Published by Promaplast Srl - Centro Direzionale Milanofiori - Palazzo F/3 - 20057 Assago (Milano, Italia) - ISSN 0394-3453 - Poste Italiane SpA - Spedizione in abbonamento postale - 70% LOM/MI/2363
MACPLAS INTERNATIONAL
THE MAGAZINE FOR THE PLASTICS AND RUBBER INDUSTRY
ITALIAN MACHINERY - ALL INDICATORS ARE GOOD FOR THE FIRST HALF OF THE www.macplas.it YEAR GREEN TECHNOLOGIES ON DISPLAY IN 2022 UPCYCLING IN THE MOST COMPLETE SENSE THE NEW FRONTIERS OF MEDICAL TPE www.sonderhoff.com
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MOLDING IS ALWAYS AT THE CENTER OF OUR PLANS
CONTENTS
23
13
10
38
MARKETING 10
EDITOR’S LETTER - 5G: NEW OPPORTUNITIES FOR POLYMERS
13
ALL INDICATORS ARE GOOD FOR THE FIRST HALF OF THE YEAR: TURNOVER AND ORDERS ARE G ROWING
16
PROGRAMME AND OBJECTIVES OF THE NEW PRESIDENT OF ASSOGOMMA
20
INCREASING PRODUCTIVITY IS THE KEY TO US
33 38 42 44 46 48 50
ECONOMIC RECOVERY
20
SUSTAINABILITY DRIVE CREATES NEW GROWTH OPPORTUNITIES
21
23
PLASTICS AND ENVIRONMENT 23 26 26 27
52 52
A NEW GENERATION OF CUTTER-COMPACTORS HIGH OUTPUT AND LOW COSTS: IT CAN BE DONE ALL FOR THE EXTRUSION OF PROFILES THE TIE BETWEEN TRADITIONAL AND INNOVATIVE DELICATE ON SENSITIVE MATERIALS A SORT OF NEW PARADIGM FOR THE PACKAGING AND CONVERTING
53
THE THREE PILLARS OF GREENPLAST 2022
54 58 61
RECORD NUMBERS FOR RECYCLING IN ITALY HYDROTHERMAL RECYCLING TO CONVERT PLASTIC
THE CHALLENGE TO TRADITIONAL MOULDING
BIOPOLYMER FOR ACOUSTIC INSULATION GENERATED
MACHINERY AND ANCILLARY EQUIPMENT 28
AN INCREASINGLY BROAD-SPECTRUM BUSINESS
WHEN CLEANING MEANS PRODUCING DUSTLESS CUT AND CHAMFER OF PLASTIC PIPES TECHNICAL AND AESTHETICAL MOULDS FOR OVER TWENTY YEARS
64 66 66
FROM ALGAE AND MARINE PLASTIC W ASTE
6
FIFTEEN YEARS OF ACHIEVEMENTS AND APPROVALS
IN THE RUBBER AND SILICONE SECTOR C ONTINUES
WASTE INTO OIL… AND NEW PACKAGING
28
UPCYCLING IN THE MOST COMPLETE SENSE
MACHINES
CONSTRUCTION INDUSTRY IS THE MAIN CUSTOMER FOR EPS
40 YEARS OF ACTIVITY, 20 YEARS OF SUSTAINABILITY
A WHOLE RANGE OF SOLUTIONS FOR THE DOWNSTREAM HIGH PERFORMANCE WITH NO COMPROMISES REDUCING OPERATING COSTS, OPTIMISING PROCESSES AND SAVING ENERGY
68 68 69 70
A BREAKTHROUGH SOLUTION FOR THE RECYCLING PROCESS A CENTRE FOR INFRARED TESTS FIVE TIMES AS INSPIRING A COMPLETE AND UNIQUE OFFER
MACPLAS INTERNATIONAL OCTOBER 2021
COVER STORY
Published by Promaplast Srl - Centro Direzionale Milanofiori - Palazzo F/3 - 20057 Assago (Milano, Italia) - ISSN 0394-3453 - Poste Italiane SpA - Spedizione in abbonamento postale - 70% LOM/MI/2363
MACPLAS INTERNATIONAL
THE MAGAZINE FOR THE PLASTICS AND RUBBER INDUSTRY
ITALIAN MACHINERY - ALL INDICATORS ARE GOOD FOR THE FIRST HALF OF THE GREEN TECHNOLOGIES ON DISPLAY IN 2022 UPCYCLING IN THE MOST COMPLETE SENSE THE NEW FRONTIERS OF MEDICAL TPE
www.macplas.it YEAR
www.sonderhoff.com
73
80
73
MATERIALS AND APPLICATIONS 73 76
THE NEW FRONTIERS OF MEDICAL TPES HIGH PERFORMANCE COMPOUNDING SOLUTIONS FOR ALL NEEDS
76 77 77
3D PRINTING MATERIAL MADE FROM RPET PCB-FREE SILICONE COMPOUNDS STRUCTURAL AND SELF-EXTINGUISHING HANDLE MADE OF GLASS FIBRE REINFORCED PA66
78
PERFECT EXAMPLES OF CLEANING WITH PURGING COMPOUNDS
80
TRADE FAIRS AND CONFERENCES 80 NEW DATES AFTER THE PANDEMIC 80 EXHIBITIONS & TRADE FAIRS 82 THE TWO-DAY CONFERENCE AND EXHIBITION RETURNS TO AMSTERDAM
82
All from a single source
ONE STOP SHOP FOR SECURELY SEALED EV BATTERY HOUSINGS The Sonderhoff brand, part of Henkel since 2017, is a technology platform offering customized sealing, bonding, and potting solutions for the automated dispensing application of 2-component material systems with Formed-In-Place (FIP) technology onto industrial components. With its broad range of technologies and know-how, Henkel is the partner of choice for complete solutions in the automotive industry and especially for electric vehicles (EV). Henkel’s conductive coatings and thermal interface material products, as well as assembly adhesives and polymer liquid sealants, are used to protect battery packs in electric cars. An important prerequisite for maintaining the service life of EV batteries is a permanently functioning seal of the battery housing in the car underfloor. The battery housings installed in the car underfloor are sealed seamlessly, with an almost invisible coupling point, using the room temperature cross-linking 2-component polyurethane foams from the Fermapor K31 product family. The CNC-guided mixing head of the DM 402 mixing and dosing machine from Henkel traverses the housing geometry and applies the medium-viscosity sealing foam with contour precision in accordance with FIPFG (Formed-In-Place-Foam-Gasket) technology. After foaming, the result is a seamless soft foam gasket that cures at room temperature. The EV battery housings are thus protected against moisture, corrosion, and dust. In addition, the sealing foams dampen vibrations caused by driving, and they are temperature and material-specific chemical resistant. Protection from these influencing factors helps to improve the longevity of EV batteries. When the battery housing cover is screwed into place, the elastic foam cell structure of the seal is compressed. Thus, the housing and cover are sealed to each other. The very good resetting ability of the foam seal allows the housing to be opened and closed repeatedly for maintenance purposes while maintaining a high level of tightness. The housing is tight, and the batteries are protected against splash water and the effects of the weather. On the cover of this magazine, you can see a polyurethane foam seal used for sealing EV battery housings; in this case, the material was dispensed at Henkel-Sonderhoff site in Oggiono, in the province of Lecco (Lombardy). www.sonderhoff.com
MEETINGS & CONGRESSES
MACPLAS INTERNATIONAL OCTOBER 2021
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MACPLAS INTERNATIONAL
ADVERTISERS’ LIST
75 AMAPLAST www.amaplast.org
Supplement of MacPlas August/September 2021
34 ATOS www.atositalia.com
43 BARUFFALDI
Editor in chief Riccardo Ampollini
25 BINOVA www.binovapm.it
Editorial staff Luca Mei, Girolamo Dagostino, Stefania Arioli
IV Cop. BMB
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32 BMTEK (KIMATIC)
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22 BREAK POLYMER
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Sales office Roberta Pagan
47 CAMPETELLA www.campetella.com
83 CHINAPLAS www.chinaplasonline.com
Editorial assistant Giampiero Zazzaro
51 CM PRODUZIONE www.cmevolutionplast.com
Editorial committee Dario Previero, Gabriele Caccia, Massimo Margaglione
37 DM INDUSTRIAL www.dmindustrial.it
36 FILIPPINI & PAGANINI
www.saldoflex.com
21 FIMIC
www.fimic.it
Contributors to this issue Amaplast, AMI, Assogomma, Ceresana, Conai, Federazione Gomma Plastica, Greenplast, Ipack-Ima, Ermanno Pedrotti, Plast 2023, Plastics Industry Association, Plastics Recyclers Europe, Ucima, University of Bozen Published by Promaplast Srl Centro Direzionale Milanofiori - Palazzo F/3 20057 Assago (Milano, Italy) Tel.: +39 02 82283735 Fax: +39 02 57512490 e-mail: macplas@macplas.it www.macplas.it Registration at the Court of Milan n. 68, 13/02/1976 Registration at the National Press Office n. 4620, 24/05/1994 Managing director Mario Maggiani Administration Alessandro Cerizza
27 GAMMA MECCANICA www.gamma-meccanica.it II Cop. GEFRAN 31 GIURGOLA STAMPI
www.gefran.com www.giurgolastampi.com
III Cop. GREENPLAST www.greenplast.org
59 GUMMIWERK KRAIBURG
www.kraiburg-rubber-compounds.com
53 HELIOS ITALQUARTZ
www.heliosquartz.com
41 HERRMANN ULTRASCHALLTECHNIK www.herrmannultraschall.com
4 IMG www.imgmacchine.it
15 IPM
www.ipm-italy.it
3 ITIB MACHINERY www.itib-machinery.com
72 JEC FORUM DACH
84 MACPLAS www.macplas.it
69 MARFRAN www.marfran.com
12 MARIS
67 MESGO www.mesgo.it
49 MIXACO www.mixaco.com
www.jec-dach.events
www.mariscorp.com
Layout and prepress Nicoletta Albiero
45 PHT PETRELLI
Printed by LOGO
79 PLAST 2023 www.plastonline.org
81 PLAST EURASIA
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Postal delivery: IFS Italy
9 PLASTIBLOW
www.plastiblow.it
5 PLASTIC SYSTEMS
www.plasticsystems.it
ISSUE PRICE: 8 euro if not sent with mother magazine
19 PRESMA www.presma.it
The managing direction of the magazine declines any responsibility for possible unreliability of editorial articles and notes coming from various sources
62 PROFILE DIES www.profiledies.it
ASSOCIATED TO:
35 SALDOFLEX www.saldoflex.com
63 SARA
www.sarasrl.eu
60 SITRA
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ASSOCIAZIONE NAZIONALE EDITORIA DI SETTORE
65 PLASTORE www.plastore.it
I Cop. SONDERHOFF (HENKEL) www.sonderhoff.com
11 STAR AUTOMATION EUROPE www.star-europe.com
57 TECNO SYSTEM www.tecnosystemfe.it
71 ULTRA SYSTEM
www.ultrasystem.ch
INSTITUTIONAL SPONSORS AMAPLAST ITA LI A N PL ASTIC S A N D RU B B ER PRO CES SIN G M ACHIN ERY A N D M O U L DS M A N U FACT U R ERS’ AS SO CI ATIO N
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SPE ITALIA SO CIE T Y O F PL ASTIC S EN G IN EERS
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IIP ITA LIA N PL ASTIC S INSTIT U T E
UNIPLAST ITA LI A N STA N DA R D ISATIO N BO DY FO R PL ASTIC S
ASSOGOMMA ITA LI A N RU B B ER, CA B L ES, WIR ES A N D SIMIL A R M A N U FACT U R ERS’ AS SO CI ATIO N
8
MACPLAS INTERNATIONAL OCTOBER 2021
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EDITOR’S LETTER
RICCARDO AMPOLLINI
“
5G: NEW OPPORTUNITIES FOR POLYMERS The fifth generation of wireless data transmission technology, as well as ushering in changes for the tablet and smartphone industry, is opening up golden opportunities, in the fields of construction and architecture, for the plastics and composites sector. The growing importance of radiofrequency (RF) transparent polymers for next generation urban infrastructure indeed translates into new market opportunities, on a scale far greater than those offered by current building applications. Furthermore, composites with customised mechanical and dielectric properties can offer even more effective solutions for high-performance 5G applications. Transmission stations and so-called radomes - this term derives from the words “radar” and “dome”, and it refers to special structures, usually dome-shaped or spherical, used to protect antennae from weather agents - require new construction materials to minimise signal losses and boost network efficiency. As indeed do the futuristic “smart light poles” that will allow mobile operators to “densify” their networks without this impacting on the urban landscape. On top of this, high energy efficiency building systems with better penetration of the RF signal will offer the most innovative designers still more opportunities. And while all this is going on, Su Xin, head of the working group on 5G technology at the Chinese Ministry of Industry and Information Technology, has revealed that China began researching 6G technology as long ago as 2018, while Neil McRae, head of architecture and technology strategy at British Telecom, speaking during an industry forum, has already sketched out the future of the 6G network and even of the seventh generation one (7G)! What can we say? Just that, for plastics and composites, the prospects in this sector look set to grow at truly exponential levels!
10
”
MACPLAS INTERNATIONAL OCTOBER 2021
VI ASPETTIAMO A BolognaFiere
23-25 NOVEMBRE
2021
www.star-europe.com
AMERICA
EUROPE
ASIA
OCEANIA
USA Mexico Brasil
Italy
Japan - China - South Korea - India Vietnam - Thailand - Taiwan Philippines - Singapore - Indonesia
Australia
Star Automation Inc Hq Menomonee Falls, Wisconsin USA
Star Automation Europe Spa Caselle di S. Maria di Sala (VE) ITALY
Star Seiki (Xiang Yang) Co, Ltd Xiangyang, Hubei CHINA
Star Seiki Co, Ltd Izumo Plant Izumo, Shimane JAPAN
MARKETING
PROCESSING AND PACKAGING MACHINERY MANUFACTURERS
ALL INDICATORS ARE GOOD FOR THE FIRST HALF OF THE YEAR: TURNOVER AND ORDERS ARE GROWING TURNOVER HAS INCREASED BY +11% IN THE FIRST SIX MONTHS OF 2021 FOR ITALIAN PLASTICS AND RUBBER PROCESSING MACHINERY MANUFACTURERS. THE PACKAGING MACHINERY SECTOR ALSO HELD ITS GROUND IN 2020, WITH A TURNOVER OF ALMOST 8 BILLION EUROS
A
positive trend for plastics and rubber processing machinery in the first half of 2021 has been announced by the trade association Amaplast: the latest mid-year survey conducted by the Mecs Statistical Study Centre records double-digit growth in both turnover and orders, consolidating the climate of renewed faith in the sector after the long and difficult period of the pandemic. With respect to January-June 2020, turnover has increased by +11%. Domestic machines sales have remained high while demand abroad principally regards replacement parts. Companies have also witnessed a clear improvement in their order books in the first six months of 2021, recording +46% with respect to the previous year. The recovery is mainly driven by the major commissions for plants by Italian customMACPLAS INTERNATIONAL OCTOBER 2021
ers (with an impressive +134% in the last quarter alone) but there is also a very positive trend in orders from abroad, both for machinery and for replacement parts (+58%). Given this trend an average of 6.4 months of production are already assured. The rebound in the domestic market thus confirms a greater propensity for investment by Italian companies, partially thanks to incentives (tax credits for modernizing systems and investing in Industry 4.0) provided by industrial policy plans. All four major sectors for plastics and rubber processing machines continue to show lively performance. Medical, packaging, and automotive, in particular, show signs of growth that should be confirmed in the coming months while the construction industry has stabilized.
Uncertainties still remain regarding the spread of the Delta variant of coronavirus and concern is still high about high raw materials prices and their relative scarcity, factors which lengthen average delivery times and compress margins. Also contributing to tensions is the unabated rise in sea freight rates, which have reached record levels. Logistic difficulties and increasing shipping prices are seen in all geographical areas and the trend probably continued through the Summer, since demand generally increases in this season.
RESULTS OF THE NATIONAL STATISTICAL SURVEY Furthermore, the Mecs Study Centre has completed its National Statistical Survey, conducted for the first time in organic form amongst Italian
13
MARKETING
manufacturers of plastics and rubber processing machinery, equipment, and moulds. The general picture shows a sector that produced revenues of 3.74 billion euros in 2020, with nearly 76% of the total from exports, confirming the historical emphasis on exports by companies in this industry. The nearly 350 companies surveyed, employing just over 13,000 people, are mainly concentrated in Lombardy (55%), Emilia-Romagna (15%), and Veneto (13%). Most of them are small companies: 74% bring in less than 10 million euros in revenues, with an aggregate value that does not reach a quarter of the total and less emphasis on exports. In parallel, large companies (26% of the total) generate 77% of the turnover and reach export quotas above 85%. The greater level of detail in the survey with respect to its predecessors also makes it possible to identify the shares of production by application and technology. The first indicator shows that packaging is the main outlet market for Italian machinery manufacturers, and more specifically food packaging (30% of turnover), followed by other packaging segments (approximately 12%). Automotive absorbs 19% of production, and construction 11%; medical, agriculture, electronics/electrotechnics, and other applications follow in decreasing order with shares ranging from 4% to 2%. As for machinery types, Mecs observed that the category of the extruders, with 17% of the total, represents the largest core of turnover for the sector; that is followed by auxiliaries at 12%, injection moulding machines at 11%, and blow-moulding machines at nearly 7%. Recovery and recycling lines and the macro-category of rubber processing machines approach a share of 6% each.
