.conairgroup.com ❙ www.koch-technik.com ❙ www.zeppelin.com ❙ www.tsm-controls.com www.pipeandprofile.com


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Wood-plastic composites | process feature

Machinery and materials innovations are helping to propel wood-plastic composites (WPCs) into new markets. Lou Reade reports

Treading the boards KraussMaffei

Wood-plastic composites (WPCs) are growing in stature:

transports wood flour and PVC dryblend into a mixer,

alongside the huge consumption in North American

which feeds the homogenised material mixture directly

Berstorff

market, sales in Europe – and, to some extent, Asia

into the extruder. Compounding using a heating-cooling

equipment

– are beginning to grow in terms of both volume and

mixer is not required, which saves production space and

helps Oceplast

sophistication.

energy (as the wood flour is already pre-dried).

KraussMaffei Berstorff has recently supplied WPC

At the same time, Pinuform of Germany has invested

direct extrusion machinery to two leading European

in three WPC twin-screw extruders and a twin-screw

extruders.

compounding extruder to carry out direct extrusion at

Oceplast, a French PVC processor, has commissioned a complete WPC direct extrusion line in order to make decking profiles at its plant in Alzenay in northern France. The core component of the line is a KMD 75-32/WPC

“The customer uses our co-rotating twin-screw extruder to compound wood flour and polypropylene based pellets, which, in the next stage, are extruded on our counter-rotating twin-screw extruders to make the

200kg/h. Other components, such as the calibration

final product,” said Finkenzeller.

designed to the customer’s requirements. The line is designed for processing extra wide profiles. “The screws have tungsten carbide armour plating, while the barrels are lined with a bi-metal bushing,” said Michael Finkenzeller, product manager for WPC

Pinuform recycles wood chips from its planing mill, then uses them to produce its WPC decking profiles. “A side benefit is that we are able to market the pellets separately,” said Holger Sieck, managing director of Pinuform. The co-rotation twin-screw extruder is well suited to

extrusion at KraussMaffei Berstorff. “Wear resistance is

direct metering of components, as the residual

very important, especially in WPC processing, since this

moisture content (up to a maximum of 12%) can be

is the only way to attain the machine service lives

optimally discharged through venting ports.

demanded by processors.”

The counter-rotating parallel twin-screw extruder –

Direct extrusion allows products to be made in a

equipped with a powerful high-torque drive – ensures

single step by direct metering of the two components

high output levels. The processing unit, with special

(PVC and wood). A two-component gravimetric system

wear protection, is suited to the extrusion of natural

www.pipeandprofile.com

decking

its plant in Ammelshain, near Leipzig.

twin-screw extruder with a maximum output of up to table, haul-off/saw combination and tilting table, are

to produce WPC

November/December 2013 | PIPE & PROFILE EXTRUSION

35


process feature | Wood-plastic composites

Battenfeld-

fibre-reinforced plastics, so ensures long

Cincinnati’s

machine service life.

partnership

and can be made for 50% less than existing industry

with Hardy

Indian alliance

Smith of India

Battenfeld-Cincinnati has established a partnership

takes advan-

with Hardy Smith of Gujarat in India, to take advantage

the profile, which uses around 20% less material. A new

tage of the

of the emerging wood-plastic composite (WPC) market

die head for the Bitrudex extrusion line also allows

emerging WPC

in the country.

significantly higher production speeds.

market there

standards, says Reifenhäuser. The cost reduction comes mainly from the design of

“This novel profile gives our customers a major

In India, WPC profiles and panels are emerging as a popular alternative to wood panels, which can be scarce

advantage: financially, and also when handling the

and expensive, due to limited wood resources.

profile, as assembly and maintenance are simplified

Hardy Smith, which began as a company in the wood industry, has been involved in the WPC market since

considerably,” said Thorsten Weber, WPC senior manager at Reifenhäuser. The Reiwood profile combines the advantages of

2011. It offers complete solutions for WPC manufacturing from concept to end product. Battenfeld-Cincinnati is a co-founder of the WPC Platform Austria, and is one of nine Austrian companies

both hollow chamber and full profile. A line to produce the profiles has been installed at the company’s extrusion technology centre, and was seen at K2013. According to Reifenhäuser, Reiwood can be installed

involved in the government-funded Coin project, which aims to improve the mechanical attributes of WPC

perfectly level and has been designed as a click system

profiles by 25% while achieving a 25% reduction in

so that planks can be conveniently connected with the

material costs.

supporting base. This is not possible with commercially available hollow chamber profiles, says the company, as

Wood working

they must be laid so that water can drain out of the

Reifenhäuser has developed a new wood-plastic

hollow chamber. Milacron Extrusion Systems recently showcased its

composite (WPC) decking profile, called Reiwood. The system consists of new profile and die-head designs

75mm parallel twin screw extruder at K2013.

Wood without wood WPCs use wood fibres within a polymer

mineral particles within the plastic

the finished material can also be tailored,

matrix to make a material that handles

matrix, is pulled through a special die

with a variety of surface textures and a

like wood in processes such as cutting.

– which then aligns the particles to create

range of colours incorporated during

a highly oriented structure. Densities of

processing.

But there is another way of mimicking the structure of wood – without using wood fibres. US-based Eovations offers a

between 0.5 and 1g/cc can be achieved. The company believes that the

Martin McDonnell, product manager at Eovations, said fabrication with the

‘fully fibrous technology’ that replicates

material could replace plastics, wood,

composite is almost identical to tradi-

the fibrous structure of wood in a plastic

WPCs and even metals in applications

tional carpentry.

material – but uses mineral fillers rather

such as building products, outdoor

than wood fibres or wood flour.

furniture and agriculture.

The technology was originally

It says that the lack of wood or

“It can be machined, milled, cut and drilled using basic carpentry skills and common woodworking tools,” he said.

developed by Dow Chemical and the UK’s

cellulose in the product makes it longer

“Fastener acceptance and hold is excellent

University of Bradford, but Eovations has

lasting than traditional WPCs.

using conventional nails, screws and

now acquired the rights to it.

Processes based on the technology

staples. Variations of the composite readily

It uses a patented extrusion/drawing

can use a variety of polymers and mineral

accept common paints, allowing durable,

process to incorporate mineral particles

raw materials. A wide processing window

attractive finishes to be applied during

into a thermoplastic matrix to create a

enables finished composite properties

product manufacturing or in the field.”

molecularly oriented lineal composite

such as density to be customised for

system. An extruded ‘billet’, which has

specific applications. The appearance of

36

PIPE & PROFILE EXTRUSION | November/December 2013

Eovations intends to license the technology to third parties.

www.pipeandprofile.com


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process feature | Wood-plastic composites

mix with HDPE – the base polymer for many PE-based wood plastic composites (WPCs). Its new product, Scona TSPE 2102 GAHD is a WPC modifier based on HDPE, which is highly functionalised with maleic anhydride. Recommended loading is 1-4%, depending on fibre content. The material’s improved compatibility facilitates easy processing even with a low shear, says the company. At the same time, the product is grafted higher, so provides greater functionality than other products on the market. This allows for a lower dosage. The ability to optimise mechanical properties significantly improve the end product, says BYK. The team that developed the new material, led by Inno Rapthel, has won an internal award from the company. Reifenhäuser

The TP75 is suited to making a number of products,

And UK-based Croda has developed a line of

has developed

including WPC profiles. It has an AC motor and drive

speciality additives that help to boost the throughput of

a new WPC

fitted as standard, and active screw oil cooling for

WPC products.

profile design,

precise process control. Options include a dry vacuum

Reiwood, that

pump, tungsten screws, and matching barrel for

bring the plastics and wood phases of the material

can be

reduced long term maintenance cost.

together, increasing both flow rate and dispersion.

made very economically

It uses Milacron’s Mosaic control system. When combined with one or more twin or single screw models, it controls the extruders while supporting other

Its Incroflo range act as lubricants which helps to

“This allows for lower processing temperatures and pressures during manufacture,” said the company. The additives also act as a barrier between the WPC

equipment downstream. This makes it suitable for

and the extruder to help reduce wear, especially on

production of co-extruded profiles, which combine

screws.

recycled and virgin materials. Milacron uses the TP twin parallel models with its

Other benefits include: optimisation of mechanical performance; better surface finish; and reduced water

TC twin conical models for co-extruded profiles. The

absorption, which in turn reduces the change of warped

technology in the co-extrusion system allows the

final parts.

combined machines to create product with a virgin material outer layer and a recycled inner core at a rate

Click on the links for more information:

of 1,360kg/hr while reducing waste.