PACKAGING MACHINERY: FIRST-HALF 2021 SALES RETURN TO 2019 LEVELS The automatic packaging machinery industry reAll four major sectors for plastics and rubber processing machines continue to show lively performance. Medical, packaging, and automotive, in particular, show signs of growth
corded a robust 21% growth in the first half of 2021 compared to the same period in 2020. In the period from January to June, exports were 19.3% higher than in the first half of 2020 and domestic sales up 31.2%. With these figures, the entire industry has returned to pre-pandemic levels, with a difference of just -1.8% compared to the first half of 2019 (a record year that saw yearend sales in excess of 8 billion euros). This performance was the combined result of 9.2% growth in the first quarter and an even higher 29.4% growth in the second quarter compared to the same period in the previous year. The growth is similar in the domestic market (+34%) and in the export market (+28.4% compared to the previous year). The Mecs Centre also published data on orders, which were up by 10.9% in the second quarter and 10.7% over the entire first half of the year. It also reported the results for 2020 in the ninth National Statistical Survey, which every year provides an overview of the packaging sector’s performance. Last year the Italian automatic packaging machinery manufacturers essentially maintained the previous year’s turnover levels. Following the record figures of 2019, the sector saw a modest year-on-year decline of 2.9% to 7.81 billion euros, in line with the result of 2018 (7.9 billion euros). Last year also saw an increase in both the number of companies in business (635 in total, +3.1%) and in the number of employees, which grew by 7% to 35,630. International and domestic markets In line with 2019, export sales accounted for 78% of the total (6,08 billion euros) but fell by 4,1%. The European Union remained the main target market for Italian packaging machinery and accounted for 41% of total turnover (2,087 million euros) including sales in Italy, followed in second place by Asia with a value of 985.8 million euros and a 19.4% share, then North America in third place with 733.1 million euros (14.4%). North America is the only macro region that saw growth in turnover (+5.9%) with respect to 2019, a year when exports dropped to 691.9 million euros. Next came non-EU Europe (8.6%, or 439.7 million euros), Africa and Oceania (8.4%) and Central and South America (8.2%). The domestic market continued the positive trend seen in recent years with sales up 1.9% year-on-year in 2020 to 1.72 billion euros. Client sectors In the breakdown of turnover amongst the various client sectors, food and beverage maintained its dominant position in 2020 and accounted for 58.2% of total turnover. More specifically, food alone made up 32.2% of total sales (2,516 mil-
14
Turnover in the first half of 2021 fell by just 1.8% compared to the same period in the record year 2019 for packaging machinery manufacturers
lion euros) and beverages 26.0% with 2,032 million euros. Together food and beverage recorded 1.7% growth in 2019. As in 2019, third place by volume went to the pharmaceutical sector with 1,356 million euros (17.4% of the total). Next came cosmetics, the only non-food sector to show growth, with a turnover of 348.7 million euros (+11.4%). The chemicals industry closes out the rankings with 270 million euros. Turnover by machinery type and the industrial structure Primary packaging machinery remains the dominant category with a 53.2% share of turnover, followed by secondary packaging (18.8%) and end-of-line machinery (13.9%). The 635 Italian packaging machinery manufacturers are mainly concentrated along the Via Emilia between Piacenza and Rimini (the socalled Packaging Valley), with further production districts located in Lombardy, Piedmont, Veneto and Tuscany. The breakdown by turnover class reveals a marked predominance of small companies (those with revenues under 10 million euros make up 79% of the total), although they account for just 17% of total turnover. By contrast, the more structured industrial companies (51 with revenues of over 25 million euros) account for 68% of turnover and 74% of exports. The outlook for 2021 “The figures for the first half of 2021 speak volumes about the good work done in 2020, when our companies continued to operate”, comments Matteo Gentili, chairman of Ucima. “Indeed, the industry took advantage of the difficult national and international situation to further develop and improve its solutions in terms of digital technologies and we are now reaping the benefits. The resilience displayed in 2020 and the growth in the first 6 months of 2021 confirm the solidity and dynamism of our sector, which continues to play a strategic role within the Italian capital goods industry. We are confident about the second half of the year and expect to see growth in several markets”. www.amaplast.org www.ucima.it MACPLAS INTERNATIONAL OCTOBER 2021
MARKETING
Managing director of the Datwyler healthcare plants and activities in Italy, the new president of Assogomma, Livio Beghini, has spent his entire professional life in the rubber world, to which he is linked by consolidated professional relationships with local companies
INTERVIEW WITH LIVIO BEGHINI
PROGRAMME AND OBJECTIVES OF THE NEW PRESIDENT OF ASSOGOMMA CONTINUOUS TRAINING AND LEARNING, DIGITAL TRANSFORMATION, INTERNATIONAL SPIRIT, TECHNICAL DEVELOPMENT OF CERISIE’S LABORATORIES AND MAXIMIZATION OF RECYCLABILITY OF RUBBER SCRAPS AND WASTE ARE THE FIVE FUNDAMENTAL GUIDELINES OF LIVIO BEGHINI’S PRESIDENCY PROGRAMME
O
n June 30, during the annual assembly of Assogomma (Italian Rubber, Cables, Wires and Similar Manufacturers’ Association), Livio Beghini was elected president for the four-year period 20212025. Beghini, who takes over from Matteo Battaini (Pirelli), thus continues his journey in Assogomma and Confindustria during which, for two consecutive terms, he was a member of the General Council of Assogomma and is still a member of the Rubber-Plastic material groups of Assolombarda and Confindustria Vicenza. For many years, Beghini has been managing director of the Datwyler healthcare plants and activities in Italy. With more than 7000 employees, Datwyler is a leading provider of high-quality, system-critical elastomer components for attractive global markets such as healthcare, mobility, food & beverage and
16
general industry. Livio Beghini has spent his working life in the rubber sector and, in particular, in companies that manufacture technical articles. For many years he has actively contributed with a spirit of enterprise to industrial associations, but also through educational initiatives in higher education institutes and universities. On the occasion of its annual assembly, the association asked the new president some questions to find out what he thinks about the situation of the sector and his plans for the newly inaugurated four-year period.
FIRST OF ALL, CONGRATULATIONS ON YOUR NEW ROLE. BEING PRESIDENT OF AN ASSOCIATION LIKE ASSOGOMMA, THAT REPRESENTS A STRATEGIC MANUFACTURING SECTOR, IS CERTAINLY ALWAYS CHALLENGING BUT
IT IS EVEN MORE SO TODAY IN THE HEALTH AND ECONOMIC CRISIS THAT IS PROFOUNDLY IMPACTING NOT ONLY ITALY BUT THE WORLD AS A WHOLE, BOTH ECONOMICALLY AND SOCIALLY. CAN YOU TELL US A LITTLE ABOUT THE ECONOMIC SITUATION OF THE ITALIAN RUBBER SECTOR? WHAT ARE TODAY’S MAIN ISSUES? “Thank you very much for the well wishes and yes, I agree that being president of Assogomma is certainly a challenge. A challenge that I gladly accept, hoping to do my best for a manufacturing sector in which I have grown professionally and which I consider an Italian treasure that we should all be proud of. The rubber sector has certainly gone through a critical phase with the pandemic which, unfortunately, we cannot say is behind us yet. Production was brought to a halt in early 2020 MACPLAS INTERNATIONAL OCTOBER 2021
because it was considered a non-essential sector, and only the commitment and effort of companies and the association enabled us to turn this decision around. The year 2020 ended with a significant reduction in production, -17%, to which technical and pneumatic articles contributed equally and which was substantially in line with the trend of other European rubber manufacturers, but was actually better than the German and French markets. Of course, since rubber has so many uses, the type of product and the market served lie behind the difference in the accounts at the end of the year. Today, the situation has changed for the better; at the beginning of the new year, we saw the first signs of a recovery both in Italy and globally. Our sector has responded well but it has been strongly penalised by the steep rise in the cost of the raw materials. In these difficult months there was a concentration of low availability of inputs, price increases, increases in transport costs, but also an increase in demand for intermediate goods as a result of the restart of the international production chains. All this translates into companies struggling to cope with the recovery and that are often forced to reduce their profit margin to maintain their market share. The question, today, is therefore that of dealing with the contingent situation, albeit holding a new vision of the future which also embraces the opportunities arriving from the European Union that aspires to spur civil society and industry towards concepts of sustainability, digitisation and upskilling to become less polluting, more technological and informed countries and, consequently, more competitive globally”.
Manufacturer of caps and rubber seals for pharmaceutical packaging, Datwyler is a Swiss company, but with two production plants in Italy (in Pregnana Milanese, Milan, and in Montegaldella, Vicenza) MACPLAS INTERNATIONAL OCTOBER 2021
Fig. 1 - Production in the Italian rubber sector from 2011 to 2020 (tons)
Technical articles
BEARING THIS IN MIND, WHAT ARE YOUR OBJECTIVES AND PLANS FOR YOUR TIME AS PRESIDENT? “In my programme, I have pinpointed five fundamental precepts that reflect my idea on what I have already said, namely: continuous learning, digital transformation, international spirit, technical development of Cerisie’s laboratories and maximization of recyclability of rubber scraps and waste. By addressing these precepts one by one, the association will be able to offer its companies new tools to make product development faster and more effective, reduce their production costs, grow by developing internal skills and, ultimately, improve their ability to do business in an increasingly competitive world”.
CERTAINLY CHALLENGING GOALS! BUT LET’S TRY TO ANALYSE IN MORE DETAIL THE PRECEPTS PROPOSED; LET’S START FROM LEARNING. CONTINUOUS TECHNOLOGICAL UPGRADING IS EXPANDING EXPONENTIALLY FROM THE IT AND WEB SECTORS TO THE ENTIRE ECONOMIC AND INDUSTRIAL WORLD. THE TRAINING AND UPSKILLING OF WORKERS IS THEREFORE NO LONGER MERELY DESIRABLE, BUT NECESSARY, FOR COMPANIES IN A TRADITIONAL SECTOR SUCH AS THE RUBBER SECTOR. HOW DO YOU INTEND TO ADDRESS THESE NEEDS THROUGH THE ASSOCIATION? “Thank you for the question, because the issue of learning is a subject that is particularly close to my heart, to which I am personally committed and for which I have also received specific powers from the Italian Plastic Rubber Federation as vice president. Companies in the rubber sector have suffered for a long time from the lack of technical and technological expertise, mainly due to the fact that schools and
Tyres
universities have not produced enough specialists in the sector. Assogomma has had its own training programme and has been close to the Foundation of Higher Technical Institutes (ITS) for many years, and I would like to strengthen this bond, further expanding the ITS model throughout Italy, promoting new contacts with universities and, in general, moving towards a model of lifelong learning. Companies in the sector will have the chance to take part in the training courses, as some already do, as well as welcome students who will be tomorrow’s technology experts. For sure, we will have to overcome some initial scepticism of those who see all of this as a burden rather than an opportunity, but, in this respect, I believe that I can use my personal experience to dispel doubts. These will be the cornerstones for launching the idea of an “Assogomma Academy” that, with the right “teaching” resources and with its students, will have to make use of modern technologies for the dissemination of knowledge. I am thinking, for example, of MOOC (Massive Open Online Courses) and e-learning in general, consolidating a model of lifelong training for the entire Italian rubber sector”.
LET’S MOVE NOW TOWARDS THE THEME OF “DIGITIZATION”. THE NEW EUROPEAN AND ITALIAN GROWTH AND FUNDING PROGRAMMES PAY GROWING ATTENTION TO THIS ISSUE. WHAT CAN DIGITISATION MEAN FOR A SECTOR IN WHICH MANY SMEs OPERATE? HOW DO YOU THINK BUSINESSES SHOULD INTERPRET THE TERM “DIGITISATION”, TRANSFORMING GENERIC CONCEPTS INTO CONCRETE PROJECTS? WHAT IS THE ASSOCIATION’S ROLE? “Digitisation, digital revolution and digital
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MARKETING The development of ITS training courses is one of the objectives of the new Assogomma presidency
transformation are different, but similar, ways of describing what could be called a paradigm shift. The times we are living in see the increasingly pervasive presence of technology in our daily life, and certainly in our way of doing business. In this context, being a large, medium or small company certainly means that this change has to be scaled but it does not eliminate the need to embrace a new way of thinking and acting, a new language. Issues such as the development of new business models based on Big Data analysis are now on the agenda and, even more so, analysis of production processes and development of event prediction algorithms. All these tools can be made available to members eager to learn the digital language through the association, that must be able to interpret the changes and act as an intermediary between the members and the institutions/sectors of maximum innovation, such as universities and start-ups”.
LET’S NOW COME TO ONE OF THE MOST TOPICAL ISSUES, THE PNRR (NATIONAL RECOVERY AND RESILIENCE PLAN) WHICH HAS BEEN APPROVED BY THE EUROPEAN COMMISSION AND WILL GUARANTEE THE RELEASE OF THE FIRST BATCH OF FUNDS FOR ITALY. ENVIRONMENTAL IMPACT OF HUMAN ACTIVITIES, SUSTAINABILITY AND CIRCULARITY BECOME “PILLARS”, KEY CONCEPTS TO BE TAKEN INTO ACCOUNT TO DESIGN OUR FUTURE. RUBBER CERTAINLY HAS THE ADVANTAGE OF BEING A MATERIAL THAT EXISTS IN NATURE, BUT ITS GREEN CHARACTERISTIC IS NOT SO WELL KNOWN. WHICH POSSIBILITIES DO YOU
SEE FOR THE SECTOR AND HOW DO YOU INTEND TO PROMOTE THEM? “The question couldn’t be more apropos! It is true that rubber has natural origins and, as such, sustainable. Just think that natural rubber now represents just under 50% of the world’s rubber consumption for the production of tyres and technical articles. But today this strength must be further enhanced in terms of material recovery and circularity. While much has been done in the world of tyres from this point of view (a perfect example of a circular economy thanks to end-of-life reconstruction and reuse techniques), much remains to be done in the production of technical articles. I am thinking, above all, about the recovery, reuse and recycling of rubber production waste. There are two fronts on which action has to be taken: giving companies clear operational instructions to apply the regulations and identify all the recoverable material; improving existing technologies to treat waste material, so that they are sustainable also from an economic point of view. The really ambitious goal to aim for is to eventually eliminate landfill disposal, with a huge environmental and economic benefit for the sector!”
LASTLY, WE CANNOT FAIL TO MENTION THAT ASSOGOMMA HAS ITS OWN NETWORK WITH A UNIQUE LABORATORY IN TERMS OF SKILLS AND CUSTOMISATION, THAT IS CERISIE. FOR SOME YEARS, THE PRESIDENT OF ASSOGOMMA AND OF CERISIE HAVE BEEN THE SAME PERSON AND THE BOARD OF DIRECTORS INCLUDES THE TWO RESPECTIVE DIRECTORS, ONE REPRESENTATIVE FROM THE TYRE
INDUSTRY AND THE OTHER FROM THE TECHNICAL ARTICLES’ INDUSTRY. A TEAM READY TO TAKE ON BOARD ALL THE NEEDS OF THE RUBBER SECTOR. WHAT IS YOUR VISION FOR CERISIE TODAY AND IN THE FUTURE? “As the new president of Cerisie, I have set myself the goal of maximising the laboratory’s ability to meet the needs of customers by giving even more added value to companies in the sector. Companies need an advanced technical partner able to support them in their business needs, especially when these translate into the development of joint research projects with the world of universities. Cerisie has the skills needed to be the link between these two worlds, industry and research. But not only. Cerisie has both the skills and the technological equipment to further develop the field of technical advice and support, essential for companies to be able to address the problems of research and development, as well as those of technical litigation. In other words, my vision is that of a Cerisie which, with the support of the entire governance team, is committed to further growth that allows it to be not only known, but even more widely recognised both nationally and internationally”.
PRESIDENT, THANK YOU FOR YOUR TIME AND WE CAN ONLY WISH YOU ALL THE BEST FOR THE COMING FOUR YEARS.
As the new president of Assogomma, Beghini will also take on the role of president of Cerisie and, therefore, has set himself the goal of maximising the laboratory’s capabilities to meet customer needs, giving even more added value to companies in the elastomers sector
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“My thanks go to the companies in the sector for the trust they have placed in me and that I hope to repay with the maximum personal commitment, backed by the structure of Assogomma, always at the service of the companies. Finally, allow me to thank my predecessor Matteo Battaini, from whom I take over a system that is already prepared and accustomed to change”. www.federazionegommaplastica.it MACPLAS INTERNATIONAL OCTOBER 2021
MARKETING
NEWS Mind the gap
Increasing productivity is the key to US economic recovery
Figure 1 - Retail sales and industrial production in the United States from June 2019 to June 2021 (Index, February 2020 = 100)
Cast PP films in Europe
Sustainability drive creates new growth opportunities Demand for cast PP films continues to grow in Europe. The heat resistant properties of the film are invaluable to food packaging converters as well as those catering to the medical and healthcare market, sectors which have proven themselves to be Covid-19 resilient industries, according to a recently published report by Applied Market Information (AMI). The Covid-19 pandemic caused consumers to become more concerned with sterility and safety of their products, choosing sealed products other unpackaged, or those with loose wrapping. This stalled the “less plastic packaging” trend although this is expected to pick
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Source: Plastics Industry Association’s analysis of US Census Bureau and Board of Governors of the Federal Reserve System data
rubber manufacturing unemployment rate was 2.9%. At that rate - lower than the overall manufacturing unemployment rate of 4.2% - the plastics industry continues to fill open positions. Looking ahead, the extended unemployment benefit ending in September could increase the economy’s labour participation rate and, in turn, productivity. “To sustain the economic recovery, industrial production needs to increase. To get to that point, the economy’s consumption and production need to be more in sync. As we continue to deal with the pandemic, however, it could continue to be a slow-moving process”, concluded Perc Pineda. www.plasticsindustry.org
up as sustainability comes back to the fore. Although cast PP film is used worldwide, the market in Europe is of particular interest, being at the forefront of the drive to sustainability and the circular economy. Cast PP films can be utilised in polyolefin-based monomaterial “recycle-ready” film constructions, making it a go-to film for many packaging applications, and spurring future growth opportunities. New manufacturing techniques are providing further options for versatility, and many cast PP film lines confirmed for future production are earmarked for capacity expansion or upgrading to improve speed and efficiency. There is still a West/East divide in terms of packaging use. Cast PP production is growing in new geographic locations, which will prompt a change in trade flows. Food packaging accounts for the largest production volume globally, with growth continuing to be spurred by changing consumer lifestyles
which require more convenience products, especially those which require heat resistance, such as retort and sterilisable pack formats. In contrast, the production of cast PP film for stationery is declining as a result of the move to paperless offices. As a consequence, food packaging’s share of overall cast PP production is increasing (figure 1). www.ami.international Figure 1 - Cast PP films production in Europe by application (2020)
Source: AMI, 2021
The Covid-19 recession was the shortest in the United States history. It started in February and ended in April last year. “While the recession was short, it stopped our economy in its tracks”, said Perc Pineda, chief economist at the Plastics Industry Association. The recession caused a contraction of 5.1% in Q1 2020 and a contraction of 31.2% in Q2 2020 measured by real gross domestic product (GDP) on an annualised basis. Thereafter, real GDP growth bounced back at 33.8% in Q3 2020 and 4.5% in Q4 2020. In the first and second quarters this year, real GDP increased 6.3% and 6.5%, respectively. Fourteen months since the end of the Covid-19 recession, the US economic recovery continues to face challenges. According to Pineda, the gap between demand for goods and services and the economy’s production of them has continued to widen. Advance retail sales and industrial production show the economy’s demand and supply growth rates are out of sync (figure 1). The economic recovery was fuelled by strong household spending. The fiscal policy response of the US government to the Covid-19 recession helped put money in family’s pockets. This initially caused a surge in consumer essential expenditures and eventually led to higher spending on durable goods and residential fixed investments spending. Supply chain difficulties as business activity restrictions started last year and low labour supply have caused the supply of goods and services to lag behind rising demand. While the economy added 943,000 nonfarm payrolls in July - taking the unemployment rate to 5.4% - the economy’s labour participation rate needs to rise to keep up with demand. This will cause an increase in the economy’s productivity. In July, the plastic and
MACPLAS INTERNATIONAL OCTOBER 2021
Some of the many and varied applications of expandable polystyrene
Global market for expandable polystyrene
Construction industry is the main customer for EPS It may sound strange, but crude oil can help with climate protection and energy saving. Less in heating or engines, but rather in the house facade: better building insulation is a key objective of the “European Green Deal”. Real estate is still responsible for almost 40% of the total energy consumption. That’s why the EU Commission is calling for a “renovation wave”. In order to drastically reduce greenhouse gas emissions, European countries are to invest around 200 billion euros a year to modernize the energy systems of homes and public buildings until 2030. Manufacturers and processors of expandable polystyrene (EPS), the
bestselling insulation material, are particularly benefiting from these initiatives to improve energy efficiency. According to the fourth edition of the Ceresana study on the global EPS market, the demand for EPS in 2020 amounted to around 6.59 million tons. EPS is a light, strong foam that can be shaped almost at will and is traded under brand names such as Styropor or Airpop. This versatile material consists primarily of air and expanded polystyrene, with the addition of flame retardants and other additives, such as graphite. Although EPS can also be found in safety helmets and life jackets, in beverage
MACPLAS INTERNATIONAL OCTOBER 2021
cups, casting moulds, and numerous other applications, however, around 53% of its market is accounted for by construction products. The construction industry uses the low-cost insulating material primarily to insulate against heat, cold and noise in new housing construction as well as in the renovation of old buildings. Its competitors are glass and rock wool, but insulating materials based on renewable raw materials are also becoming increasingly popular. Japan and South Korea, for example, also have ambitious climate protection goals with regards to buildings. In Asia Pacific and the
Americas especially, EPS is not only used for insulation materials, but is also widely used for packagin, for example for transporting fresh fish or electronic products. The segment packaging accounts for over 40% of the total demand for EPS around the globe. According to the Ceresana’s report, the Asia-Pacific region accounted for around 57% of the global EPS demand in 2020. For China, analysts expect growth rates to remain above average, despite a slowdown in the construction industry. Per capita demand for EPS packaging is rising, particularly in emerging and developing countries. www.ceresana.com
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RECYCLING WILL NEVER BE THE SAME
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The press event dedicated to the presentation of the Greenplast exhibition was held on July 7 at the Milanofiori Directional Centre in Assago (Milan, Italy)
PLASTICS AND ENVIRONMENT
GREEN TECHNOLOGIES ON DISPLAY
THE THREE PILLARS OF GREENPLAST 2022 ENVIRONMENT, BUSINESS AND CULTURE. THESE ARE THE THREE GUIDING PRINCIPLES FOR THE EXHIBITION/ CONVENTION CONCEIVED AND ORGANIZED BY PROMAPLAST TO RESPOND TO THE NEED TO ILLUSTRATE AND PROMOTE THE SUSTAINABILITY OF A VERSATILE KEY MATERIAL, PLASTIC, IN DAILY CONSUMPTION BY ERMANNO PEDROTTI AND RICCARDO AMPOLLINI
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press event in Milan was held on July 7, in-person but also online, to present Greenplast, the new exhibition that will run at Fiera Milano from the 3rd to the 6th of May 2022, organized by Promaplast and dedicated to materials, technologies, and converting processes for plastics and rubber, but with the main focus on environmental sustainability, recovery, recycling, circular economy and energy efficiency. At the press event, the organizers has therefore launched the website greenplast.org, which already hosts detailed information on the exhibition’s objectives, organization, costs, partnerships, and so on.