❙ www.kraussmaffei.com ❙ www.battenfeld-cincinnati.com ❙ www.reifenhauser.com ❙ www.milacron.com ❙ www.byk.com ❙ www.croda.com/pa ❙ www.eovationsllc.com

Modified behaviour BYK-Chemie has developed a new modifier for WPCs that claims to offer increased compatibility. The starting point for the development was the fact that coupling agents based on LLDPE are difficult to

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PEX | materials feature

Projects like the Pier 15 Exploratorium in San Francisco show the full advantage of PEX pipe. Lou Reade reports

Taking the heat Crosslinked polyethylene, or PEX, is the material of

Installation time on the

choice for specialist piping applications – such as

project was reduced through

geothermal or radiant heating systems. In this area,

the use of Uponor’s Radiant Rollout

Uponor recently won the Plastics Pipe Institute’s

mats on around 80% of the floor

Project of the Year in the building & construction

surface. The custom-designed mats

division, for its work on the Pier 15 Exploratorium in

are prefabricated to project specifica-

San Francisco.

tions at the company’s factory in Apple

The project used 200,000 feet of Uponor North America’s Wirsbo Hepex crosslinked polyethylene

Valley, Minnesota. “The mats feature pre-pressurised More than

(PEX-a) tubing for the radiant heating and cooling

rolls of PEX-a tubing loops fitted with Uponor Propex

system that uses the San Francisco Bay as a heat sink

engineered polymer fittings, which are safe for burial in

20,000 feet of

and heat source.

the slab,” said Him Ly, senior design engineer of

Uponor’s PEX

The project, designed by EHDD Architecture of San

technical services at Uponor. “Once on the job site, the

Francisco and engineered by Integral Group of Oakland,

mats roll out like carpeting over the floor space,

renovated a century-old building on San Francisco’s

providing approximately 85% faster installs compared

Pier 15 into the largest net-zero energy and net-zero

to conventional radiant tubing methods.”

carbon museum in the US, says Uponor. The 330,000 sq ft structure is projected to be 57%

The Pier 15 project showcases the importance of flexible PEX can work around existing structural

90.1 energy standard, thanks in part to the radiant

components to renew an old building; and it provides an

heating and cooling system.

educational tool within the Exploratorium, explaining

peers in the plastics pipe industry,” said Bill Gray,

15 Exploratorium in San Francisco

plastic pipe in two ways, says Uponor: it shows how

more efficient than the requirements of the ASHRAE

“We are proud to receive this recognition by our

pipe has been used in the Pier

the energy-efficiency benefits of PEX-based radiant heating and cooling systems.

Uponor has launched several new products, including the

At the same time, Uponor has launched several new

Propex EP

Exploratorium is an excellent example of the benefits of

products in its engineered polymer (EP) product line to

45-degree

flexible plastic pipe and how it can transform a historic

meet increasing commercial demand for PEX pipe.

president of Uponor North America. “The Pier 15

building into an impressively sustainable project.” www.pipeandprofile.com

elbow

It now offers a Propex EP 45-degree elbow to November/December 2013 | PIPE & PROFILE EXTRUSION

41


materials feature | PEX

Rauvitherm pre-insulated energy transfer

facilitate directional changes at a 45° angle. The elbow is available in 1.5in and 2in sizes and features Uponor’s unique Propex connection that

pipes from

capitalises on the shape memory of Uponor PEX-a pipe

Rehau are

to create strong, durable connections that hold tight at

designed for small- to medium-sized projects

high radial force. “With our continued growth in commercial plumbing, we are striving to fill the need for products that make it faster and easier to install PEX in various commercial plumbing applications,” said Jayson Drake, director of plumbing and fire safety at Uponor. The company is also launching a range of reducing and multi-port tees.