ENVIRONMENT “For a long time, plastics were associated with just two factors: cost and performance”, Dario Previero said during the press conference. In addition to being president of Amaplast, Previero is the commercial director for his family MACPLAS INTERNATIONAL OCTOBER 2021
business, Previero-Sorema, established in the early 1920’s to deal in textile and woodworking machinery, but which, as early as 1950, had the foresight to switch operations to the design and construction of plastics recycling machinery. Therefore: if there is somebody who knows about the logic of recycling, this is precisely Previero, who in fact went on to say: “In all sectors, because of major technological advances, other factors came into play, such as lightweighting of plastic components which posed no problem for the environment but also multilayer performance materials, which are unfortunately difficult to recycle. As if that was not enough, making it difficult to work through this challenge, other variables have recently emerged, such as the speed with which consumer trends change - once it was a matter of years, now it is a matter of months and the legislative action, more sensitive to consumer opinions and emotions, introducing new rules on managing packaging at the end of
life, not easy to “metabolize” in the time allowed by the regulations. Therefore, we need more discussion and information which, starting with scientific data, enables us to make decisions that will allow us to meet environmental objectives without damaging the plastics industry. And it is in the wake of these practical needs, and also to overcome the calamitous impact of Covid-19, that the idea of creating an aggregation and reflection event began to grow in the heart of our association: Greenplast is, therefore, an exhibition-conference devised to respond in particular to the need to illustrate plastic materials from the standpoint of best practices for the environmental sustainability”. And so, from the 3rd to the 6th of May 2022, Fiera Milano will host the entire plastics and rubber industry at the Rho-Pero exhibition centre in an event dedicated to innovative solutions to boost sustainability, energy efficiency, options for reducing-reusing-recycling, and progress towards a circular economy. As experienced
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PLASTICS AND ENVIRONMENT
Mario Maggiani, director of Amaplast and CEO of Promaplast, organizer of the two exhibitions Greenplast 2022 and Plast 2023
CULTURE
The president of Amaplast, Dario Previero
first-hand by the Amaplast president working in the family business, companies in the industry have been investing in these areas for years, leading the way as dynamic and competitive market players.
BUSINESS “The exhibition/convention Greenplast will also allow operators to evaluate plastics and rubber processing technologies and the new Industry 4.0 paradigm with particular reference to our Made in Italy, which has stood out all over the world for its hi-tech solutions”, Amaplast director Mario Maggiani explained before going into detail on the spectrum of voices and categories that make up the exhibition areas, which are: • virgin, low-impact, low-carbon-footprint raw materials, secondary raw materials, biopolymers, additives; • semi-finished and finished products made from innovative, recycled, or biologically sourced materials; • machinery, equipment, and systems that combine low energy consumption with high performance, high-efficiency processing, and are able to use innovative, recycled and/or biologically sourced materials; • systems and machinery for the selection, processing, and recycling of industrial and post-consumer plastics and rubber waste; • support and consulting services for plastics and rubber production generally, and for recovery and recycling; • public corporations, consortia, and organizations active in the plastics and rubber recycling.
“The project will also promote occasions for contact and development”, added Fabrizio Vanzan, exhibition manager for Promaplast, the service company of Amaplast (Italian Plastics and Rubber Processing Machinery, Ancillaries and Moulds Manufacturers’ Association). “It is not by chance, therefore, that our exhibition will be held concomitant to other machinery exhibitions. In particular, Ipack-Ima, international exhibition for the packaging industry, considering the affinity between the packaging and plastics industries (some 50% of all packaging is made using plastics) and the fact that in the packaging world - and in particular amongst consumers, as mentioned by Previero - there is a strong demand for sustainable products. Furthermore, the fairgrounds will also host the concomitant Print4All, dedicated to printing technology, and Intralogistica Italia, with systems for industrial materials handling and supply chain, which will highlight the complementary spheres of business culture and know-how from the 3rd to the 6th of May 2022 at Fiera Milano”.
The simultaneity of Greenplast and the exhibitions described by Vanzan that are planned for May in Milan gives an immediate sense of the high level of business culture and/or the exchange of manufacturing experiences to be found at Fiera Milano. A symbiosis which, for those who attended the last Plast exhibition in 2018, contributes to reviving The Innovation Alliance project, which reported positive results for visitors and exhibitors. But at Amaplast, for 2022, there was a desire to do even more. “I confess that, when we were conceiving this exhibition-conference, we wanted to structure it in a similar way to the US fair APR or the Plastics Recycling Show Europe in the Netherlands, perhaps better known as PRSE”, Dario Previero concluded. “Therefore, Greenplast will also host an international conference of a day and a half, the details of which are still being worked out... though we can already confirm that some speakers are of international renown. The conference will obviously be dedicated to the themes of the exhibition, with a particular, natural leaning toward the plastic products and packaging segments”. In closing the press conference, Amaplast director mentioned that, after the disruption caused by the pandemic, the plastic industry will resume its key triennial fair, Plast, now rescheduled from the 5th to the 8th of September 2023. “Thirty thousand square metres have already been confirmed by the exhibitors, who have so far wanted to guarantee their participation at Plast 2023”, Mario Maggiani commented with satisfaction. www.greenplast.org
Dialogue with the entire plastics industry will resume with the international trade fair Plast, rescheduled from the 5th to the 8th of September 2023
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MACPLAS INTERNATIONAL OCTOBER 2021
PLASTICS AND ENVIRONMENT NEWS Conai’s report for 2020
Record numbers for recycling in Italy In 2020, packaging recycling rates in Italy exceeded all forecasts. The health emergency did not slow down the development of this area of the circular economy: according to last Conai consortium’s report, last year 73% of the packaging placed on the market was recycled, that is 3.3% more than in 2019. More than 9.5 million tons of packaging were recycled out of the total of 13 million tons introduced onto the market. The latter figure, as already announced last March, fell by more than 4% in 2020 compared to 2019 due to the exclusion of the packaging for commercial and industrial applications. However, the recycling volumes have not declined thanks to the increase in the separate collection of urban waste, which has been the driving force that has not suffered from the
difficulties following the lockdown. In detail, 371,000 tons of steel, 47,400 tons of aluminum, 4.048 million tons of paper, 1.873 million tons of wood, 1.076 million tons of plastics, 2.143 million tons of glass have found a second life. When adding the energy recovery figures, the total volume of packaging avoiding the landfill has further grown reaching 83.7%. Almost 11 million tons in total. “Conai’s figures are very important, as they make us understand that we are going in the right direction. In the sphere of packaging recycling, Italy confirms its leadership by achieving the EU target four years in advance”, stated Laura D’Aprile, head of the ecological transition and green investments department of Italy’s Ministry for Ecological Transition.
In a year heavily conditioned by the pandemic, the contribution of the Conai system to Italy’s recycling results is growing; in 2020 the consortium collected 52% of the packaging sent for recycling (50.2% in 2019). In this picture of an increasingly virtuous Italy, the work carried out by Conai with local authorities has played a fundamental role. In 2020, over 7,400 Italian municipalities have signed agreements with Conai, thus entrusting the packaging waste obtained from separate collection flows to the consortium, reaching 97% of the Italian population. To cover the higher costs that municipalities incur in collecting waste separately, in 2020 Conai awarded 654 million euros, while 452 million were allocated to finance treatment, recycling and recovery activities.
“Resources come from Conai member companies, which are the ones who bear the costs incurred in the end-of-life management of the packaging they originally placed on the market”, explained Luca Ruini, the president of Conai
In 2020 the delivery of packaging waste to Conai grew throughout Italy, with slight differences between the geographical macro-areas. This growth was driven by the North of the Country, which scores a + 6% of packaging from separate collection entrusted to the consortium system compared to 2019. In total, more than 2.84 million tons. The increase in the Southern regions is almost the same: +5% compared to 2019 (more than 1.51 million tons), while Central Italy, which is close to 1 million tons, recorded a +4% growth. www.conai.org
Co-operation between Dow and Mura Technology (an igus’ partner)
Hydrothermal recycling to convert plastic waste into oil… and new packaging
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will further drive the scaling of Mura’s advanced recycling process. The world’s first facility to use HydroPRS on a large scale is currently being built in Teesside, UK. The first line with a capacity of 20,000 tons per year is expected to start operation in 2022. Once all four lines are completed, Mura will be able to HydroPRS technology has the potential to recycle all kinds of plastic and recover oil from it
igus
The revolutionary HydroPRS technology for hydrothermal recycling, developed by the English start-up Mura Technology, promises the conversion of plastic back to oil in just 25 minutes, thanks to a process that uses water, heat and pressure. The aim is to build a sustainable circular economy for different polymers and prevent plastic waste from entering the environment. The start-up Mura Technology has already entered into collaborations with the engineering services company KBR and the motion plastics specialist igus. This latter company was the first investor from the industrial sector at the end of 2019 and had further increased its investment to 5 million euros in March. Now, Dow Chemical, a global developer and producer of plastics, is joining as another major partner. The collaboration
recycle up to 80,000 tons of plastic waste per year and supply Dow with the raw materials obtained through the process. Therefore, Dow will use this to develop new plastics for food packaging and other packaging products that will eventually be returned into global supply chains. With its contribution, Dow also intends to demonstrate that Mura’s solution can meet both the sustainability and performance requirements of the industry and that products made with HydroPRS can be used on a large scale to produce new plastics. igus CEO, Frank Blasé, welcomes the collaboration: “Strong partnerships are needed to help this technology achieving a breakthrough and thereby create a noticeable effect for the environment. We are delighted for Mura that Dow is on board”. www.muratechnology.com
MACPLAS INTERNATIONAL OCTOBER 2021
A research by the University of Bolzano
Biopolymer for acoustic insulation generated from algae and marine plastic waste Obtained through the processing of red seaweed, the biopolymer invented and patented by Marco Caniato, researcher and lecturer at the Faculty of Science and Technology at the University of Bolzano (Italy), allows plastic material waste and other types of inert materials to be used to create a foam that works extremely well as a thermal and acoustic insulating material for industrial, civil and maritime applications. It also seems to be a promising ally in the battle against the dispersion of plastic materials in the sea. In collaboration with the University of Trieste (Italy), Caniato developed this material using the agar agar seaweed extract, a polysaccharide normally used as a natural gelling agent which, once calcium carbonate has been added, can be mixed with pulverized plastic. In the development of this product, materials derived from industrial and domestic waste were used, specifically PE, PET and expanded polystyrene (EPS), as they are typical of the plastics most commonly found in the marine environment. After the gelation phase, the samples are frozen at -20°C for 12 hours
MACPLAS INTERNATIONAL OCTOBER 2021
Some samples of the new biopolymer foam developed by researcher Marco Caniato
and finally freeze-dried to remove the water. The final result is a porous material that can be used, for example, in construction, in place of rock wool. But it is not only the product that is environmentally friendly. In fact, the manufacturing process includes recycling of the water collected, after defrosting, at the end of freeze-drying step. This is not the first time that scientists have devised innovative ways of re-using plastic waste; others, in the past, have used it as fillers in asphalt mixes, for example. However, until now, no one had come up with an idea of this kind for recycling the plastics that float on the surfaces of our seas plastics that are difficult to recover and process, as they are often mixed with other materials (plastic or non-plastic) and covered with sea salt. “The characterization tests we ran confirmed that the product has excellent insulating properties and that it can easily compete with traditional insulating materials, such as rock wool or polyurethane foams. We have shown that it is possible to recycle marine waste using a sustainable, cleaner and more ecological approach, and that this makes it possible to build with an environmentally and economically viable material”, Marco Caniato declared. www.unibz.it
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PROCESSING MACHINERY
IMG - PLASTICS AND RUBBER MACHINERY, PRODUCTION CELLS, RETROFIT PROJECTS
AN INCREASINGLY BROADSPECTRUM BUSINESS CHOOSING A SUPPLIER IS ALWAYS AN EXTREMELY TIME- AND RESOURCE-CONSUMING PROCESS FOR THE PURCHASING DEPARTMENT OF A MANUFACTURING COMPANY, WHICH HAS TO ENSURE BOTH TIMELY AND RELIABLE INTERVENTIONS WHILE ALSO SEEKING TO IDENTIFY THE SOLUTIONS OFFERING THE BEST VALUE. FROM THIS PERSPECTIVE, IMG’S STRATEGY, WHICH IS TO COMBINE A BROAD AND COMPLEMENTARY RANGE WITH EFFICIENCY AND PROFESSIONALISM, IS CERTAINLY WELCOME BY ERMANNO PEDROTTI AND LUCA MEI
A
pparently, the Neapolitan historian and philosopher Giovanbattista Vico (1668-1744) would often point out that certain elements of the natural world provide excellent illustrations of the idea of cyclicity: the cyclical patterns of the moon, sun, seasons and tides have continued unchanged for billions of years. In the human sphere, the economy, too, can be defined as cyclical, given that its fluctuations are linked to alternating phases of expansion and recession. In this case, however, the oscillations are neither predictable nor constant. “If we talk about economic trends with our parents or grandparents, they will tell us that back in their days, economic crises tended to occur around once every 10-11 years”, begins Davide Bonfadini, sales manager of the Brescia-based manufacturer IMG, who we recently met at the company’s headquarters in
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Capriano del Colle, near Brescia (Italy). “Conversely, over the past 13 years, since 2008, the markets have gone up and down several times, and rapidly too”. The concept of boom and bust is of course a well-recognised aspect of capitalism, while “creative destruction” is a concept central to the thinking of Austrian economist Joseph Schumpeter (1883-1950). Like it or not, this is simply how the system works. Now, though, the question is: can we expect to see a post-pandemic boom? Bonfadini tries to give us an answer. “As a result of the fluctuations, related to the pandemic, that characterised 2020, our specialist field of injection moulding machines for rubber and plastic materials, like all manufacturing industries, and other sectors as well, saw declines in volumes of both orders and production, even though, to be honest, great
performances at the end of last year have helped us to make up for the lost months. Indeed, with regard to the plastics sector, we managed to close 2020 with results just 2% down on 2019. Instead, since the rubber sector is so closely bound up with the automotive world, that side of our business was harder hit; in fact, our performances in this area were in line with the figures issued by Anfia (the Italian association of the automotive industry), which, in the period January-June 2020, recorded over 11 million fewer vehicles produced compared with the same period in 2019. And we shouldn’t forget that the 92.1 million cars built in the course of 2019 already represented a 5% decline compared with the volumes for 2018. In short, the automotive industry has suffered a great deal and, as a consequence, so has the rubber sector. Nevertheless, confirming the rule that economMACPLAS INTERNATIONAL OCTOBER 2021
ic cycles are made up of unpredictable fluctuations of varying amplitude, I can say that the current year, 2021, has brought a positive economic bubble. So, yes, we are currently enjoying a post-pandemic boom that, because of the different materials our machines process, has, for us, given rise to two curves, or two separate trends. To illustrate the current situation, by last May, Haitian had already equalled the plastic moulding machinery sales volumes it recorded over the whole of 2020. But the thing that really matters is that we are managing to keep up this high pace. The only “fly in the ointment”, if you like, is the fact that the congestion characterising this post-Covid period is having the effect of slowing down deliveries from China and elsewhere. But this can be interpreted as a natural bottleneck, given the very short time still separating the slowdown due to the pandemic and the current strong recovery; it is, in any case, a situation we are still able to manage. As for the design and production of machines made here in Italy, that is to say our IMG rubber moulding presses, we are seeing a recovery there as well, as an effect of the automotive sector’s gradual adjustment to the transition from fuels to electric, but also of the current difficulties sourcing both mechanical and electronic parts. Indeed, the latter is a factor that has favoured IMG’s practice of developing and building almost exclusively ad hoc machinery. Whatever the factors at play, as our grandparents would often say when things were going well, we are currently “making hay while the sun shines”. Not least because no one can say whether the present bubble will carry on and shape the sales trends of the coming years. And by “making hay”, I also mean that
Davide Bonfadini, sales manager of IMG, near a Haitian machine. The Brescia-based company has been the exclusive distributor of Haitian in Italy for about a dozen years
we are reinvesting heavily in order to expand our range, both in terms of technology and the sectors we cover. Because this is what the customer wants”.
THE REAL MEANING OF A “BROAD SPECTRUM” MARKET VIEW As a premise to the words of Giovanni Ruggeri, marketing manager for IMG - also present at the interview together with Davide Bonfadini and Osvaldo Paderni, head of the technical department - it is worth noting that while for an individual a “need” expresses the necessity to minimize a discomfort and maximise a pleasure, in the manufacturing sphere “need” is linked to stringent technical specifications, so the minimization of discomfort and maximization of yield rewards the supplier who can
IMG develops and manufactures rubber moulding machines almost always tailored to the customer’s specific application or processing needs; in the picture a machine being assembled at the Capriano del Colle plant, in the province of Brescia, the long-standing headquarters of the company MACPLAS INTERNATIONAL OCTOBER 2021
offer a wide range of solutions, technologies and know-how. In other words, the winner is the one who has a “problem-solving ability”. “Our dogma is that the more varied the portfolio of solutions offered to the customer, the easier it is to cover the company’s operating costs”, explains Ruggeri. “In this sense, our double soul as importers of Haitian injection moulding machines for plastics and, even before that, as manufacturers of rubber moulding machines, still provides us with an exclusive advantage in terms of diversification and growth of our know-how”. In support of the dogma mentioned by Ruggeri, it must be said that since 2009 IMG has been the official and exclusive distributor for Haitian injection moulding machines for thermoplastics in Italy: the Mars III (hydraulic toggle-joint machine with servo drives); the Jupiter III (two-platen hydraulic machine with servo drives); the Zeres III (electric machine with two hydraulic actuators - Zhafir brand); the Venus III (all-electric presses - Zhafir brand). In addition, over the last 12 years IMG has installed in Italy over 1,000 IMG moulding machines incorporating a number of technologies: punching screw systems, screw plus piston (or “FIFO”) for elastomers, BMC loading and injection systems, LSR and/or silicone paste moulding systems. These solutions have been increasingly developed and integrated into ad hoc production cells complete with Haitian robots and - of course - Industry 4.0 logics. Ruggeri underscored an equally strategic aspect: IMG, before being the Italian distributor for Haitian, was already a manufacturer of rubber moulding machines. “Historically, the rubber market is mostly oriented to the supply
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PROCESSING MACHINERY
of parts on strict specifications of either car manufacturers or, alternatively, OEMs. Here in Italy, in the Sarnico area, in the province of Bergamo, there is the highest worldwide concentration of subcontractors specialized in the processing of rubber for the automotive sector. It is estimated that in Sarnico there are no less than 3,000 rubber moulding machines that continuously produce parts for the big German, French, American and Asian names. Data in hand, 80-85% of these machines are made by IMG. And almost all of them are tailor-made - in the sense that we offer a range of basic machines, that has also grown in tonnage in the last two years, but when you are closing the order with the customer there is always a piece of equipment, a servo drive, a mould coupling, an axis stroke or a tiebar distance to customize. Therefore, while on the one hand the specific need of the customer is satisfied, on the other hand our know-how is steadily expanded”. Once again, to support the words of Giovanni Ruggeri, we would like to emphasize some technical features typical of the basic version of IMG rubber moulding machines, albeit limited to two models: GUM H, a horizontal machine with hydroblock clamping unit with four struts and high pressure cylinder, clamping force from 1,000 to 4,500 kN, injection capacity from 170 to 900 cm3, mould opening stroke from 600 to 1,000 mm, specific injection pressure 2,400 bar, mould thickness up to 400 mm; GUM Vertical, a moulding machine with vertical bottom-to-top hydraulic clamping unit, clamping force from 2,000 to 4,000 kN, injection capacity from 1,000 to 2,000 cm3, mould opening stroke from 650 to 1,080 mm, specific injection pressure from
Osvaldo Paderni (right in the picture) and Giovanni Ruggeri in the production and assembly department of IMG machines
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2,400 to 2,500 bar, mould thickness from 50 to 550 mm. “All IMG rubber moulding machines, whether standard or special, are equipped with a servo pump hydraulic system to enhance energy savings”, Osvaldo Paderni, manager of the technical department for rubber machines, underlines, “in the sense that as it has been widely tested and applied A Haitian press being prepared for delivery. In the first half of 2021, in the sector of cutIMG delivered about 300 injection moulding machines for plastics ting machine tools produced by the Sino-German manufacturer there is energy consumption only when a given movement is Here are some of the features of this brand carried out via the PLC. Otherwise the drives new horizontal machine: clamping force 3,000 are on standby. But there is more that I would kN, injection capacity 500 cm3, mould openlike to emphasize: next year we will launch the ing stroke 710 mm, specific injection pressure first all-electric rubber moulding machine. While 2,300 bar, double toggle-joint clamping unit this is a long-standing feature for plastics, it is with five closure points and floating platen slidan absolute novelty in rubber processing. We ing on ballscrew guides, central ejector driven have been working on it for years and we even by a dedicated servomotor, frame for the third have a prototype running at the premises of a plate of the floating platen driven by two asynpartner customer, however - due to the com- chronous motors with gearbox. plex dynamics of rubber moulding - every time However IMG has held on to the deepest we obtained an improvement, then complica- know-how from its past. tions took over. Now I would say that all prob- “IMG has a long history in retrofitting injection lems have been solved; not least the price is- moulding machines, be they for thermoplassue. The basic components of a machine that tic elastomers or thermosetting resins”, comprocesses rubber cost much more than those ments Osvaldo Paderni, adding that “still today, of a plastic injection moulding machine. This is the experience built up by the workforce allows also because the figures of the rubber industry the company to carry out complete retrofit projare very different from those of plastics”. ects able to turn presses into machines that are technologically up to date and ready for Industry 4.0, as well as fully compliant with current safety regulations. To do this, we only take the base from the old press, making the necessary changes, grinding the platens, replacing the remaining components with new ones such as the electric system, adding a Moog control system, and accessories such as the pump inverter, hydraulic jack controls, robot interface etc”. Last but not least, IMG is now also starting to distribute, in Italy, its Haitian machines for die casting, where aluminium, zinc or magnesium alloys are injected at high pressure into a metal mould. The basic consideration behind this is both simple and rational: Haitian has been making these machines for over twenty years and Brescia is among the European cities with the greatest number of die casting companies. Not a bad example of a broad-spectrum market view! www.imgmacchine.it MACPLAS INTERNATIONAL OCTOBER 2021
FLEXIBILITY & EFFICIENCY IN WELDING
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LINE SBM 800-1200-1400-1700-2100 SPECIAL & STANDARD APPLICATION Flat bags with lateral sealing, shopper, bottom sealing & block notes Boutique bags Square bottom bags Aprons & Gowns
ELECTRONIC PERFORATOR 1200-1400-1700-2200 Independent machine equipped with its own PLC and print detection. It can be installed in line with extruders or in line with a bag making machine. Continuous perforation for holes from ø 2 to 80 mm.
√ All BMTEK lines are equipped with control and management electronics, single-brand. √ Each line consists of completely independent machines. √ All the accessories we propose are “plug and play”.
Via G. Matteotti, 26 – 40057 Loc. CADRIANO di Granarolo dell’Emilia (BO) Phone.: +39 051 6926178 - sales@bmtek.it - www.bmtek.it
PROCESSING MACHINERY
A 2021 OF ANNIVERSARIES
40 YEARS OF ACTIVITY, 20 YEARS OF SUSTAINABILITY FOR FORTY YEARS ON THE MARKET AND FOR TWENTY YEARS ON THE ROAD OF THE SUSTAINABILITY OF MACHINES AND PROCESSES, PLASTIBLOW HAS BEEN ABLE TO ASSERT ITSELF AS A NATIONAL AND INTERNATIONAL POINT OF REFERENCE IN THE BLOW-MOULDING INDUSTRY, BRINGING THE MADE IN ITALY ALL OVER THE WORLD
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021 is an important year for Plastiblow, a year of celebrations, a story to tell, and many results to underline. In 1981 Plastiblow starts producing blow-moulding machines as an independent company under the control of Plas-
timac Group and at K 2001 the company shows its first fully electric blow-moulding machine: the road to low energy consumption, efficiency, greater precision, and reduction of noise, cycle time and maintenance interventions is opened.
The machine PB12ES-480 Coex3, featuring an E60/25 extruder, two E50/25 extruders, die with diameter of 70 mm, and distance between centre of 120 mm, for the production of three-layer containers
INCREASINGLY TOWARDS THE CIRCULAR ECONOMY Namely, forty years of machines installed all over the world and for every application, and twenty years of continuous improvements that allowed Plastiblow to build machines with the highest energy efficiency class (Class 10 Euromap 46.1). Today the technology applied to extruders and extrusion heads makes it possible to use more and more recycled plastic material for the central layer of containers, with very minimal external and internal layers of virgin plastic, without affecting performance, and aesthetic appearance of product and safety of the content. An important step towards a more sustainable and circular economy.
RELENTLESSLY GOALS Moreover, in this 2021 of anniversaries, the already partially-achieved short-term goals by Plastiblow are: - the expansion of its facility with the reorgaMACPLAS INTERNATIONAL OCTOBER 2021
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PROCESSING MACHINERY
nization of spaces, which is already bearing the first fruits in terms of production efficiency and reduction of delivery times; - the strengthening of the after-sale service, to meet the requirements of an increasingly extensive number of machines installed, thanks to the hiring of new technicians and joint ventures with foreign partners; - the strengthening of the commercial team, with the addition of young, competent and full of enthusiasm area managers. Plastiblow gratitude goes out to all who contributed to the growth of the company and who enabled the achievement of these important goals: employees and their families, customers, suppliers, friends and all collaborators.
A COMPLEMENTARY RESOURCE TO VIRGIN PLASTICS Nowadays Plastiblow considers post-consumer recycled plastic (in the opening picture) as a complementary resource to virgin plastics. Through the use of a consistent percentage of post-consumer recycled plastic material, it is now possible to obtain “greener” containers, with a lower environmental impact than in the past. Such a percentage can even reach 80% of the total weight of the container,
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Containers produced with recycled plastics and (in the circle) the percentage used for each layer
a good news for all sectors that need to produce in a more sustainable way. In this sense, Plastiblow, as a manufacturer of extrusion blow-moulding machines, has for many years considered itself at the forefront of experimentation and technological innovation. So much so that today it can offer blowing machines and complete systems not only with low energy consumption (amongst the lowest in the sector), but also able to create lighter and more eco-sustainable multilayer coextruded containers, thanks to an ad hoc design, using an important percentage of recycled plastic polymers. Recycled post-consumer resins maintain more or less the same physical-chemical and processing characteristics of virgin plastics. The main difference is basically attributed to an
aesthetic factor, but, as above mentioned, in this specific case the percentage of use (which can even reach 80% of the total weight) is limited to the central layer of containers, while for the internal safety layer, in contact with the product contained, and the external aesthetic layer, virgin material is used, but in a very modest percentage compared to the total weight. Basically, there is no quality and safety problem to obtain containers that are completely similar to those produced only with the virgin material. Experiments and tests developed for some time by Plastiblow on its electric machines, in cooperation with well-known European and world producers of eco-sustainable materials, have confirmed the versatility of such a production technology. www.plastiblow.it
MACPLAS INTERNATIONAL OCTOBER 2021
AUTOMATIC BAG MAKING MACHINE MODULA SERIES: 800 -1100 -1300 -1500 MM. High speed production of bottom seal bags, T-Shirt bags and Block Notes NON STOP production for bags up 700 mm. and with PAUSE operation up to 2000 mm. Stacking table for up to 8 lines bags collection (with or without pins) Film feeding speed up to 180 mt/min.
Since 1961
ROLL-FLEX R-3000 | 1100 – 1300 – 1500 MM. High speed production of pre-cut bottom seal rolled-up bags, taped with gummed paper Production for bags up to 2000 mm. long Automatic winder unit with taping devices up to 4 tracks Film feeding speed up to 180 mt/min
Via IV Novembre, 153 - 21058 Solbiate Olona (VA) Italy - Tel. +39 0331 64 90 12 info@saldoflex.com - www.saldoflex.com
FLEXO PRINTING MACHINE FFS SUPERFLEXOL 4 COLOURS GEARLESS - 1000MM.
Production line for Industrial bags – Heavy Duty (FFS) Automatic unwinder and revolver winder for up to 1500 mm. diameter reels 2-band embossing & gussetting unit Printing speed up to 300 mt/min.
Since 1961
FLEXOL 6 COLOURS GEARLESS - 2200MM. Inking through closed chamber doctor blades Automatic pre-register at machine start and printing unit motorized forwarding with job memorization and recall Printing width 2200 mm. Printing speed up to 300 mt/min.
Via IV Novembre, 153 - 21058 Solbiate Olona (VA) Italy - Tel. +39 0331 64 90 12 info@saldoflex.com - www.saldoflex.com
NEXT-GEN PRESSES
OVERMOULDING VERTICAL INJECTION PRESSES Since 1955 Turra has been operating in the field of engineering and manufacturing of vertical injection presses being the suitable solution for overmoulding of inserts with different sizes and specific shapes. In 2020, a new family of products was born, the Ergon, next generation presses: modern and functional design; compact structure and excellent control of the injection process; unlimited application fields; available in customized versions; 100% made in Italy.
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PROCESSING MACHINERY
SINGLE SCREW PLUS COROTATING TWIN SCREW SYSTEM
UPCYCLING IN THE MOST COMPLETE SENSE THE MUCH SOUGHT-AFTER CIRCULAR ECONOMY BECOMES A REALITY ONLY WHEN IT OFFERS ADEQUATE ENVIRONMENTAL AND ECONOMIC SUSTAINABILITY. WITH THIS IN MIND, MARIS HAS COME UP WITH A NEW UPCYCLING PROPOSAL FOR THE WORLD OF RECYCLING. THANKS TO AN ORIGINAL TANDEM COMBINATION OF A SINGLE SCREW EXTRUDER AND A COROTATING TWIN SCREW EXTRUDER, THIS NEW SOLUTION CONFERS REAL ADDED VALUE ON RECYCLED PRODUCTS BY ERMANNO PEDROTTI AND LUCA MEI
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ccording to the Ellen MacArthur Foundation’s definition, circular economy is a generic term that describes an economy designed to be able to regenerate itself. In a circular economy there are two types of material flow: the biological kind which can be put back into the biosphere, and technical waste which has to be revalued without ever entering the biosphere. What this academic definition tells us is that the circular economy is an economic system planned in such a way as to promote the reuse of materials in subsequent production cycles, thereby minimising waste. As Lucia-
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no Battistutta, sales area manager at Maris, remarks from the perspective of an industry operator, “From the Green Deal to the first European climate law, and also with Next Generation EU, we have all been well aware that the European Union has given itself a growth strategy designed to move Europe in the direction of a zero climate and environmental impact society. In order to adapt to the resulting green policies, industry, and primarily the plastics sector, is striving to recycle as much as possible. As industry operators well know, the business of plastics recycling began with the “noblest” materials, or the most easily recyclable ones, for
which there is an already well-established supply chain. Just think to a polymer such as polyethylene terephthalate (PET), used in plastic bottles, which has a well-defined composition, is readily selectable, and has recently been approved for reuse in the production of new bottles for the food industry. But then we also have a whole series of other plastics - these account for the majority, or at least a substantial proportion - that, for a variety of reasons (for example because they are contaminated by other polymers or pollutants), need to undergo more significant, complex and demanding revaluation processes”. MACPLAS INTERNATIONAL OCTOBER 2021
These words take us straight to the crux of this article: continuous recycling process allowed by the tandem combination of a single screw extruder and a corotating twin screw extruder - a system developed by Maris. Although this is not a new combination in plastics processing, this solution, thanks to its remarkable mix of technological and process devices and developments, confers new life and greater value on waste products. Before examining this combination in detail, it is useful and interesting to set it in context and take a background look at Maris, an all-Italian family-run industrial reality, currently in its second generation. Now, with approximately 100 employees, it reckons with competitors that are true global industrial giants.
THE BUZZWORDS: TECHNOLOGY AND TAILOR-MADE PRODUCTS ... ALWAYS!
Source: Maris
Established near Turin in 1962, with a mission to manufacture extruders and dies for the production of pipes and profiles, Maris quickly became a leading player in the early development of polymers, aspiring to contribute to the evolution of the related nascent technologies. To set the story in context, it is worth remembering that isotactic polypropylene was invented in the 1950s by the Italian chemist Giulio Natta, who won the Nobel Prize for chemistry in 1963, a year after Maris was founded. Maris soon chose compounding as its main mission, and the 1970s saw it build-
ing new corotating twin screw extruders with self-cleaning screws and modular sections. The 1980s brought two- and three-lobes plasticising screws, while in 1990s the company embarked on the production of hightorque, high-performance lines, and also began offering Maris lines to new application sectors. “This is a far-sighted family that, ever since the 1960s, has focused on the production of corotating twin screw extruders for application wherever there is a need to process materials continuously”, says Luciano Battistutta. “I am talking about a range of sectors: first, the production of masterbatches, which soon became a traditional application for Maris; then the production of highly filled, reinforced compounds, TPE, TPV, adhesives and bioplastics, and now rubber compounds and - remaining in the world of elastomers -the recently patented continuous de-vulcanisation process. In this latter case, the vulcanised rubbers are recycled using a continuous system, allowing them to be reused (in proportions ranging from 15% to 50%) in new formulations for the same original application. What is more, the percentage of de-vulcanised material in the compound can be further increased to obtain different formulations. In this regard, we can affirm that our de-vulcanisation process can also be applied to post-consumer materials, since it involves careful material selection, identification and treatment steps. I am referring, in particular, to the large volumes of end-of-life
Figure 1 - “Just to summarise the particular features of this tandem solution”, Muscato explains, “we have now reached a point at which it is possible to fully exploit the potential of both the single screw extruder and the corotating twin screw extruder, in a single machine and in a single step” MACPLAS INTERNATIONAL OCTOBER 2021
Luciano Battistutta, sales area manager at Maris
tyres (ELTs) that we can certainly consider a very useful “secondary raw material”. Still in application terms, recycling, or better, upcycling, is a constantly evolving and growing sector. Maris is already strongly present and operational in this field and proud to have already implemented numerous innovative processes in the treatment of post-consumer materials and production waste; for example, in the fields of polyolefins, PVC, PET and also expanded materials”. And this leads us on to a further characteristic of Maris, namely the fact that it has opted to be a “one-stop shop”.
MARIS’ CHOICE BETWEEN “MAKE OR BUY” IS DEFINITELY “MAKE” “Make or buy” is the choice between building a product in-house or buying it from an external supplier. The choice is based on the comparison of the total costs to be incurred in the two cases, taking into account both availability on the market - and therefore any critical issues associated with it - and the resources available within the company. It is a fundamental strategic choice for the management of a company; a choice which defines the integration level of upstream and downstream operations and determines the cost structure, the organization and also the positioning on the market. The “make” option offers above all the advantage of ensuring direct control over the production operations, the supplies and the quality of the final product. It also makes it possible to maintain and devel-
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MARKETING
op a proprietary technological know-how. “We have always been proud to be 100% owner of our technology”, Battistutta underlines, “and this is possible because the fundamental parts of our corotating twin screw extruders are made entirely in-house with top level production processes and quality. Evidence of this is the production of screw elements, process sections (barrels), as well as the manufacture of complete gearboxes, which represent a focal point of an extruder. This is a choice that allows us to build machines that stand out for their high quality standards and versatility”. Logistically, in addition to the office building, Maris is composed of three other large and distinct departments. The largest is the production department, where last generation CNC machining centres operate along with more consolidated metalworking systems, because, as Battistutta explains: “The alternation of cutting-edge machines and other more traditional ones makes it possible to manage the individual phases of orders with flexibility and to achieve, therefore, a very high customization level”. Equally important is the department dedicated to the assembly and testing of extrusion lines. Maintenance of extruders is also carried out here. “We are able to carry out regular and extraordinary maintenance on extruders built several decades
1,000 SQUARE METRES WHERE IDEAS BECOME REALITY
Bruno Muscato, the process expert within the research and development team of Maris Technological Center
ago (and still operational). This prerogative allows us to provide a reliable, effective, high quality after-sales service and, therefore, to establish lasting relations with our customers”, Battistutta adds. Last but not least, the third department is the Maris Technological Center, which deserves a separate chapter.
Maris has always been the owner of its technology; the fundamental parts of its corotating twin screw extruders are made entirely in-house with top level production and high quality processes
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The Maris Technological Center is the department responsible for the study and optimization of the customers’ production processes, as well as for the research and development activities aimed to constantly improve the technology of twin screw extruders. At Maris, in fact, there is no standard order and the watchword is flexibility at the service of the customer. Therefore, the customers communicate the information useful for the configuration of the pilot line to the research and development team of this department. Then the line is tested using the materials supplied by the customer and, if necessary, laboratory analyses are carried out to test the quality of the finished product under different processing conditions. In this regard, Bruno Muscato, the process expert within the research and development team, says: “To evaluate in real time the results of the tests carried out at the Maris Technological Center we have set up a laboratory where we perform the characterization procedure with an optical microscope in reflection and one in transmission, as well as the rheological and melt index analyses. Finally, we can assess the mechanical properties of the materials, after moulding, with a dynamometer”. It is with a certain pride that Bruno Muscato - who is an industrial chemist - showed us the “filter test”. A fast analysis devised by Maris, thanks to which, by measuring the clogging speed of the filter, it is possible to measure the dispersion of fillers/ pigments within the polymer matrix. All this makes us understand how a family-run company can compete in an international context in the world of extrusion. As a confirmation of this, in fact, Maris cooperates with universities, public and private authorities (Italian and international), but also with manufacturers of ancillary production systems, with engineering companies and with car manufacturers in the development of research projects such as the one that allowed the company to obtain the patent for its rubber de-vulcanisation technology. “Our Technological Center is equipped with four lines of different sizes that enable us to carry out both basic research activities and production simulations on an industrial scale”, Muscato explains, “starting from the 20-mm screw diameter line (for laboratories or very limited productions), then passing to the 30 mm and the 40 mm versions, and fiMACPLAS INTERNATIONAL OCTOBER 2021
HERRMANN ENGINEERING Compound obtained with the upcycling process on the Evorec Plastic Plus line
nally arriving to the largest line, with a screw diameter of 58 mm. These extrusion lines allow us to replicate the final application conditions with an excellent degree of precision and to perform the appropriate scale-ups by identifying the most suitable machine size to reach the production target of the customer. The range of our extruders is very wide: their diameter can reach up to 223 mm and the hourly output rate varies depending on the formulation and size of the machine. The twin screw corotating extruders are modular and this gives us the possibility of varying the extruder length according to the processing needs, as well as to feed solid or liquid materials in different points of the extruder thanks to specific barrels. Our extrusion lines can be integrated with upstream and downstream equipment (providing, in practice, a turnkey solution) thanks to the cooperation with the sector’s most renowned brands. At the Technological Center all this equipment is at our disposal in order to identify the most appropriate solution to meet the customers’ needs”. Upstream equipment can include a wide choice of gravimetric feeders for solids and liquids, while downstream it is possible to find gear pump, screen changer, underwater, water-ring, remote and air pelletising systems and, finally, vacuum or high vacuum pumps.
FOCUS ON EVOREC PLASTIC PLUS: SINGLE SCREW PLUS COROTATING TWIN SCREW EXTRUSION SYSTEM Maris’s response to the need to recycle highly contaminated materials with a high moisture content is the Evorec Plastic Plus. This comMACPLAS INTERNATIONAL OCTOBER 2021
bination of two technologies - a single screw extruder and a corotating twin screw extruder - makes it possible to recycle very critical materials with a single extrusion system. “Just to summarise the particular features of this tandem solution”, Muscato explains, “we have now reached a point at which it is possible to fully exploit the potential of both the single screw extruder and the corotating twin screw extruder, in a single machine and in a single step. In other words, by combining two specific, complementary expressions of our know-how, we have made it possible to feed non-free-flowing materials, carry out double filtration, obtain highly homogeneous materials, and introduce additives/fillers into the recycled polymer. It is also possible to process materials with a high moisture content and a very high level of contamination; this would not be possible with a twin screw extruder alone, but thanks to this combination, it is now feasible”. Regarding the upcycling example described in this article, figure 1 comes to our aid, showing the five phases of the single screw extruder: 1) grinding, dehumidification, storage; 2) feeding; 3) melting; 4) first degassing; 5) first filtration. After these operations, the post-industrial or post-consumer waste is ready to be fed continuously towards the corotating twin screw extruder. Figure 1 also lists the phases of this second step: 1) homogenization; 2) second degassing; 3) side feeding of polymers, fillers or additives; 4) third degassing; 5) second filtration and granulation/pelletising. www.mariscorp.com
From the initial idea to the development of an application, through to process optimization, we work together with you to find the best possible solution.