Energy efficiency Also in North America, Rehau has expanded its range of PEX-a pre-insulated energy transfer pipes with the addition of Rauvitherm. Designed for small- to medium-sized projects, it features closed-cell crosslinked polyethylene (PE) foam, which combines insulating properties with high flexibility. Its HDPE outer jacket is designed to withstand typical outdoor conditions, and is bonded to the pipe’s outer insulation layer to reduce risk of water infiltration. Rauvitherm is available as a single-pipe solution in 25-125mm diameters, and as a dual-pipe solution in 25-63mm diameters. At the same time, the company’s Raugeo PEX-a piping system has been certified for use in Canada following revisions to the CSA Group’s new Standard C448/2013

PEX updated Borealis showcased a number of polyolefin pipe grades at K2013, including a new version of its crosslinkable PEX-a compound. It relaunched its enhanced HE1878E-C2, claiming it is the first fully-stabilised, ready-compounded PEX-a to achieve Class 5 listing. The Class 5 listing corresponds to the highest chlorine-resistance rating in accordance with the ASTM F876 standard for PE crosslinked pipes using the ASTM F2023 test method. ASTM F876 is the standard specification for PEX tubing in North America. The advanced qualification of Borealis HE1878E-C2 opens up a new range of opportunities for pipe producers in North America, while enabling producers in Europe, Asia and the Middle East to gain a competitive edge thanks to product differentiation, says the company. The PEX-a pipe boasts benefits such as enhanced durability, high

Design and Installation of Earth Energy Systems. The previous regulations specified the use of non-crosslinked PE pipe for ground heat exchangers, but the revised standard means that PEX-a pipes and F2080 cold-expansion compression-sleeve fittings may now be used in these applications in Canada. “Specifiers and installers across Canada have been requesting the option to use PEX-a systems, in some cases to take advantage of its unique fitting and manifold options,” said André Carrier, chairman of the CSA C448 technical subcommittee. “PEX-a pipe and cold-expansion compression-sleeve fittings have been used in Canada for several decades in applications such as radiant heating, snow and ice melting, and water service and distribution.” Simon Koenig, business team manager for renewable energies at Rehau, said the installation and long-term performance advantages of PEX pipes would be put to good use in emerging applications. “This is a great step forward for the Canadian geothermal market, at a time when the cost and supply challenges of traditional energy sources are the catalyst for considering and employing earth energy systems,” he said. He added that PEX-a pipes provide an advantage in vertical installations, as they are flexible enough to be formed into a compact U-bend for insertion into a standard 13cm (5in) borehole without the use of joints or connections. And, as the Raugeo coils are extruded and fabricated in Rehau’s North American production facility, the pipe can be delivered to the work site with the U-bend already formed. “Where connections are required, the unique properties of PEX-a allow the use of ASTM F2080 Everloc cold-expansion compression-sleeve fittings that install quickly and without the use of heat or electricity, in any weather conditions,” he said. He said that the pipes are also approved for use with HDPE electro-fusion fittings (as per ASTM Standard F1055), in installation temperatures as cold as -20°C (-4F). “Raugeo PEX-a is a reliable piping system engineered for tough ground conditions,” he said.

temperature resistance, excellent flexibility and low creep. As a minipelletised compound, the material also offers significant production

Click on the links for more information:

advantages: it requires only the addition of peroxide, minimising the risk

❙ www.uponor-usa.com ❙ www.borealisgroup.com ❙ www.rehau.com

of additive dosing errors; it is easy to handle; and its cost efficiency is also improved. 42

PIPE & PROFILE EXTRUSION | November/December 2013

www.pipeandprofile.com


Pipeline Coating 2014 International conference on pipeline protection, coating technology, materials and markets

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AMI’s Guides to THE THERMOPLASTICS PIPE EXTRUSION INDUSTRY IN EUROPE, NORTH AMERICA AND SOUTH AMERICA

Three unique reports give you an essential understanding of the pipe extrusion industry and its key players in the European and American continents. • •