Friedrichshafen GERMANY
12. – 16.10.21 www.herrmann-engineering.com
PROCESSING MACHINERY
BINOVA PLASTIC MACHINERY: 2006-2021
FIFTEEN YEARS OF ACHIEVEMENTS AND APPROVALS THE ITALIAN COMPANY BASED IN PROVINCE ON NOVARA HAS ALWAYS BEEN ABLE TO LISTEN TO CUSTOMER NEEDS AND TRANSLATE THEM INTO SOLUTIONS. A SKILL THAT COME FROM AFAR. A PROOF THAT NOTHING CAN BE IMPROVISED AND THAT ONLY IN THIS WAY THE COMPETITION OF MAJOR INTERNATIONAL COMPETITORS CAN BE WITHSTOOD WITHOUT AWE
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ounded in 2006, Binova springs up taking immediate advantage from the many years experience in the field of the plastic material extrusion of its chief executive Luigi Maria Borzoni and the associated company Tecnova, involving in their project a team of employees of great capacity and skills. Since almost 5 years, the company gained a full strategic autonomy, financial and industrial, in order to face present and future challenges with a strong responsibility in the decision making and in full control of its development process. Its main feature has always been the capability to develop plants studied on purpose to satisfy the customer’s exigencies. The flexibility and the persistent willpower of innova-
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An almost-ready Binova line
tion allowed Binova to compete and counteract companies famous all over the world with consolidated structures. The first big project faced by Binova was dated 2008, when an important French company purchased a 4000 kg/h recycling and compounding plant for polypropylene. The same customer, during these last ten years, committed to Binova the revamping of an existing single screw plant and the manufacture of other two plants for 1500 kg/h of production (the latest delivered in 2015). This is only one of the examples that, once a customer meets Binova, does not find a simple plant manufacturer but even a partner always available to examine the most suitable solutions to improve and enhance his MACPLAS INTERNATIONAL OCTOBER 2021
A screenshot of the management system of a Binova line
production potentiality and the quality of the material produced. Another strong point of the company is the efficient after-sale service that gives the customer the possibility to benefit of a wide availability of spare parts in case of need and a focused technical assistance. In addition, all the plants manufactured in the last eight years, are equipped with an Ethernet connection that enables to control, and eventually correct, remotely, the productive process of the plant.
PRESENT AND FUTURE PROJECTS The most recent projects put in evidence, once again, the willing of the company to face up the market and its trends with more and more advanced solutions. First, a plant for an important French customer for recycling and compounding ABS and PS scraps with the use of a co-rotating twin-screw extruder equipped with continuous double filtration for the production of high quality pellets. The plant can reach an hourly production of about 1200 kg, based on the characteristics of the processed material. Another plant for compounding scraps of
polypropylene, polyethylene and polystyrene with a production capability of 1500 kg/h, equipped with co-rotating twin screw extruder EBB92/44LD and compactor, has been installed by an important Spanish company that, after having considered any possible alternative available on the market, chose Binova as partner for this investment. The company was supported by the consultancy of an important research and develop-
ment foundation, qualified in the analysis of products and processes and their technical and economical feasibility. Binova celebrates its fifteenth year of activity proud of having acquired an important order backlog, and to have in deal at least three important and exclusive projects that will hopefully become concrete within the end of this year. www.binovapm.it
SUCCESSFUL SOLUTIONS FOR YOUR DOWNSTREAM EQUIPMENT
Baruffaldi Plastic Technology Srl Via Walter Tobagi, 13-15 | 48034 Fusignano RA T +39 0545 52652 | info@baruffaldi.eu
baruffaldi.eu
MACPLAS INTERNATIONAL OCTOBER 2021
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PROCESSING MACHINERY
GAMMA MECCANICA REGENERATION LINES
A NEW GENERATION OF CUTTER-COMPACTORS UNINTERRUPTED DEVELOPMENT OF ITS LINES AND THEIR SINGLE COMPONENTS ARE ONE OF THE MAIN CAPABILITIES THAT GAMMA MECCANICA USES TO KEEP UP WITH TIMES IN WHICH MATERIALS TO BE RECYCLED ARE INCREASINGLY CONSIDERED A RESOURCE NOT TO BE WASTED. AND TOWARDS WHICH AWARENESS IS GROWING, NOT ONLY BY THE OPERATORS IN THE SECTOR
A
ccording to the latest report released by Conai, a non-profit Italian consortium dedicated to plastics recycling, in 2020 Italy exceeded recycle forecasts with a 73% recycling rate of packaging placed on the market. Nevertheless, compared to other renewable materials (steel, aluminum, paper, wood and glass), plastic remains the most difficult material to recover. Last year, with 48.7% of recycled plastic, the recycle target of 50% set by the EU for 2025 was almost reached, but this goal also includes the revaluation of the plastic in the form of fuel. For those who work in plastics industry, waste-to-energy is not a solution, because it means that an economic resource go to “ashes”. Recycling is, however, growing more signifi-
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cantly than waste-to-energy in part due to the separate collection of post consumer waste, but also to the continuous technological evolution of recycling equipment that allows a more wide range of plastic waste to be recycled.
PERFORMANCE AND APPLICATIONS IMPROVED As an Italian company specialized in the design and production of lines for recycling plastic materials, Gamma Meccanica has once again responded to client requests and created a new generation of cutter-compactors. The goal was to improve the per-
formance of these machines and their application on materials more difficult to recycle. To achieve the goal, the technical staff carried out various tests on lab lines and conducted studies involving A lab suppliers. At the end, with the tandem information received from cusline tomers, Gamma Meccanica improved its equipment.
MACPLAS INTERNATIONAL OCTOBER 2021
An AFT160 cutter-compactor
The cutter-compactor receives the waste material to be regenerated in the form of films, sheets, rolls or precut. Inside the cutter-compactor the material is shredded, densified and, when required, mixed with additives (even in powder), making it suitable for the phase of extrusion. The new AFT cutter-compactor developed by Gamma Meccanica offers several advantages over previous models thanks to a series of structural changes and technological accessories.
COMPONENTS REDESIGNED To operate the disc with the rotating blades, the kraft band belts were used. The refined tightening improves the production efficiency, and the internal geometries of various components have been redesigned. Six rotating blades can be installed on the disc compared to the three of the previous models. This ensures higher production levels, especially for those materials that require more residence time. Under the silo, in the bearing area, a sealing system for dust has been developed to keep cleaner work environment, preventing dust from damaging the most sensitive parts of the line. The position of the feeding screw motor, that pushes the material from the cutter-compactor to the extruder, has been redefined to make the unit more compact. The operator has more space to move around the machine, and the
engine is more stable because it is less stressed by vibrations. Moreover, it is possible to install a feeder for powder additives. Its position was chosen to allow the better mixing of additives with the material to be recycled and to limit its dispersion into the environment. The AFT cutter-compactor has always been equipped with suction systems for released vapours, such as air saturated with moisture extracted from the treated material. The treatment of the powders requires more attention. It is therefore possible to install a pre-abatement device for dust and fines, in order to make less burdensome for the user the treatment of the air and dust particulate released into the environment. The most interesting aspect of the new AFT is the possibility to combine it with extruders of different sizes. For example, a GM 125 Compac extruder was provided with an AFT125 only. Now it is possible to combine it with a cutter-compactor of a larger size, in this case with an AFT160. With very humid materials, the bigger cutter-compactor improves the preparation of the material for the extrusion phase, obtaining a higher production capacity and a better quality of the granule. It is possible to process material with a percentage of humidity that can reach 20%. The new combinations are efficient even with materials of particularly large sizes or thicknesses that are more difficult to treat. www.gamma-meccanica.it
MACPLAS INTERNATIONAL OCTOBER 2021
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PROCESSING MACHINERY
NEWS Injection moulding with IML
High output and low costs: it can be done
Attending once again at Fakuma, at the German exhibition BMB presents an eKW 16Pi/700 full electric, high-performance and low energy consumption injection moulding machine, with IML technology for the production of thin-wall food containers. This is a full electric machine suitable for moulding packaging and thin-wall containers. Thanks to the direct electric drives for opening, closing, injection and plasticizing phases, the overlapping movements are controlled with great
A plastic container produced with injection moulding and IML
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precision, accuracy and, consequently, repeatability. The low energy consumption of BMB unique direct electric drives and the use of recycled material usable for producing food packaging, make this application an exceptional example of eco-sustainability. The main objective of this application is to improve the performance of the entire work cell, aiming at a constant production in excess of 2000 pieces/hour, limiting at the same time production costs due to the electric dri-
One of the injection moulding machines displayed in operation at Fakuma 2021
ves for each movement of the machine and the automation system. Incorporating a vision system, each product can be
controlled in terms of quality and rejected in case of an anomaly. www.bmb-spa.com
MACHINE TECHNICAL DATA Mould clamping force
1600 kN
Mould opening force
160 kN
Mould opening stroke
550 mm
Platens dimensions H x V
750 x 750 mm
Distance between tie-bars H x V
510 x 510 mm
Screw diameter
45 mm
L/D rate
23
Injection volume
355 cm3
Injection rate
555 cm3/s
Injection specific pressure
2000 kg/cm2
PROCESS DATA Product
Food container
Number of cavities
2
Mould manufacturer
Dijkstra Plastics
IML automation system
Brink
IML label
Viappiani Printing
Vision system
Keyence
Cycle time
3,2 s
Raw material
Total - PPC 12642
Ancillaries
Piovan Group
Chiller
Industrial Frigo
MACPLAS INTERNATIONAL OCTOBER 2021
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PROCESSING MACHINERY
NEWS Tecno System turnkey solutions
All for the extrusion of profiles Producing customized turnkey systems, such as extrusion lines equipped with moulds and integrated online or offline solutions, Tecno System is amongst the leading companies in the development of lines for thermoplastic profiles. The company offers a high level of experience, specific and consolidated know-how and constant R&D efforts combined with the professionalism of high-skilled team, in order to deliver to clients the smartest solutions. All products are completely designed, manufactured and tested in the company facility in Consandolo (Ferrara, Italy) applying very stringent process quality standards and ensuring therefore the full compliance with the European standards. Regarding turnkey solutions, all activities like designing, manufacturing, testing, installing and servicing, training and documenting the products are managed directly, with no need to rely on third parties. This approach has multiple advantages for end customers in terms of management efforts, with the possibility to interact with just one referee. The whole project process develops in many specific steps. First, the commercial phase where the sales department supports the customer’s requests suggesting the
strategic decisions about the investment, developing different solutions, and leading the client to the most suitable for its needs. The result is a “custom made” solution whi-
The Italian company is investing many efforts in the digitalization of its extrusion lines, adapting them to the Industry 4.0 prerequisites
ch represents a high value-added product, particularly appreciated in Italy and abroad. The project moves then to the design phase where the engineering departments examine and validate the customer tailored solutions, with a special attention paid to energy efficiency, safety, innovation, high performance and other crucial aspects for the final products. The design step is followed by the manufacturing processes that rely on high skilled employees and an excellent network of suppliers, resulting in top quality products with special attention to robustness and reliability. Ultimately there is the testing phase where also the final acceptance test takes place in the presence of the end customer. After sales service still remain one of the most added value of the company. By opting for Tecno System’s extrusion lines processors are able to satisfy different capacity (5-350 kg/h) and a vast range of purposes in the field of extrusion of profiles and pipes as well, made of a great variety of thermoplastic materials such as plasticized and rigid PVC, PP, PC, HDPE, LDPE, PP, PMMA etc. Particular attention is paid to the field of PVC profile extrusion for windows, shutters, ducts etc. Another strength is the construction of extrusion lines dedicated to single- or multi-layer medical pipes made with medical grade raw materials (soft PVC, TPU, Pebax etc.) used in clean room environments. Concerning the innovation, Tecno System is investing many efforts in the digitalization of its extrusion lines, adapting them to the Industry 4.0 prerequisites. As well as constructing extrusion lines and tools, the Italian manufacturer has also the ability to provide technologies for mechanical processing of profiles. Great experience in the punching system ambit allowed Tecno System to develop integrated and customer tailored solutions for extrusion lines, strategic in the company’s market policy. www.tecnosystemfe.it
Tecno System is specialized in the manufacturing of turnkey complete solutions for profile extrusion
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MACPLAS INTERNATIONAL OCTOBER 2021
PROCESSING MACHINERY
NEWS Vertical presses from Turra
The tie between traditional and innovative machines Since 1955 Turra has been operating worldwide in the field of engineering and manufacturing of vertical injection presses, being the suitable solutions for overmoulding inserts with different sizes and specific shapes. Turra also offers the possibility to add automations for loading inserts and unloading finished parts, and to install several injection units to overmould different thermoplastics, thermosettings and silicone materials even in different colours. Over the years, the company has developed and consolidated skills and
Another machine “made in Turra”
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know-how in different sectors, giving customers the opportunity to choose between a traditional product (Traditional line) or an innovative and highly technological product (Ergon line) born in 2020. Both lines are available with no table (NT series), with single/ double sliding tables (ST series), with rotary table (RT series), and a wide range of clamping forces up to 200 tons. Ergon is characterized by a compact, modern and functional design: thanks to its load-bearing structure, the machine is strong and ri-
A RT160 model of the Ergon range
gid and the positioning of the piston group into the upper part of the press makes it possible to have the mould support 850 mm from the ground, allowing to have a user-friendly machine in a safety environment. The press traditional columns have been replaced by guides and slides on ball bearings and the inverter-controlled hydraulic pump contributes to the energy saving of the machine. The long experience in multiple sectors allowed Turra to obtain full control and high repeatability of the injection process through an intuitive parameters management. Ac-
cess to the injection unit also from the back of the press, as well as the electrical cabinet and hydraulic unit integrated into the base, make easy maintenance. A servo-controlled motor ensures accuracy and speed of sliding and rotary table, available with a diameter up to 2,000 mm. The parameters of the press can be easily checked and viewed thanks to the new operator interface. All Turra machines are also compliant with Industry 4.0 and can be integrated with automations through cartesian systems, Scara or robots (special designs are also available
on demand). Application fields of Turra presses include industries such as automotive, electric and electronic, medical, technical moulding, eyewear, cables, footwear ecc., and the technical department of the company is always available to develop and propose solutions for any customer needs. Turra is part of DM Industrial, a mix of extraordinary excellences brought together in order to create an industrial group based on specialization and high quality in terms of reliability, productivity and precision. www.omfturra.com www.dmindustrial.it
MACPLAS INTERNATIONAL OCTOBER 2021
Luca Corti Communication
EVOLUTION PLAST
Via Grigna 9 - 20027 Rescaldina (Mi) ITALY -Tel. +39 0331 545704 - Fax. +39 0331 590961 www.cmevolutionplast.com - info@cmevolutionplast.com
PROCESSING MACHINERY
NEWS Leaf-S8: an ambitious project COROTATING TWIN SCREW EXTRUDERS
Delicate on sensitive materials
A version of the RS80 extruder
The corotating twin screw extruders built by Sara generate an extremely low amount of heat and reach high mixing performance levels with low energy consumption, as a result delivering finished products featuring excellent foam properties and improved lambda and cell structures. The screws can be fed by means of an independent mechanism so that their adjustment does not affect output rates, while friction is extremely reduced thanks to the addition of heat from the outside, which is much easier to adjust. The positive conveying of the melt eliminates fluctuations and facilitates the dimensional control of the extrudate. This is also beneficial for the mixing action, which is carried out without overheating the material. The system also guarantees better dispersion and homogenization. Automatic cleaning is fast and thorough and is carried out without further over-
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heating the material. As less energy is necessary to reach the rated power, the stress on the machine is reduced. Energy consumption is comparatively low since the actual value is very close to the required technical value. Sara extruders are particularly suitable for processing highly sensitive polymers as well as for extruding parts that require low process temperatures, dry mixtures and materials that are difficult to feed or need to be completely degassed. Finally, with an appropriate screw configuration, it is also possible to use foaming agents in the same extruder. The latest innovations from Sara include the RS80 twin-screw extrusion for processing PS, PE and PET foam, with an output capacity of 30 to 140 kg/hour, 75 mm centre distance, screws with a maximum diameter of 98 mm, an L/D ratio of 25/1 and a 30 kW main drive. www.sarasrl.eu
A sort of new paradigm for the packaging and converting To enter the new high-end packaging and converting market, Saldoflex recently created a new printing machine capable of competing at the highest level in the field of high-quality food packaging. The project was carried out in close cooperation with Bosch Rexroth, resulting in a highly innovative solution: the new Leaf-S8 central-drum machine. Thanks to artificial intelligence, the proprietary system allows the automatic set-up of printing pressures so that the process gains in terms of efficiency and reduction of material waste up to, according to Saldoflex estimates, at least ten times compared to other solutions. Leaf-S8 in not only innovative but also extremely compact, with a diameter of the central drum of 2,270 mm, thus resulting one of the most compact large-format machines of its kind. Its sizes (length of 14.5 m, width of 4.5 m) guarantee a maximum print width of 1,600 mm and a maximum print development of 1,300 mm. Thanks to its advanced level of user experience (totally customizable control dashboard and possibility for the operator to control any parameter through the touch screens positioned in different points of the machine) and a series of technological novelties resulting from FEM A particular of the new compact analysis conducted by the Saldoflex but performing Leaf-S8 machine R&D team, Leaf-S8 is proposed as a highly innovative solution on the converting market. The flexibility and functionality of the user experience of the Leaf-S8 confer significant advantages to the printer: the strengthen productivity, the convenience of management and the timeliness of the intervention, which in turn contributes to reducing material waste. Given the flexibility and ever shorter runs required by the current market, the speed in changing jobs becomes essential. Together with Bosch Rexroth, Saldoflex has paid great attention to the development of the pneumatic expulsion system and extraction of cliché and anilox to speed up job changeover times, ensuring a high safety standard for operators and maximum prevention from scratches or damage to the sleeves, especially with wide printing widths for large formats. The innovative concept of the Leaf-S8 could take shape also thanks to the automation solutions by Bosch Rexroth, among which the two “brains” IndraMotion MLC, managing respectively more than 20 print axes and 40 positioning axes of 10 colours, the 530 torque motor, that guarantees precision and fluidity of movement to the large central drum, the IndraDrive drives, with onboard safe motion functions. www.saldoflex.com MACPLAS INTERNATIONAL OCTOBER 2021
A Presma rotary moulding machine for solid silicone
The challenge to traditional moulding in the rubber and silicone sector continues The new Roto LOP RS 2000 F-6
The competitiveness and efficiency of the automated production process in the name of quality and safety represent, for Presma, the foundations on which it builds proposals that increasingly meet the expectations of rubber and solid silicone processors. The company has recently introduced a specific rotary moulding machine for solid silicone. Due to the experience gained in the construction of static vertical moulding machines for an important Italian company, Presma convinced the same customer to evaluate the concept of a “multi-station unit” to reduce the downtime of curing and consequently increase the productivity. The new Roto LOP RS 2000 F-6 is a six-station, vertical rotary injection moulding machine, equipped with a sliding lower mould half for insert loading and part unloading, with the horizontal injection unit, and with a horizontal screw and
punch injection unit. The feeding of the silicone in loaves through a “pick and place” system ensures a precise transfer from the conveyor belt to the storage position, in front of the “punch cylinder” feeding the screw. The main advantage of such a configuration is the possibility of significantly reducing the cycle time compared to a single-station machine. After the injection into the mould, it is not necessary to wait for the compound to cure before unloading the product and then start again with another injection, because, with the mould still closed, the table rotates and brings the next mould to the injection position. The operation is repeated as many times as the number of stations and, at the end of the rotation cycle, the curing process of the material injected into the first mould is complete, allowing the product to be unloaded. The widely achieved goal was
the injection of 1500 g of silicone within a moulding cycle of 60 seconds. On the other hand, the cycle time of a single-station injection moulding machine could not be less than 360-380 s using 6/8-cavity moulds with a curing time of 300 seconds, when considering the moulding, ejection and insert positioning phases; the production that would be obtained is around 60-80 pieces/ hour compared to the 120 pieces
now obtained with the rotary solution, using six 2-cavity moulds. Further advantages are represented by an easier mould manufacturing and reduced sprues. The number of stations on the rotary table makes this technology very flexible. By installing different moulds, in fact, it is possible to obtain, in the same cycle, products of the same material which are different in shape and size. www.presma.it
PLASTIC & RUBBER INFRARED AND UV SOLUTIONS FOR EVERY APPLICATION WELDING OF PLASTIC PARTS Heating of prepreg composite materials LAMINATING Shrinking of plastic foil
STRETCHING OF PLASTIC FILMS
IR HEATING FOR PET PREFORMS Thermoforming of plastic parts Deburring of stamped part
EMBOSSING PROCESS DRYING OF PLASTIC PELLETS Crystallization and drying of PET, PPS, PLA Curing of paints on plastic
Softening process Forming process Bending process Vulcanization processed in rubber industry Drawing of plastic tubes SEALING PROCESS
GLUING PROCESS
Come and visit us! Hall A4 / Booth 4126 12 - 16 October 2021 Friedrichshafen - Germany
www.heliosquartz.com
MACPLAS INTERNATIONAL OCTOBER 2021
Helios Quartz Group SA Via Roncaglia 20 6883 - Novazzano - Switzerland Tel. +41 (0) 919233555/6 - Fax +41 (0) 919233557 swiss@heliosquartz.com
Helios Italquartz S.r.l. Via delle Industrie 103/A - 20040 Cambiago - Milano - Italy Tel. +39 02 95 34 93 18 - Fax +39 02 95 34 50 85 italy@heliosquartz.com
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ANCILLARIES AND COMPONENTS
CONTROLLED-ATMOSPHERE CLEANING OVENS - A TECHNOLOGY ENHANCING PERFORMANCE AND SAVINGS
WHEN CLEANING MEANS PRODUCING
THE INFRARED HEATING SYSTEM INCORPORATED INTO THE PHT-PETRELLI CLEANTECH OVENS OFFERS AN INNOVATIVE WAY OF REMOVING THE POLYMER RESIDUE THAT, CYCLE AFTER CYCLE, BUILDS UP INTO EXTRUSION HEADS, INJECTION NOZZLES, SCREENS, AND SO ON. WHAT IS MORE, IN REMOVING THIS RESIDUE, THE SYSTEM SIGNIFICANTLY REDUCES CYCLE TIMES AND ALLOWS GREAT SAVINGS IN TERMS OF ENERGY COSTS. IT THUS BEARS OUT THE CONCEPT THAT CLEANING IS, QUITE SIMPLY, PART OF THE PRODUCTION CYCLE BY RICCARDO AMPOLLINI AND ERMANNO PEDROTTI
“R
egardless of whether we are talking about thermoplastic extrusion processes or injection moulding, once you have clocked up a certain number of production cycles, you can expect to need to carry out complex and costly cleaning operations”, began Osvaldo Lo Negro, sales manager at PHT-Petrelli Heating Technologies, during a recent interview with MacPlas editors. “Since the cleaning operations cannot be carried out in masked time, production inevitably has to be paused while they are taking place. What is more, disassembling, cleaning and reassembling an extrusion head can take up to 4-5 weeks. Therefore, it’s obvious that plastic processors have to reckon with a considerable burden in terms of costs and procedures every time their machinery must be stopped to allow the restoration and main-
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tenance procedures necessary for keeping it in good working order”. This, then, is the current state of art regarding
the maintenance of extrusion and/or injection moulding equipment, and it is a situation with which sector operators are, of course, familiar. At this point, Patrizio Petrelli, research and development manager, having given us technical and operational details of the Cleantech series of infrared ovens he has patented, went on to outline the company’s philosophy on R&D, manufacturing, installation and strictly tailored customer services - a philosophy conceived by and inherited from his father, Antonio Petrelli, who founded the company back in 1959.
ELECTROMAGNETIC THERMOREGULATION UNIT Electromagnetic thermoregulation unit for extrusion barrels
“Since I took over the reins of the company in 1984, I have been careful to follow in our founder’s footsteps, which means listening to customMACPLAS INTERNATIONAL OCTOBER 2021
ers’ needs”, Petrelli said. “Even today, PHT focuses very much on product customisation. It is an approach that has allowed us, for example, to create and patent innovative techniques for transferring heat to the rolls of extrusion calenders, which were previously heated using diathermal oil, or even steam. These are innovative techniques on account of both their advantageous intrinsic cost and the great energy savings they allow, which can amount to almost 70%. Indeed, they are techniques that make it possible to control and differentiate temperatures along the entire length of the rolls, which is impossible to do with diathermal oil systems. Basically, what I am talking about here is electromagnetic wave radiation, an energy transmission technique that, in our case, involves infrared electromagnetic waves, which are transformed into heat on contact with any type of body. Really, we only need to consider the laws of physics in order to understand why it is that electromagnetic waves, travelling almost at the speed of light (a speed they reach in vacuum conditions), are able to heat surfaces rather than the air. This aspect alone provides a clear clue as to how this targeted technology achieves significant savings in terms of energy consumption”.
TECHNICAL FEATURES OF THE CLEANTECH OVENS BY PHT The international patent related to the controlled-atmosphere oven for the cleaning of extrusion or injection moulding machine parts is one of the most recent obtained by the company. “I first designed these ovens twenty years ago”, continued Patrizio Petrelli. “We built about fifteen ovens in total, but the project seemed to be too innovative for those times. In fact, although there was, even then, a lot of attention to the optimization of cycle times, the process engineers were mainly focused on moulding cycle times and/or on automation times. Even the forms of waste defined by the Toyota Production System (TPS) did not cover maintenance that much”.
The sales manager, Osvaldo Lo Negro, close to some modern IR heating elements by PHTPetrelli and, above all, the large cylindrical thermoregulation unit used for a precise control of calender roll temperature
This reference to TPS is quite interesting. In fact, for the Japanese company, the canonical forms of waste are still today the excess of: activity (carrying out activities that do not produce value), movement (moving to reach materials far from the point of use), defects (producing scrap or rework), stock (buying too many materials), production (producing more than requested by the customer), waiting (using time in a non-productive way), transport (moving materials without creating value). Therefore, in 2016 Petrelli decided to resume the project of the controlled-atmosphere cleaning oven, modifying and transforming it into a modern system by implementing a whole range of measures. “A very interesting product was born”, Osvaldo Lo Negro recalled. “Today we deliver the oven in two standard sizes, with diameters of 400 mm and 700 mm which identify the operating dimensions inside the chamber of the ovens themselves. A much larger oven, with an operating diameter of 1,500 mm for accommodating extrusion heads up to 20 tons, is also being completed and tested. Soon, an oven for screws, barrels and flat heads in lengths of up to 8 metres “Even today, like fifty years ago, PHT emphasises product customization: an approach that has led us to create and patent innovative temperature control techniques”, says Patrizio Petrelli, at the centre of the photo together with his partner Dana and his son Antonio
MACPLAS INTERNATIONAL OCTOBER 2021
will also be implemented. The characteristic of this technology is precisely the fact that, unlike the traditional methods of maintenance cleaning, the parts to be cleaned don’t need to be disassembled. This is an important detail, because the time necessary for the cleaning of the parts can be reduced from the previous 4-5 weeks to only 24-48 hours! An impressive improvement, the result of many tests by PHT engineers which, in fact, transforms cleaning from a mere maintenance operation into a strategic factor for production. A major improvement that is making the difference, in terms of competitiveness, for companies that already use PHT Cleantech ovens!” At this point, the sales manager underlined a concept that is fundamental for him, and as such is duly emphasized in the title of this article: in his opinion the cleaning of components, which is usually part of maintenance activity, should be considered an integral part of the production cycle and treated as a real production activity, since, like production itself, it can lead to a real profit for those who buy the right oven. “The first cleaning tests on the prototype of the new Cleantech oven were carried out on laser filters”, Patrizio Petrelli commented, “which, objectively, are amongst the most delicate components to be cleaned. Laser filters, in particular, are quite expensive and, while with traditional methods they do not withstand more than 2-3 cleaning cycles and then begin to deform or their holes get clogged, thus decreeing their end of life, thanks to our infrared ovens these filters have become a sort of “highlander”. On the other hand, the occlusion of the holes is a physiological consequence of the cleaning process traditionally done with oxygen, which produces a carbon residue that gradually clogs the holes. In our ovens, instead, the process is oxygen-free: in fact, we use nitrogen. And then again... thanks
55
ANCILLARIES AND COMPONENTS Last generation ovens, model Cleantech 400 (left) and Cleantech 700
to special IR probes placed inside the oven, we can accurately control process temperatures, so as to prevent any deformation of the parts, even the thinnest ones”. It is also interesting to note that the absence of oxygen in the polymer degradation process (as just mentioned by Petrelli), together with the effectiveness of the cleaning process, eliminates any risk of combustion, making the oven absolutely safe. Then, in relation to the aforementioned control of process temperatures, it must be said that each oven of the Cleantech series is equipped with a PLC that controls the cycle in all its aspects, avoiding on the one hand degradation, deformation, cracking and the carbonization of surfaces and, on the other hand, facilitating the operator’s task. The latter just needs to select, on the control unit screen, the type of polymer to be removed and the entire process of residue elimination is carried out automatically. In fact, cleaning cycles can be programmed, stored and then retrieved when needed. “Indicatively, the standard cycle of one of our ovens can last 160 minutes, of which 40 minutes for heating, 90 minutes for actual cleaning and 30 minutes for cooling down the equipment below the safety threshold of 300°C”, Lo Negro underlined. “Once the cleaning process is completed, the oven door opens vertically, the operator takes the part and the machine is immediately ready for another cleaning cycle. Another advantage of our oven is that it can be installed and used anywhere, since it only needs electricity and compressed air. The nitrogen generator is located inside the machine, making the equipment totally autonomous. In addition, for virgin materials, no suction hood is necessary since the oven incorporates our patented afterburner in practice, a sort of “catalytic converter” - which prevents the release of harmful particles and/or gases into the atmosphere. Thanks to this device, PHT has been able to certify that the fumes from the oven are totally harmless”.
sumer waste”. Patrizio Petrelli then made the valid point that the size of certain extrusion heads, the structural complexity inherent in some devices, and the high cost and value of the devices needing to be cleaned tend to be factors that lead users to opt for the “PHT approach”. A combination of healthy pragmatism and understandable initial scepticism led some prominent customers to want to verify, step by step, the results obtained in the course of various cleaning tests, which were carried out jointly. “Tecnomatic, a leader in the design and construction of machines for the plastic pipe industry, was a case in point”, Lo Negro recalled. “Basically, from the outset, they gave us space and placed their trust in us, but in return they wanted to be involved in the post-cleaning verification stage. When the PHT and Tecnomatic engineers, working together, disassembled the first extrusion head, after it had been cleaned internally by one of our first infrared ovens, they couldn’t believe their eyes! The polymer was totally disintegrated, without a single minute having been wasted preparing the device for cleaning. These and other collaborations have allowed us, for example, to test our cleaning process directly
THE USERS’ “SEAL OF APPROVAL” “Over the past year we have delivered several ovens to Montello, one of Europe’s leading companies in the field of plastics recycling”, Osvaldo Lo Negro remarked, with obvious satisfaction. “We were able to fully meet the customer’s needs; furthermore, given the materials processed, that experience has given us confirmation of the oven’s efficiency. What’s more, in July, we delivered a new oven to another important recycling company: the Tuscan firm Revet. It is significant that our equipment goes to industrial realities like these, where cleaning operations are really tricky on account of the materials they process, which come from urban post-con-
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The handshake between Francesca Sancinelli, director of the Plastics Recycling Division at Montello, and Osvaldo Lo Negro, PHT-Petrelli’s sales manager, finalizes the collaboration agreement between the two companies, which began in 2021
on the huge extrusion heads used by some of the main manufacturers of blown film systems, and ultimately, to deliver our ovens to an important multinational corporation in the chemicals and compounding sector”.
BECOMING A SERVICE PROVIDER: THE LOGICAL NEXT STEP The term “return on investment” (ROI) is generally understood as a balance sheet item that indicates a company’s profitability and economic efficiency, regardless of the sources used: essentially, it is a measure of how much the capital invested in that company will yield. “As far as the ovens in our Cleantech series are concerned, the return on investment is simply linked to its hours of use”, explained PHT-Petrelli’s sales manager. “For example, if a company has no need of frequent cleaning, then it perhaps wouldn’t be worth it investing money in our equipment. However, if it still wanted to take advantage of the speed and effectiveness offered by our cleaning system, then it could choose to move towards a new entrepreneurial model. Providing cleaning services for third parties is a business model that, especially abroad, has already taken off thanks to the fact that, as the data show, it offers a very interesting ROI. This is why PHT has decided to work with an ad hoc company, “O-Life”, that uses our ovens, and only our ovens, to provide a “franchise service” throughout Europe. So far, service provision agreements have already been reached and implemented in countries such as Spain, Poland and Hungary”. “So, thanks to the franchising philosophy, we are able to support entrepreneurs who believe in this new business segment, i.e., that of excellent cleaning services for third parties that are delivered in a fast and competitive way, but above all who are keen to preserve the value and productivity of their plastic processing machinery”, Osvaldo Lo Negro concluded. www.petrelliheating.com MACPLAS INTERNATIONAL OCTOBER 2021
TURNKEY SOLUTIONS
ANCILLARIES AND COMPONENTS
ELECTRIC PLANETARY MACHINES
DUSTLESS CUT AND CHAMFER OF PLASTIC PIPES FROM IPM A NEW SERIES OF MACHINES TO SOLVE THE PROBLEM OF MANAGING DUST AND CHIPS DURING AN ONLY APPARENTLY SIMPLE OPERATION
O
ne of the crucial points in the extrusion line for plastic pipes it has always been the cutting machine. It could seem a very simple operation, but guaranteeing a good cut and chamfer in a short time, with high quality, for short and long pieces, it is not so easy, especially in the managing of chips and dust during the exportation of material. In order to face such need, IPM has developed the TPE new series of electric planetary cutting machines, dustless, working inline with the extrusion plant for cutting plastic pipes (PVC, PP, PPR, HDPE, LDPE etc.), with diameter from 15 to 200 mm, at high production speed (1400 cut/h). These are new cutting machines studied for high fast extrusion lines for plastic pipes with different lengths. In these planetary cutting machines, the pipes enter the machine frame and are supported by rolls up to the universal clamps, composed by eight pressers with radial movement (no twist is exerted on the pipe), and positioned near the cut-
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The pipes enter the machine frame and are supported by rolls up to the universal clamps, composed by eight pressers with radial movement, which lock the pipes during the cutting cycle and keep them tightly
R
ting and chamfering area, which lock the pipes during the cutting cycle and keep them tightly. The functioning of the machine is only electrical and pneumatic, and there are not hydraulic circuits, with the elimination of parts like the electrical creeping contacts which would be subject to the natural wear. There are not frictions caused by creep in the moving system (linear guides with runners to recirculating balls, bearings, neutral pins), with a consequent reduction of the natural wear of the internal mechanical components and high sturdiness. The cutting-trolley movement is motorized and the hardware and software platform by which the machine is developed is from B&R. With this platform it is possible to implement, on the same machine: Euromap protocol; eight length cutting programmer; synchronization with marking device; “TAV” flying cut. All functions and related parameters are implemented on a single operator panel, facilitating the machine setting. The “TAV” type carriage adMACPLAS INTERNATIONAL OCTOBER 2021
w
GWK
vancement allows to combine short pipe cuts with long pipe cuts at a higher speed than a machine with simple motorized feed that is forced to return to the rest position after each cut. The repeatability of the cut for the “TAV” system is higher than a simple motorized feed. Since it is a position control (the cut point is virtually defined on the pipe, and it travels with it), the speed variations of the extrusion line do not affect the accuracy of the cut. The integration between Euromap and TAV protocol is made possible by the adoption of the B&R platform, and it allows, in the event that the extruder foresees a scheduling of several different cutting lengths, the resumption of cutting on the fly, and the possibility of maximizing production even in the Euromap mode.
SATELLITE SYSTEM AND MORE The heart of this cutting group (trolley) consists in a “satellite system”. Unlike traditional cutters, there is no type of actuator, either electric or hydraulic, inside the rotor. The radial movement of the tools is obtained by staggering the belts that control the movement of the rotor. This reduces the maintenance required by the hydrau-
Another interior detail of the machine
lic system and the wear of the brushes and the tracks for the transmission of electrical power. On the rotor, there are three groups that perform the function of support for the cutting and the chamfering tools and the contrast roller. The group that supports the chamfering tool is equipped with a “copy” system that allows the creation of a perfectly centred and uniform chamfer even in the case of pipe imperfections. In order to have a smooth and cleaned cut surface without noises, different tools are used (characterized by a particular profile which is highly resistant thanks to special heat treatments) according to the pipe material to be cut: - for PE pipes, in two of the three arms are installed the feelers, while in the third arm is mounted the cutting tool; the cut is made by means of a
neutral cutting disc (“pizza cut”) without removal material, with no production of dust and chips (up to a maximum wall thickness of 20 mm); - for the PP pipes, in the first arm is mounted the cutting disk, in the second arm is mounted a chamfering tool, and in the third arm is installed the feeler; the cut and chamfer are made together, guaranteeing the perpendicular cut and the homogenous chamfer around all the circumference (up to a maximum wall thickness of 20 mm); - for the PVC pipes, in the first arm is mounted the cutting tool, in the second arm is mounted a chamfering tool, and in the third arm is installed the feeler; the cut and chamfer are made together, guaranteeing the perpendicular cut and the homogenous chamfer around all the circumference (up to a maximum wall thickness of 15 mm). For cutting and chamfering of PP and PVC, IPM has devised a new “chip breaker” device for chips management. In practice, the advancement of the cutting and chamfering tools is generated by a recirculating roller screw and gear motor that create an “alternating movement” of the tool, which causes the “breaking” of the chip, which is then easily sucked up. www.ipm-italy.it
RUBBER COMPOUNDS. SILICONE COMPOUNDS.
Gummiwerk KRAIBURG Antibacterial elastomer compounds for customerspecific requirements.
MACPLAS INTERNATIONAL OCTOBER 2021
www.kraiburg-rubber-compounds.com GWK_AZ_antibacterial compounds_20210913.indd 1
59 13.09.2021 12:00:07
HIGH QUALITY MASTERBATCHES
www.sitramasterbatch.com Via Visanna, 2 03038 Roccasecca (FR) - Italy +39 0776 590001 Via T. Tasso, 480 80127 Napoli - Italy +39 081 646953
amministrazione@sitramasterbatch.com commerciale@sitramasterbatch.com acquisti@sitramasterbatch.com logistica@sitramasterbatch.com laboratorio@sitramasterbatch.com produzione.sicurezza@sitramasterbatch.com
ANCILLARIES AND COMPONENTS
ATOS, SINCE 2000 ON THE MARKET
TECHNICAL AND AESTHETICAL MOULDS FOR OVER TWENTY YEARS A COMPANY VERY SPECIALIZED IN THE MANUFACTURE OF MOULDS TO MEET ANY TECHNICAL AND AESTHETICAL NEEDS IN THE INJECTION MOULDING OF PLASTICS AND, MORE RECENTLY, ALSO RUBBER
H
eadquartered in San Quirino (Pordenone, Italy), Atos is specialized in the design and production of injection moulds for plastic and rubber articles since 2000.
TEAM Thanks to its in-house project department and its specific softwares, the company is able to quickly reply to all enquiries, support and involve customers through all the manufacturing phases. Its know-how, both in mould design and production and in final plastic articles, allows the company to carefully evaluate and analyse every single order, to proMACPLAS INTERNATIONAL OCTOBER 2021
pose the best alternatives and to solve both technical and organizing problems in order to offer the best solution. All that is possible thanks to the close cooperation within its staff and to a constant dialogue with customers. Atos is a medium-sized company with a staff of fifteen employees, all of them motivated, empathetic and always moved by a proactive spirit.