Overview of the thermoplastics pipe market Company information on 1020 production sites manufacturing thermoplastics pipes

AMI’s Guide to The Thermoplastics Pipe Extrusion Industry in Europe 490 sites

Thermoplastics pipe extrusion represents a significant market for polymer materials in Europe and America. However this market is affected by the fortune of the building industry and the investments governments are prepared to make to improve their infrastructures. The trends in polymer usage vary across the regions and are affected by a number of factors. These three different reports will provide you with an inside knowledge of the pipe extrusion industry in these different regions of the world. In each guide and for each region you will find the following information:

AMI’s Report on The Thermoplastics Pipe Extrusion Market in North America 315 sites

• Market data and analysis • Company information Production plants are listed alphabetically with their full addresses, telephone, fax numbers, email and website. • Managerial contacts • Polymers processed • Type and size of pipes manufactured

AMI’s Guide to The Thermoplastics Pipe Extrusion Industry in South America 215 sites

Applied Market Information Ltd.

For more details or to order click on each title or contact Régine Futter on: Tel: + 44 117 924 9442 Fax: + 44 117 989 2128 Email: sales@amiplastics.com

www.ami-publishing.com


Materials | technology

BIOPLASTICS

Replacing rubber in racing cars For many years, Evonik has supplied

vehicles worldwide. The current car uses

materials for components on the Lotus

MLT 8000.3 with an orange outer layer.

Exige – which are then tested under

This system is around 70% lighter than

motor racing conditions. This year,

cooling line systems with steelflex tubes. The coolant lines have three layers:

Lotus used a multi-layer tube system that incorporates a bio-based Evonik

the inner layer is a specially adapted

resin for the first time.

grade of polypropylene; the second is an

The company has supplied grades of

adhesion promoter layer; and the outer

its Vestamid polyamide to Lotus before,

layer consists of the Vestamid (or

for use in its multi-layer line for

bio-based Vestamid Terra). Evonik’s bio-based polyamides have

charge-air cooling. Now, the line incorporates new Vestamid Terra, which

been used commercially since 2010 as

is derived from sustainable sources.

mono-layer tubes in air brake lines of

The multi-layer tubes are lightweight

utility vehicles, but this is the first time they have been used in multi-layer

replacements for rubber hoses and reinforced lines. The MLT 8000 multi-

tubing systems for coolant lines.

layer tubing system has been used in

❙ www.evonik.com

TPUs

PP

Pipe grades take the pressure Sabic has added to its range of

distribution. Properties include

for corrugated pipe systems

pipe grade materials with PP

a broad processing window,

and compact solid wall pipe

Rely 61EK61 PS, a polypropyl-

and a high stiffness in combi-

systems for various sizes.

ene (PP) pipe material.

nation with high impact

The material is produced

TPUs for extrusion applications US-based Alliance Polymers

resistance – even at low

in Europe and available

and Services (APS) has

the PP Rely and Vestolen A

temperatures. This, says Sabic,

worldwide. The grade’s

launched a series of

Rely ranges, which are aimed

leads to more reliable pipe

thermal stability and

thermoplastic polyurethane

at pressure pipes.

systems through minimised

mechanical properties also

(TPU) extrusion grades.

leakage and the prevention of

make it suitable for making

ground water pollution.

industrial sheets for

polyether-based Zythane

applications in construction

TPUs is formulated for a

The Rely family comprises

The material is the result of several years of research to produce a PP pipe grade with

It also meets the most

The 7000 series of

high molecular weight and

stringent industry require-

and chemical engineering.

range of applications,

custom-made rubber particle

ments, EN 13476 and EN 1852

❙ www.sabic.com

including technical profiles, pneumatic tubing, cable jacketing and film and sheet.

MASTERBATCH

Green products ensure FR performance Tosaf has launched a new line

61386-1.

Offered in a range of hardnesses – from 70 Shore A to 45 Shore D – the new

of Very High Concern’ (SVHC).

materials offer high trans-

At the same time, many pipe

parency when extruded

the production of corrugated

chlorinated paraffins had been

producers are trying to make

natural, as well as low

pipes used as conductors for

used to achieve this. But they

their products comply with

temperature flexibility,

electrical cables in construc-

are now under attack from two

the Low Smoke Zero Halogen

hydrolytic stability, microbial

tion. These conductors must

regulations: Reach, which has

regulation (LS0H; IEC

resistance and resistance to

meet the European Flame

banned the use of short-chain

607541).

weak bases and acids.

Retardant (FR) Standard IEC

chloroparaffins as ‘Substances

❙ www.tosaf.com

❙ www.apstpe.com

of ‘green’ masterbatches for

www.pipeandprofile.com

In the past, low-cost

November/December 2013 | PIPE & PROFILE EXTRUSION

45


technology | Machinery

CO-EXTRUSION

Multi-layer extrusion for hot water pipe Austrian pipe extruder

PE-RT, an oxygen barrier

Multitherm recently ordered

layer and an external layer

a new production line from

made of PE-RT. Coextruders apply the

KraussMaffei Berstorff.

adhesive agent between the

The core components of the complete extrusion line

individual layers. Multitherm

are a mono extruder and four

produces the pipes for use in

coextruders from KraussMaf-

heating systems and

fei Berstorff’s single-screw

underfloor heating systems. Every year, Multitherm

series, as well as the company’s KM 5L-RKW 91-63

produces several million

multi-layer pipe head.

metres of plastic pipes made

“With the order, Multith-

of PE, PE-RT and PP in a

erm will replace an existing

range of different dimen-

extrusion line for the production of triple layer pipes, in order to satisfy market

sions. Its main market is Europe, but it

at KraussMaffei Berstorff. The new line produces hot water pipes

also sells its products as far afield as

demands for more functional layers,” said

(with diameters ranging from 14 to

Australia.

Andreas Kessler, general sales manager

40mm) with an internal layer made of

❙ www.kraussmaffei.com

ANCILLARIES

Belling and cutting machines go green At the recent K2013 exhibition,

version. Maintaining existing

absence of a hydraulic unit;

pressure and underground

Sica of Italy showed a number

quality standards and product

and, ease of use and quick

sewage PVC pipes is

of new ‘green’ machines that

reliability, the new machine

format change.

distinguished by the electro-

are designed to save energy,

introduces a number of

materials and costs:

technical features at a reduced

by the newly designed Everbell

forming carriage. By

The Multibell 200M is joined

mechanical movement of the

price. Advantages over the

socketing machine for

eliminating hydraulic

PVC, PP and PE pipes, claims

previous version include: more

processing PP pipes. Like the

movements, oil leakage into

to solve the old problem of

compact dimensions with

Multibell, it has been totally

the environment is avoided,

chips and dust. Thanks to a

equal productivity; a new way

redesigned by Sica.

and ordinary maintenance is

patented design, the company

of multi-socketing pipes;

Its new cutting machine, for

Unibell 200 E&P for

reduced. The energy needed

says it can cut and chamfer

for the forming positioning is

without removing any material.

used only for the duration of

The machine guarantees a

the carriage movement. Also,

clean, perpendicular cut with a

the total absence of hydraulic

knife as well as a precise,

units brings a significant

well-defined chamfer, allowing

energy saving, because

it to maintain productivity at a

hydraulic units have a lower

satisfactory speed.

total efficiency than the new

The company also intro-

device. The benefits include:

duced two new belling

faster return on investment;

machines.

greater market competitive-

Its Multibell 200M, for PVC

ness; and less impact on the

sewage pipe, reaches 900

environment.

sockets/hour with the flagship

❙ www.sica-italy.it

46

PIPE & PROFILE EXTRUSION | November/December 2013

www.pipeandprofile.com


This month’s free brochure downloads Simply click on the brochure cover or link to download a PDF of the full publication

Tecnomatic: extrusion die heads This 24-page brochure from Tecnomatic provides detailed information on the company’s wide range of extrusion die heads. These include the latest Venus designs for PE/PP processing and its RadialType Distributor for PVC pipes.