SKILLS AND TECHNOLOGIES In 20 years of activity, Atos has always met the agreed delivery terms: its statistics show 0.00% delays of more than one week and 0.008% of delays of more
An Atos example mould
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ANCILLARIES AND COMPONENTS A multiskill team
than three days. This goal, that it has established from the very beginning of its activity and that it wants to keep in the future, represents its main characteristic as well as biggest satisfaction for customers. The company faces challenges in the most different sectors: from automotive, household appliances, packaging and lighting to telephony, fastening systems, industrial transport, sports and leisure, in terms of both technical and highly aesthetic articles, with complex geometries, high quality and precision items and with surface finishing such as erosion, polishing, chrome plating, painting, photoengraving. In recent years, it has also expanded in the rubber and die casting sectors. The company manufactures 1, 2 and 3k moulds, rotary, transfer, cube, for air moulding, with IML, multicavity (up to 64 cavities), for overmoulding and thermosetting. Moulds are supplied ready to use after being tested, with test reports and materials certification. On request, the company also supplies additional tests and small production batches. Its production range includes prototype alu-
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minium moulds with automatic and semi-automatic functioning, pilot moulds, low-cost moulds for small runs and with tight specifications. Moulds reach maximum dimensions of 900 x 1200/1400 mm, with a total weight of 5,000 kg, for parts from 2 to 1500 grams. The company provides maintenance, repairing and adjustment services for its moulds or those produced by third parties, produces mould parts and executes precision machining in general. Its machinery is distributed on an area of
1200 square meters, recently upgraded with one simultaneous 5-axis milling machine with six pallet-changers, and consists in three CNC milling machines, one 5-axis CNC milling machine, one CNC EDM machine, one wire EDM machine, one grinding machine, one lathe and two drill machines. Its motto summarizes the union among human intellect, ideas and technologies aimed to achieve always increasingly exciting goals. www.atositalia.com
MACPLAS INTERNATIONAL OCTOBER 2021
ANCILLARIES AND COMPONENTS
NEWS Baruffaldi developments in the last year
A whole range of solutions for the downstream With over 60 years of experience in the design and construction of customized solutions for processing plastic profiles and pipes, in the last year Baruffaldi Plastic Technology has reached an important goal in the research and development field to perfect and empower the productivity and the process quality of some excellences of its product range. In addition to the various versions of calibration tables and haul-offs developed for the machines restyling in 2015, during 2021 another version of Baruffaldi patented hot blade guillotine has been designed. As a matter of fact, the technical office has conceived two dual hot blade guillotines of two different size. Each one can cut plastic profiles coming from two extrusion lines close together. Moreover, the servo-driven guillotines can execute angled cuts thanks to the rotation of the cutting group that is assembled
The iCut system
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on a specific metal plate. The dual guillotines are available in two different sizes, according to the dimensions of the profiles to be cut: the smallest one has a cutting section of 100 x 200 mm and the biggest one has a cutting section of 200 x 300 mm. In addition to these, Baruffaldi can customize the guillotine according to the customer specific requirements. Under the Primac brand, Baruffaldi technicians also developed the iCut innovative system for cutting pipes. What differs from the conventional pipe cutting systems is the absence of the planetary blade. The reduced size improves the dynamics and enables to cut short pipe sctions at a greater speed and with no material removal, thus avoiding the production of dust. This solution features a very low energy consumption and a quick-action cutting process that guarantees a high-quality final product without burrs or swar-
The “dual” guillotine
fs, enhancing the surface quality. Advantages of this new-concept cutting unit include a reduced number of moving components and less maintenance, as well as increased precision and flexibility to meet specific customer needs with cut performance. Another project that Baruffaldi technicians developed during the last year consists in a new version of the high-speed pneumatic
punching machine. The machine, which is part of an assembly system for aluminum roller shutters, will also be implemented in the extrusion lines for plastic profiles. This type of punching unit can be applied to plastic profiles with a reduced thickness. In case of thicker profiles, Baruffaldi has designed the Povi 3000 reinforced hydraulic punching machine, also available with two punching heads. During 2020-2021, Baruffaldi also conceived a completely new machine which was implemented both in the extrusion lines and in the off line systems for punching and coining electrical cable ducts. It is a palletizer, an automatic unit equipped with a robot with two rotational clamps that move vertically and horizontally, taking the cable ducts, rotating them by 180°, and depositing them in an orderly manner. The machine can orderly couple the cable ducts to facilitate the operator manual boxing. The downstream equipment has always been Baruffaldi strength and, thanks to its experience in this field, the company designs customized solutions according to the specific needs of each customer. www.baruffaldi.eu
MACPLAS INTERNATIONAL OCTOBER 2021
ANCILLARIES AND COMPONENTS
NEWS A new approach to filtering
FV200 corrugator
High performance with no compromises Nowadays, the FV200 corrugator by Itib Machinery represents a certainty in its range of equipment with proven performances and reliability. Pushed by the today demanding market, in 2018 Itib decided to develop a no-compromises corrugator: high output and quality were the main targets, along with reliability and limited maintenance. Open structure, direct cooling, vacuum forming, aluminium moulds, zooming central channel and compliance with Industry 4.0 specifications are its main features. FV200 covers the full range of cables ducting pipes from 40 to 200 mm; high production speed is possible in the full range thanks to an optimal die length. The outlet channel is also short to maximise the
A view of the pipe exiting the moulds
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length of the central channel and the cooling capacity. The moulds are manufactured from solid aluminium blocks made on five axis CNC machines, and each of them is fixed to a carrier by a single bolt for an easy and fast locking. The carriers are on rollers, running in grooves; a couple of automatic clutches detects any load exceeding the set value. The hoses for the cooling system are above the moulds chain for their free running and bending, avoiding friction and wear. It is possible to open and close the forming channel to use moulds dedicated to the pipe size for an optimal cooling efficiency. The vacuum comes from the top of the moulds by a device placed above the central channel; the device moves automatically to its position according to the mould size, set in the control touchscreen. The corrugator can move in any direction for perfect centring of the die-head. The improvements and technical solutions adopted in the FV200 corrugator allow very high performances. With a maximum mechanical speed of 35 m/min and 800 kg/h output of HDPE two-layer pipes in the 50 pairs of moulds version, the FV200 corrugator can satisfy the needs of the most demanding customers, side by side to the shorter FV200/38HP with 38 pairs of moulds, which allows a lower investment without compromising the quality. www.itib-machinery.com
Reducing operating costs, optimising processes and saving energy The Pegoraro family - at the helm of Geoplast Group, of which Break Polymer is part has always understood the potential of plastics and since 1974 has been involved in the remanufacturing and production of machinery for A Break moulding plastic maPolymer branded terials and recycled plastic products. screenchanger “Thanks to our in-house engineering centre, we develop new technologically advanced systems for new application solutions that have less impact on the environment and on our lives, aimed at promoting the recyclability of products at the end of their life by increasing the use of recycled plastics”, said Mirco Pegoraro, Geoplast CEO and Break Polymer managing director. A visionary approach that matches the circular economy model. All projects are oriented towards machinery and finished products, with the aim of providing a technological solution of higher environmental sustainability and a competitive advantage in terms of cost savings for the end user. After more than 45 years of experience in the plastics sector, adopting an innovative approach in R&D, a new generation of continuous automatic self-cleaning filters for recycling has been designed with the aim of adding value to the plastic material to be treated. The Italian company Break Polymer is inspired to maximise the complete production cycle by rethinking a new business model and wants to be the global benchmark in plastics decontamination. “Our self-cleaning filter machines are built to the highest standards of mechanical design and the filtration technology guarantees excellent quality and reliability. The innovative “Break” systems can be easily integrated into the existing process chain to ensure the highest quality. Our purpose is to reduce operating costs, optimise production processes and save energy for the entire production plant. Innovation is at the heart of technological development and our focus is on breaking the mould, rethinking new solutions and adopting more sustainable methods and systems to make a profitable impact on everyday life”, concluded Mirco Pegoraro. The innovative machines produced by Break Polymer adopt digital control systems, with configuration for Industry 4.0. www.breakpolymer.com MACPLAS INTERNATIONAL OCTOBER 2021
ANCILLARIES AND COMPONENTS
NEWS
The SPA screw pump
Fimic presents SPA
A breakthrough solution for the recycling process Today, Fimic is one of the few companies on the market with a range of five different types of automatic filters for melt filtration, five different technologies designed to match each customer requirements and chosen according to the final application, the required filtration level, the material to be processed and the needed hourly production. In 2021 Fimic is introducing an innovative technology and a breakthrough solution, thus reinventing the working process for plastics recyclers. The latest technology developed by the specialists in automatic self-cleaning melt filters is a screw pump that allows to easily transport plastic melt from the extruder to the filter without using conventional gear pumps. It requires very low maintenance and results the ideal solution to achieve the highest
possible quality out of the recycling lines, significantly lowering operational and maintenance costs. Everybody knows that regular gear pumps used in plastics recycling are very sensitive to contaminations, getting damaged very easily by contaminants especially when using post-consumer plastics. That is why constant maintenance is required and often also the installation of a second filter to protect the pump itself, with significant increase in investment, manpower, and maintenance costs. Additionally, gears must be periodically replaced by the operator, causing a further downtime leading to operation losses. The SPA screw pump by Fimic allows considerable savings, because operational costs are reduced to a very minimum. In fact,
there is no need for maintenance, nor to install a safety filter for pump protection, nor expensive spare gears that the operator will no longer be forced to replace. Regular gear pumps are complex to operate, while the SPA is easy to use and does not require periodic replacements by the operators. It can be installed either before or after the filter, being perfect for applications which require a double filtration step, or to help twin-screw extruders to build up enough pressure without melt return and with no safety filter to protect it. The SPA system installed before the filter allows to protect the twin-screw extruder used especially in compounding applications, and installed after the filter allows to stabilize the pressure of the material and to maximize the
An ever-closer partnership
A centre for infrared tests Founded in 1940, Helios Quartz was born as a family-owned company in Milan, Italy. Over the years the company has grown into a big group of companies with two production plants - the historical one in Italy (Helios Italquartz) and the new facility in Switzerland (Helios Quartz
Customized complete solutions, infrared modules, already cabled and ready to be installed
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Group) - combined with its own commercial branches in the United States, South America and Asia (China and Hong Kong). Today, Helios Quartz is an international player and a renowned supplier of systems for quartz glass processing and manufacturing of infrared emitters and ultraviolet lamps. The company also produces special equipment for industrial, scientific and medical applications. TÜV certified, Helios Quartz is a very flexible and dynamic group which is deeply oriented towards internationalization and which is living a strong and stable growing phase with great momentum. In the last few years, Helios Quartz has developed a cutting-edge centre for infrared testing in the historical production plant in Cambiago, close to Milan, Italy. In
productivity of the filter and the extruder themselves. SPA combines both Fimic typical high engineering standards and the highest quality of manufacturing materials, to offer a superior, reliable, and high-performance product. SPA innovative operation guarantees to all players in the recycling industry significant savings in operational costs, as well as an excellent final result www.fimic.it
this infrared centre, customers can perform tests on several types of plastic materials and different applications, such as stretching, thermoforming, embossing, lamination and deburring, just to mention a few. It is possible to test both material samples and also roll-to-roll films with three types of wavelength (short, medium, fast medium), in order to find the right one for any specific process and material. On the basis of the test results, company can design customized complete solutions, infrared modules, already cabled and ready to be installed. These tests are part of the collaboration with Helios Quartz’s partners: they can determine needed process time and distance, for example, and, at the same time, allow the customers to see the product they are going to buy and use. In this way, mistakes and engineering flaws can be avoided and partners can be helped improving their systems. www.heliosquartz.com
MACPLAS INTERNATIONAL OCTOBER 2021
Under the “Herrmann Engineering” umbrella
Five times as inspiring The structure of Hermann Ultraschall services has been optimized under the umbrella term “Herrmann Engineering”. Every single step, from the initial contact with the customer to delivery and start-up of the complete system, is secondary to achieving the best weld results. The ultrasonic specialists can provide a unique combination of services. The German company has systematically examined its business structure and defined five pillars which help to understand the needs of the customers, and to fulfil these needs perfectly. As well as trust, technical expertise, a modular product kit and a global organization, the realization of sustainable solutions is also a central focus. “Our aim is to be viewed as a trusted advisor. This is the only way that the customer can confidently share the sensitive information with us that we need to understand his requirements exactly”, CEO Thomas Herrmann explains. Once the customer requirements have been established, the project management begins. The company calls this phase “Application Engineering”. To develop the welding process which is perfectly adapted to suit the specific project, all the relevant aspects are considered, starting from the consulting process for the perfect joint design, to manufacturing the sample parts, right up to the start-up of the complete system and training of the employees. The project is only complete once the company has done what is pos-
MACPLAS INTERNATIONAL OCTOBER 2021
Herrmann Engineering incorporates all the relevant aspects into the development and implementation of an optimal production process
sible. It sums this claim up with the phrase “Perfect Product”. A big help here is the extensive, modular product kit, which contains the right combination to solve almost every challenge. In the shortest possible time, weld systems are created which can be integrated seamlessly into existing production environments and which provide long-lasting performance during operation. Once the weld systems are operational, Herrmann Ultraschall continues to support its customers. Under the motto “Global Service”, specialists in over 40 ultrasonic laboratories and tech-centres in 20 countries are ready to promptly help and advise, and they regularly perform customer service tasks and inform customers of new trends and options. The ultrasonic technology is also especially sparing with resources. The process requires less energy than alternative methods and is also more stable. Weld results which can be reproduced in detail ensure that very little material is wasted. Less material is required also for the weld joint itself than in other joining processes. In this way, Herrmann Ultraschall is helping companies to manufacture their products with low energy and material consumption, and offer more sustainable solutions to their customers. Research is also being carried out into the solutions of tomorrow, such as the use of recycled or biodegradable materials. www.herrmannultraschall.com
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INSTRUMENTATION AND CONTROL
NEWS Gefran melt pressure sensors for polymers
A complete and unique offer Gefran - the Italian multinational group specialised in the design and production of sensors, industrial process control systems, electric drives and automation components - offers a complete range of melt pressure transducers and transmitters for high temperatures, designed to meet the highest safety standards, while fully respecting the environment. There are two main manufacturing technologies at the base of the melt sensors by Gefran: these can be either fluid-free, following a silicon piezoresistive operating principle (Impact - I Series sensors), or work by means of filling fluids through a strain gauge system (K, W, M Series). These sensors, available in four designs - rigid stem, flexible stem, flexible with thermocouple, and exposed tip - guarantee a precise installation whenever it is necessary to measure the pressure and possibly the temperature of the fluid, both in traditional extrusion systems and in potentially explosive areas. In this scenario, Gefran was one of the first companies to design a sensor with Atex, SIL2 and PLd certifications, as well as a Hart digital communication protocol, dedicated mechanical flanges, and a fluid-free transmission system. This is the HIX Series (Hart - Impact Atex), designed for the use in potentially explosive environments and with the typical advantages of the Impact sensors by Gefran. More specifically, thanks
Melt pressure sensor model HIX
to a contact membrane up to 15 times thicker than the traditional versions, the pressure is transmitted directly to the sensitive element, which features a micro-worked silicon structure (Mems). The HIX series, with a current output signal, withstands temperatures of up to 350°C and covers a pressure range from 0...10 bar to 0...1,000 bar, making it the ideal choice for the extrusion of low-viscosity plastics. Another advantage of this solution is the quick installation, thanks to the ready-to-use flanges offered by Gefran. The family consists of three further models whose construction principle is based on the hydraulic transmission of pressure and on the transfer of mechanical stress through filling liquids with a low coefficient of compressibility. More in detail, the K series
Melt pressure sensor model HMX
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is characterised by a mixture of sodium and potassium (NaK) which allows the sensor to withstand up to 538°C. The W series is characterised by an FDA-approved diathermic oil filling, which is typically used in the production of plastics for medical or food products. Finally, the M series uses mercury as a transmission fluid and it is employed in all circumstances approved by European Directive 2011/65/UE - RoHS II, in environments with temperatures of up to 400°C. The melt pressure transducers for polymers are able, through an internal self-compensation, to cancel the effect of pressure signal variation caused by temperature variation, thus eliminating the typical reading error of traditional sensors, caused by the heating of the filling fluid. Additionally, the innovative GTP+ coating introduced by Gefran R&D team ensures greater hardness, considerable resistance to high temperatures and a low coefficient of friction, bringing to an increased durability for all sensors. Finally, the full range of melt pressure transmitters comes in a SIL2 and PLd certified version. The K, W, M models can also be equipped with a Hart serial communication (HKE, HWE, HME models). For polymer production plants in potentially explosive environments, the models HWX, HMX - which are Atex EXia, EAC, PAC, Kosha, Peso certified and the models HWF, HMF for US market FM certified - are particularly suitable. The series with digital output IO-Link, 1.1.3 version, completes a unique offer on the market. www.gefran.com MACPLAS INTERNATIONAL OCTOBER 2021
NOTHING CLEANS BETTER...
...FOR A BETTER WORLD.
...THE TIME YOU NEED TO CHANGE COLOR AND REMOVE BLACK SPOTS USING ULTRA PLAST ® PET-CS.
Ultra System S.A.
Rue de l’Ancienne Pointe 30 - 1920 Martigny - Switzerland Tel +41 27 7226271 email: info@ultrasystem.ch www.ultrasystem.ch
3D printer with cubes made of Marfran.Med TPE compounds
MATERIALS AND APPLICATIONS
THERMOPLASTIC ELASTOMERS
C.I.Ma.I.Na - UNIMI and Marco Ferrari
THE NEW FRONTIERS OF MEDICAL TPEs THE NEW FRONTIERS THAT WE WANT TO TALK ABOUT ARE THOSE OF ELASTOMERIC, FLEXIBLE AND SOFT MATERIALS INTENDED TO BE USED IN THE PRODUCTION OF BOTH DISPOSABLE AND REUSABLE MEDICAL DEVICES, OR IN PHARMACEUTICAL PACKAGING
H
istorically, one of the first elastomeric materials used in the medical field was polyisoprene rubber (IIR), widely used for various applications, from devices to components, and to packaging. On the one hand, the use of polyisoprene is well established and recognized by the market, however it has numerous critical issues that are emerging at the level of the production process, in a world that is increasingly attentive to sustainability seen as the recyclability of waste and reduction of the same. In line with the above, the introduction of thermoplastic materials has allowed a significant qualitative leap in terms of waste / product ratio. Amongst the various soft thermoplastics, the one that had the greatest diffusion and first established itself in the medical sector is certainly plasticized PVC, thanks also to its high economic competitiveness. However, the widespread use of phthalates and the subsequent introduction MACPLAS INTERNATIONAL OCTOBER 2021
of restrictions on the use of PVC in medical devices and pharmaceutical packaging, as well as the increase in applicable requirements, has created space for the emergence of new elastomeric materials in the medical and pharmaceutical fields: thermoplastic elastomers (TPE) based on styrenic block copolymers (SBC).
BORN FOR MEDICAL APPLICATIONS The Italian company Marfran (formerly known as Francesco Franceschetti Elastomeri until December 2020) has been producing TPS (TPE based on SBC) for medical and pharmaceutical packaging sectors for many years now, and in 2015 inaugurated a new plant dedicated to medical materials Marfran.Med. That plant is positioned inside an ISO 7 class clean room that houses the entire production process: from the preparation of the compounds, through the compounding phase, to the packaging of
the finished product. As per the relevant legislation, the entire process is carried out in a controlled environment under ISO 13485 certification. Thanks also to this innovation, in recent years Marfran has developed a wide range of Marfran.Med medical compounds based on both saturated and unsaturated block styrene copolymers, intended for the most varied and consolidated applications in the medical device and pharmaceutical packaging sector. Thanks to the extreme ease with which they can be overmoulded or coextruded with polymers such as polypropylene and polyethylene, widely used in the medical field, Marfran.Med TPEs allow to simplify the production process of many medical devices, especially for those that require complex assembly steps. In addition, the range of products is completed by the availability of some families of Marfran.Med compatible for overmoulding or co-extrusion with the most
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MATERIALS AND APPLICATIONS
common polar plastics, such as ABS and PC (table 1). The Marfran.Med GL and GLE are amongst the most recent developments in the medical field of Marfran. These products have been specially developed to allow solvent bonding using cyclohexanone or tetrahydrofuran (THF), a method frequently used in the medical sector. Marfran.Med TPE compounds can be subjected to the most common sterilization processes applied in the medical and pharmaceutical fields, as showed in table 2. The company’s technicians also add that TPE Marfran.Med compounds have passed the following biocompatibility tests: • ISO 10993-4 - Emolisys; • ISO 10993-5 - Citotoxicity; • USP §88 Class VI - Intracutaneous reactivity; • USP §88 Class VI - Acute Systemic toxicity; • USP §88 Class VI - Implantation test.