➤ Click here to download

Starrett Bytewise: profile inspection Laser Measurement

OLUTIONS

• • • •

• • • • • •

This brochure from Starrett Bytewise features the Profile360 laser measurement system for the in-line inspection of extruded window profiles. It monitors angles, squareness, gaps, grooves and other key dimensions.

Piovan: refrigeration systems This 12-page brochure from Piovan focuses on the company’s refrigeration systems, including scrollcompressor chillers, screw-compressor chillers, inverter-driven chillers, thermo-refrigerators and free-cooling systems.

➤ Click here to download

PlasMec: PVC mixing/cooling This brochure covers PlasMec’s HEC High Efficiency Horizontal Cooler for the production of rigid or plasticized PVC dry-blend. Available in sizes up to 8,000 litres, it delivers high levels of efficiency, throughput and quality.

➤ Click here to download

Struktol: Polymer additives Over 10-pages this publication lists the full range of Struktol additives for thermoplastics processing applications, providing matrix selection guides for the most common polymers with recommended addition levels.

Schill & Seilacher family of companies, with representation in

ganization with over a century of specialty chemical expertise,

rocessing products under the brand name STRUKTOL® – a name

nd performance. Struktol manufactures chemicals for the plastics

ns, silicone emulsions, products used in latex processing, and

retardants.

dditives business is by no means typical or ordinary. Chemistry

lligent Additive Solutions, Struktol products are designed to customers. Our technical specialists, R&D chemists and

novative solutions for the ever-changing polymer industry –

n with increased productivity, better quality parts and lower

ormance, Struktol Customer Service initiatives have become

TEB0047/2012

Intelligent Additive Solutions for Today’s Thermoplastic Industry

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Advertise in this magazine You can use Pipe and Profile Extrusion magazine to promote your products and services to the global extrusion industry. Download the new 2014 media pack to find out more about our targetted web and app readership and highly competitive advertising rates.

➤ Click here to download

If you would like your brochure to be included on this page, please contact Claire Bishop. claire@amimagazines.com. Tel: +44 (0)20 8686 8139


extruder of the month

Reddiplex Head office: Date founded: Managing director: Ownership: Profile:

Droitwich, UK 1969 Owen Boylan Private Reddiplex supplies a wide range of both standard and custom extrusions to customers across the world, from its factory in the UK. Its products include rigid, flexible, solid rubber and sponge rubber extrusions, in materials ranging from PVC to polycarbonate. The main industries it supplies are building and construction, automotive, aerospace and marine.

Plant locations:

The company has a single 30,000 sq m manufacturing plant in Droitwich in Worcestershire, UK, from which it supplies its entire range of products. In addition to extensive production facilities – for single hardness, co-extrusion and triplex extrusion – it boasts an in-house design department that can design and manufacture extrusion dies.

Recent projects:

Reddiplex recently supplied a decorative cover strip to JSC Minsky Avtomobilny Zavod (MAZ), one of the largest automotive manufacturers in central and eastern Europe. The cover was clipped into an aluminium drain section that runs the entire length of a bus chassis. To decorate the part, Reddiplex used an embossing machine to roll the desired pattern onto the profile, after it had been extruded. Recently, the company also supplied a sealing system to Lewmar Marine, which incorporates solid EPDM and sponge in a single profile.

To be considered for ‘Extruder of the Month’, contact the editor on lou@pipeandprofile.com

Forthcoming features The next issues of Pipe and Profile Extrusion magazine will have special reports on the following topics:

January/February 2014 Engineering plastics and composites PVC Stabilisers Indian market trends Screenchangers/melt filtration

March/April 2014 Screws and barrels Polyolefin developments Titanium dioxide trends Chinaplas preview

Editorial submissions should be sent to Lou Reade: lou@pipeandprofile.com For information on advertising in these issues, please contact Claire Bishop: claire@amimagazines.com Tel: +44 (0)20 8686 8139


Catch up on our recent issues for FREE Simply click on the cover to see the full magazine, or download the issue in the relevant Apple or Android app Pipe and Profile – October The October edition of Pipe and Profile Extrusion looks at the latest innovations in optical fibre ducting, trenchless pipe technologies and downstream automation. Plus, a preview of the materials and equipment on show for extrusion processors at K 2013. ➤ Click here to view

Compounding World – November The November edition of Compounding World has a special report on improving safety in compounding plants, two in-depth articles on carbon black, and a review of the latest mixers. Plus there’s news from K 2013. ➤ Click here to view

Film and Sheet – October The October issue of Film and Extrusion includes articles on polycarbonate sheet developments, recycling technologies, the latest in BOPP, and market opportunities in India. Plus it has 14 pages of K show highlights. ➤ Click here to view

Pipe and Profile – September The September edition of Pipe and Profile Extrusion has features on the latest developments in medical tubing, pressure pipes, weld joint inspection, and pipe dies. Plus it has a detailed preview of the K 2013 exhibition. ➤ Click here to view

Pipeline Coating – November The November edition of Pipeline Coating examines global energy markets, internal flow coating for gas pipelines, a major refurbishment project in Iran, plus details of the Ethylene Pipeline South project. ➤ Click here to view

Injection World – October The biggest ever edition of Injection World is packed full of features on electronic applications, conformal cooling, 3D printing, hot runners, PET performs and thermoplastic composites. Plus there’s a huge guide to K 2013 for moulders. ➤ Click here to view

Take out your own FREE subscriptions to any of the magazines. Click on the logos below to simply register on-line.


dates for your diary

Global exhibition guide 2013 5-8 December

Plast Eurasia, Istanbul, Turkey

www.plasteurasia.com

Plastivision, Mumbai, India

www.plastivision.org

21-23 January

Swiss Plastics, Lucerne, Switzerland

www.swissplastics.ch

28-31 January

Interplastica, Moscow, Russia

www.interplastica.de

12-16 December 2014

29 Jan - 1 Feb

Samuplast, Pordenone, Italy

www.samuplast.it

11-13 February

Plastec West, Anaheim, CA, USA

www.plastecwest.com

16-19 February

Saudi Plastics & Petrochem, Riyadh

www.saudipp.com

4-6 March

Plastics & Rubber Vietnam, Ho Chi Minh

www.plasticsvietnam.com

7-10 April

Plastivision Arabia, Sharjah, UAE

www.plastivision.ae

Chinaplas, Shanghai, China

www.chinaplasonline.com

23-26 April 8-14 May 27-30 May 16-22 June 17-19 July 3-6 September 15-19 September

Interpack, Düsseldorf, Germany

www.interpack.com

Plastpol, Kielce, Poland

www.targikielce.pl

Argenplas, Buenos Aires, Argentina

www.argenplas.com.ar

Plastic Technology Expo, Bangkok, Thailand

www.technobiz-asia.com/PIEC2014

Indoplas, Jakarta, Indonesia

www.indoplas.com

Plastex, Brno, Czech Republic

www.bvv.cz/plastex-gb

30 Sept-2 Oct

Interplas, Birmingham, UK

www.britishplasticsshow.com

6-10 October

Equiplast, Barcelona, Spain

www.equiplast.com

Fakuma, Friedrichshafen, Germany

www.fakuma-messe.de

14-18 October

AMI conferences for pipe & profile extruders 24-26 February 2014

PVC Formulation, Duesseldorf, Germany

11-13 March 2014

Cables, Cologne, Germany

18-20 March 2014

Masterbatch Asia, Bangkok, Thailand

20-22 May 2014

Pipes in Infrastructure, Duesseldorf, Germany

17-18 June 2014

Polymers in Cables, Philadelphia, Pennsylvania, USA

24-25 June 2014

Profiles, Philadelphia, Pennsylvania, USA

24-26 June 2014

Masterbatch, Berlin, Germany

3-5 November 2014

Wood-plastic Composites, Vienna, Austria

For information on all these events and other conferences on film, sheet, pipe and packaging applications, see

www.amiplastics.com

DON’T MISS A SINGLE ISSUE Register now for your free subscription at:

www.pipeandprofile.com And don’t forget to tell your colleagues, customers and suppliers about the magazine. You can use the e-mail button above (the envelope symbol in the browser) to help spread the word.


Pipe and Profile Extrusion Nov/Dec 2013