INNOVATION AND CUSTOMIZED SOLUTIONS THANKS TO 3D PRINTING The product portfolio presented so far is part of a “standard” range of materials for those companies which want to approach the market as a supplier of medical products. The Italian company Marfran does not want to be just a “supplier” of medical TPEs, but its aim is to offer innovative and customized solutions, believing that one of the most advanced development frontiers in the medical field is that of “customized medicine” and the creation of “teaching programs” preparatory to it. For this reason, Marfran collaborates to the “PrintMed-3D” project (https://printmed-3d. com/), funded by Regione Lombardia (Italy) and coordinated by the University of Milan. The project was created with the intention of responding to the growing demand for personalized medical services in the clinical, diagnostic and pre-clinical fields, in a context in which the contraction of available eco-
Table 2 - Sterilization method for each Marfran.Med compound
Table 1 - Two-component injection moulding or co-extrusion compatibility
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This 3D printed cube is an example of a complex structure manufactured with a soft Marfran.Med TPE
nomic resources and the aging of the population require the adoption of more efficient and targeted approach to ensure the economic sustainability of the system and the quality of assistance. Thanks to the development of new materials and the use of latest generation 3D printing technologies, it will be possible to create anatomical models with mechanical and functional characteristics similar to those of natural models. Originally developed image processing approaches will allow the virtual and physical realization of human organs to be merged into a single platform. PrintMed-3D therefore lays the foundations for the construction of a personalized medicine model, which enables the programming and planning of the phases of surgical interventions, improving the effectiveness of treatments, decreasing the risks for the patient and reducing the operative and post-operative times. Thus, Marfran can create customized models of anatomical parts both for didactic purposes and in view of a personalized medicine that allows the doctor to study the patient without touching him. The Italian company is able to produce TPE Marfran. Med ultrasoft compounds capable of replicating the consistency of some tissues of the human body through 3D printing… these are the challenges that apply to Marfran! TPE Marfran.Med compounds can be used with the most modern additive manufacturing technologies for the production of medical devices and customized training. The company’s technicians believe this is the new true frontier of medical materials. www.marfran.com MACPLAS INTERNATIONAL OCTOBER 2021
ADV Amaplast A4 it-ing.indd 2
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MATERIALS AND APPLICATIONS
NEWS MASTERBATCHES AND COMPOUNDS
HIGH PERFORMANCE COMPOUNDING SOLUTIONS FOR ALL NEEDS As part of the Hexpol Compounding’s High Performance Compounding division, the Italian company Mesgo Iride Colors offers a complete product portfolio, including colour masterbatches, black masterbatches and conductive compounds, in the field of colouring plastics, liquid and solid silicone, organic and fluorinated compounds. The Mesgo Group and its four headquarters in Italy, one in Poland, one in Turkey, and including synergies with the other Hexpol Compounding companies, has more than 50 production sites worldwide. Therefore, it has a significant potential to reach customers around the world. This also makes it possible to serve several market segments, such as automotive, transportation, construction, consumer goods, oil & gas, energy, industry and food. Mesgo Iride Colors produces colour masterbatches in granules containing predispersed organic and synthetic pigments, suitable for polyolefins, styrene resins, polyamides and PET, biopolymers and “green resins” from post-consumer waste. They can be used for any application: injection moulding, blow moulding, sheet extrusion, blown films, sheaths and insulation for electric cables, and much more. Another product line by Mesgo consists of the black masterbatches (HAF, SRF) called TangoBlack, characterised according to the type and concentration of carbon black, the presence or lack of mineral fillers, and according to the carrier (base polymer): for example, polyolefin resins, styrene resins, as well as biopolymers and “green resins”. Another way to identify black masterbatches is linked to the kind of application for which they are needed; for this reason Mesgo has created specific products. Different carbon black-free solutions are also available, and they are suitable for those applications in which products need to be visible to infrared selection systems, the so-called NIR systems. Conductive compounds complete the selection. They are formulated with particular types of carbon black, used for the fabrication of products with dissipative or conductive properties. Mesgo Iride Colors also has a wide variety of additive masterbatches for application in traditional, fluorinated-organic, silicone, solid and liquid elastomers and thermoplastic resins. Thanks to the labs used for each product line and to the Mesgo Group R&D Centre, equipped with specialised researchers and high-tech instruments, the Italian company can offer a good support to its customers in developing the product, assuring competitiveness and sustainability in fine tuning. www.mesgo.it Colour masterbatches in granules manufactured by Mesgo Iride Colors
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Application of recycled polyethylene terephthalate
3D printing material made from rPET Materials manufacturer Covestro introduces its first material developed by the additive manufacturing business recently acquired from DSM: a glass-fibre filled recycled polyethylene terephthalate (rPET) for 3D pellet printing. Made from post-consumer PET waste, Arnite AM2001 GF (G) rPET perfectly fits Covestro’s vision for a circular economy and illustrates how complementary the two organizations are in their approach to adding more value to additive manufacturing and industrial production overall. The glass-fibre filled pellet material brings structural performance to a part at a substantially lower carbon footprint than virgin material. Manufacturers can now make their supply chain more circular without the need to compromise on performance. The recycled PET has been optimized for 3D pellet printing. This technology, also known as Fused Granulate Fabrication (FGF), allows for fast and economically viable additive manufacturing of largesize parts. Direct printing of applications lowers cost by reducing product development time. Plus, 3D printing allows design flexibility, which can help reduce material cost. 3D printing is an intrinsically more sustainable production method as it only uses the material that is needed. By also making the material more sustainable, Covestro helps manufacturers shift toward a circular economy. Arnite AM2001 (G) rPET’s mechanical properties and broad processing window makes it ideally suited for structural applications across a variety of industries, including pedestrian bridges, tiles for cyclist or pedestrian tunnels, architectural applications like cladding or partition walls, in- and outdoor
Developed by the Covestro Additive Manufacturing business (recently acquired from DSM), Arnite AM2001 (G) rPET is suitable for high performance and structural applications using 3D pellet printing/fused granulate fabrication (FGF)
furniture, small boats, packaging crates or tooling. Hugo Da Silva, head of Additive Manufacturing (former-DSM) commented: “The introduction of this high-performing material for 3D pellet printing is an important step in creating circular supply chains. With PET packaging accounting for more than 50 percent of total plastic waste, extending its lifetime by re-using it as feedstock offers a broadly available alternative to virgin raw materials - without the need to compromise on performance or total cost of ownership”. Patrick Rosso, head of Additive Manufacturing (Covestro) added: “We’re excited about the introduction of this circular material designed by our new colleagues. It perfectly fits the Covestro vision of a Circular Economy. This material is the best proof point we could want to underpin the two teams’ joint ambition to bring the market a stronger materials partner that can help accelerate industrial additive manufacturing”. wwww.covestro.com MACPLAS INTERNATIONAL OCTOBER 2021
Peroxide and addition cross-linked compound alternatives
PCB-free silicone compounds The manufacture of extrusion articles by means of pressureless vulcanization (hot air, salt bath) of silicone rubber using the common peroxide DCLBP, Di(2,4-dichlorobenzoyl) peroxide, results in the release of polychlorinated biphenyl (PCB), which is harmful to both the environment and people’s health. The German company Gummiwerk Kraiburg offers peroxide and addition crosslinked compound alternatives containing chlorine-free cross-linking systems for pressureless cross-linking and which therefore do not form any PCBs. While these compounds do vulcanize somewhat slower, this is far from being a decisive factor in high-temperature vulcanization (200°C or higher) in a hot-air tunnel. The time differences can be reduced so much by raising the temperature that the dwell times in the vulcanization tunnel are hardly that much longer in practice. The odour created during the processing of the peroxidically cross-linked DCLBP alternative can be eliminated using an extraction system integrated into the process.
The addition cross-linked alternative compounds also feature a higher level of mechanical quality than those cross-linked with peroxide. For instance, the elongation at break, e.g. of a standard compound 70 ShA, increases significantly, from 370% to 600%. Similarly, the tear strength increases from 25 N/mm to 42 N/mm according to ASTM D624B. This makes it possible to produce cables and hoses with even better tear resistance and extensibility. In addition, the better compression set of these compounds (from 33% to 10%, 24 hours at 175°C) also makes increased pressure stresses possible. Polychlorinated biphenyls accumulate in fatty tissue and damage the nerve and immune systems. In some cases, these substances also lead to cancer and malformations and deformities in unborn children. Quite recently, several manufacturers in the German state of North Rhine-Westphalia were forced to restrict their production activities after dangerous concentrations of PCB were detected in the
The SPII story continues with Lati
Structural and selfextinguishing handle made of glass fibre reinforced PA66 The Italian company SPII is a leader in the design and construction of components and equipment for railway vehicles. The company specialises in complete driver desks and haptic panels for railway and industrial applications. Some time ago, the company decided to review its approach to the use of synthetic materials, including thermosetting resins, in its applications, and thus opted to introduce structural, self-extinguishing thermoplastic compounds. To allow this transition, the new materials needed to perform better than resins such as BMC or phenolic ones, par-
ticularly in terms of mechanical strength and durability. The company last generation grips, used on traction/braking control devices, are therefore made from Latamid 66 H2 G/50-V0HF1, a PA 66-based compound reinforced with 50% glass fibre in weight produced by Lati. Thanks to a halogen-free system of additives with a low environmental impact, the com-
MACPLAS INTERNATIONAL OCTOBER 2021
Traction/braking handle made of Latamid 66 H2 G/50-V0HF1
Gummiwerk Kraiburg offers chlorine-free silicone compounds which do not release any polychlorinated biphenyl (PCB) during pressureless vulcanization. Thanks to the use of an alternative cross-linking method, the fission products of these compounds do not contain any PCB
areas around these facilities. This prompted the state government to impose stricter monitoring on companies processing silicone and encourage manufacturers to switch to alternative solutions. The state of North Rhine-Westphalia has submitted a recommendation in this matter to Germany’s federal states’ parliament, the Bundesrat. The amendment of the ordinance on industrial plants requiring special approval (the fourth BImSchV [Ordinance on the Implementation of the Federal Immission Protection Act]) is intended, in light of the PCB emissions produced by plants processing silicone, to establish a uniform approach to be applied throughout Germany for preventing damage to the environment. www.kraiburg-rubber-compounds.com
pound is self-extinguishing. The feasibility of the project was first evaluated through FEM simulations, which served to validate the product from a structural point of view: this was a necessary stage in order to establish whether the strength of the material, the clamping system and the special arrangement of reinforcing ribs would allow it to pass the necessary test. Once it had passed the test, which also included application of a vertical force of 1,000 N on the horizontal arm of the lever, SPII launched production of this modern accessory, which, unlike the previous solutions, is suitable for end-of-life recycling.
The Lati compound has a breaking strength of almost 200 MPa, which puts it on a par with the best non-self-extinguishing solutions. It also boasts excellent aesthetics and processability, the latter a key attribute for ensuring a simple and productive moulding process. The material has a certified UL94 V0 rating from 3 to even 0.4 mm, and according to IEC 60695-2-12 it has a glow wire flammability index (GWFI) of 960°C. It is therefore potentially an ideal grade for structural and metal replacement applications, even ones requiring very low thicknesses and also maximum flame retardancy. Finally, its UL 746 B relative temperature index (RTI) is 130°C at all thicknesses. This demonstrates the considerable durability, over time at different temperatures, of the material’s main mechanical, electrical and flame retardant characteristics. www.lati.com
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MATERIALS AND APPLICATIONS
NEWS Ultra Plast by Ultra System
Perfect examples of cleaning with purging compounds The idea of two entrepreneurs led to a private industrial group with six mixing units around the world. The Swiss company Ultra System produces only purging compounds. This is its specialty, while its mission is to solve “problems” and reduce plastic waste. Leader in the sector of purging compounds, Ultra System boasts a customer portfolio that ranges from packaging to households, from automotive to toys, up to medical/pharmaceutical and cosmetic sectors. That’s why Ultra Plast has all the necessary certifications to work in those fields: ISO, Reach, food contact, clean room. The Ultra Plast brand - over 20 products belonging to the fifth gene-
ration of purging compounds from the company - has characteristics that make it almost unique on the market: it does not contain abrasives (100% chemical cleaning, so it does not damage the metal parts of the machine); it does not require soaking time (“sandwich procedure”); it does not release smoke or bad smell; it is fast and simple to use, effective, with a highly competitive cost-in-use. The use of Ultra Plast is necessary to reduce the time during colour and/or material changes, for the removal of previous colour deposits, for the elimination of black points and impurities, for restarting after a short machine stop (shut-down).
It is now widely demonstrated that using plastics (or, worse, detergents etc.) for cleaning generates higher costs, lower quality, longer downtime, higher carbon footprint, higher energy costs. In short words, it is more expensive than using Ultra Plast. It is like washing your hands without soap: a lot of water, a lot of effort, a lot of time and bad results. And, in 2021, non-conformities such as impurities, black points, milky-shadow, stripes can no longer be accepted. As Ultra Systems technicians have seen, the use of plastics as These preforms represent the perfect example of cleaning with Ultra Plast purging compounds. In the second preform from the left, the purging compound has been injected
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“purge” implies a greater amount of downtime (sometimes even a few hours); this means time that processors are not dedicating to production for their customers, and that they are simply throwing away. Another important point is that many processors consider purging compound as an additional cost. Not only Ultra System, but all purging compound manufacturers have proven that this is not the case. On the contrary, professional purging reduces production costs. And it is possible to prove it. If we consider the case of injection moulding, a lot of processors do not want to use purging compounds for hot runners, fearing that they can be damaged. On the contrary, Ultra Plast can be used without any problem because it is safe, as it does not contain any abrasive components. And the preforms are the perfect example, as the readers can see from the picture in this page (in the second preform the purging compound has been injected). Of course, Ultra Plast also finds application in extrusion, blow-moulding and cast-film or blown-film production. Furthermore, live demonstrations at potential user production site are the best way to appreciate the effectiveness of Ultra Plast purging compounds. The Swiss company also organizes training courses for its agents/distributors, arranges virtual conferences and participates at various trade fairs (the next ones will be Fakuma and Arabplast). www.ultrasystem.ch
MACPLAS INTERNATIONAL OCTOBER 2021
TRADE FAIRS AND CONFERENCES
Plast 2023
New dates after the pandemic
EXHIBITIONS & TRADE FAIRS 2021 October 20-23 - K Plus (Istanbul, Turkey) October 26-28 - PPP Nigeria (Lagos, Nigeria) October 26-29 - Ecomondo (Rimini, Italy) October 27-28 - LuxePack New York (New York, United States) October 27-31 - PackShow (Bucharest, Romania) November 4-5 - PRSE, Plastics Recycling Show Europe (Amsterdam, The Netherlands) November 11-13 - Central Asia Plast World (Almaty, Kazakhstan) November 15-18 - Arabplast (Dubai, United Arab Emirates) November 16-18 - Utech Europe (Maastricht, The Netherlands) November 16-18 - MetsTrade, Marine & Composites (Amsterdam, The Netherlands) November 17-19 - Tyrexpo Asia (Singapore, Singapore)
The organization team announced the upcoming edition of Plast, international exhibition for the plastics and rubber industry, which will be held on September 5-8, 2023, at the Fiera Milano fairgrounds in Rho-Pero (Milan, Italy)
November 18-20 - PPP Expo Africa - Kenya (Nairobi, Kenya) November 23-25 - Mecspe (Bologna, Italy) November 23-25 - Plastics & Rubber Vietnam (Ho Chi Minh, Vietnam) November 23-26 - PPP Iraq (Erbil, Iraq)
As we all know, the Covid-19 pandemic caused the cancellation or rescheduling of almost all events all over the world, including the international triennial Plast exhibition, originally scheduled this year on May 4-7. Given the continuation of the health emergency, and in keeping with the complex world tradeshow calendar for the sector - which is slowly being pieced back together - the exhibition has finally been rescheduled for September 5-8, 2023. Exhibitors originally enlisted in Plast 2021 have already moved to ensure a place at Plast 2023, confirming 30,000 square metres of exhibition space. Applications for new exhibitors officially will open in June 2022. The previous edition of Plast, which took place in 2018, recorded over 1,500 exhibitors in a net space of 55,000 m2 and drew in more than 63,000 visitors, with a significant increase in visitors from other countries, reaffirming the international appeal of the specialized fair in Milan. In keeping with tradition, Plast offered operators a broad and varied technology showcase, especially as regards the core of the exhibition, i.e., the machinery, auxiliaries, and moulds for plastics and rubber processing. More than 3,500 different equipment were exhibited in six exhibition halls. This sector represents a major slice of Italian manufacturing, with a production value estimated by the trade association Amaplast at 3.74 billion euros in 2020, with exports accounting for some 70% of production. In keeping with previous editions, the content of Plast 2023 will not be limited to machinery but range from innovative materials to cutting-edge production processes, and from hightech finished products to personalized services. As usual, a rich programme of seminars, workshops, press conferences, and company presentations will ensure a wealth of opportunities for professionals in the sector to meet and exchange ideas with other operators. www.plastonline.org
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December 1-4 - Plast Eurasia (Istanbul, Turkey) December 1-4 - Rubber (Istanbul, Turkey) December 1-4 - Plastics & Rubber Indonesia (Jakarta, Indonesia) December 2-4 - PPP Expo Africa - Ethiopia (Addis Ababa, Ethiopia)
2022 January 9-12 - Plastex (Cairo, Egypt) February 17-21 - Plastindia (New Delhi, India) February 22-24 - Utech Middle East/Africa (Dubai, United Arab Emirates) March 8-10 - JEC World (Paris, France) March 14-16 - Plast Alger (Algiers, Algeria) March 16-17 - Injection Moulding & Design Expo (Detroit, United States) March 29-31 - FiltXpo & Idea (Miami Beach, Florida, United States) April 5-8 - FIP (Lyon, France) April 5-8 - Interplast (Joinville, Brazil) May 3-6 - Greenplast (Milan, Italy) May 3-6 - Ipack-Ima, Print4All, Pharmintech and Intralogistica (Milan, Italy) May 18-21 - HanoiPlas (Hanoi, Vietnam) May 24-26 - SPS Italia (Parma, Italy) June 1-4 - Plastexpo / Packexpo (Casablanca, Morocco) June 10-13 - Iplas (Chennai, India) June 27-30 - DKT IRC (Nuremberg, Germany) September 26-30 - Colombiaplast (Bogotà, Colombia) October 19-26 - K 2022 (Düsseldorf, Germany) November 22-24 - PPP Kenya (Nairobi, Kenya) NOTE: The trade show calendar could be subjected to change due to the health emergency caused by Covid-19. Therefore, we invite you to visit www.macplas.it to take note of all possible postponements. MACPLAS INTERNATIONAL OCTOBER 2021
TRADE FAIRS AND CONFERENCES
PLASTICS RECYCLING SHOW EUROPE
THE TWO-DAY CONFERENCE AND EXHIBITION RETURNS TO AMSTERDAM
The Plastics Recycling Show Europe (PRSE), the pan-European exhibition and conference dedicated to plastics recycling, returns to the RAI Amsterdam (The Netherlands) on November 4-5, moving to Hall 12 to accommodate demand for a larger exhibition and conference space, and therefore expanding the floorplan to over 8000 m2. “PRSE is a must-visit event to stay up to date with the latest developments and gain the insights into the legislative landscape of plastics recycling in Europe”, said Ton Emans, Plastics Recyclers Europe president. “The fifth edition will take place more than two years after our last in-person event in 2019. The pandemic has been a very challenging time for everyone, but also a period of unprecedented change”. The latest trends in the plastics recycling sector will be explored in depth throughout the two-day conference, which provides a holistic view of the whole plastic recycling value chain, drawing together political leaders, major brands and the plastics recycling and manufacturing industry. Updating delegates on the latest political and legislative developments in plastics recycling in Europe will be the opening conference session entitled “Making Plastics Fully Circular: What’s Next?” Materials focus sessions on the first day will explore the challenges, issues and opportunities within the sector for mechanical recycling, covering PET, PVC and technical plastics. The second day’s opening conference session is “Closing the Circle with RecyClass” and is followed by polyolefin material focus sessions which will examine the current status of polyolefin waste streams including high- and low-density polyethylene. The conference concludes with a final session looking at polypropylene and polystyrene recycling. Event sponsors Erema, Poly2Poly and Basf are also due to make presentations. The winners of all seven award categories at the Plastics Recycling Awards Europe 2021 will be announced at the event on November 5. All finalists will be showcased in the exhibition, as will the winners of the 2020 awards, which were presented virtually. www.prseventeurope.com
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MEETINGS & CONGRESSES Germany November 3-4 - Düsseldorf: bio!Pac - Polymedia Publisher (www.bioplasticsmagazine.com) November 8-10 - Cologne: Waterproof Membranes - AMI (www.ami.international/events) November 16-18 - Cologne: PVC Formulation Europe - AMI (www.ami.international/events) November 23-24 - Frankfurt: JEC Forum DACH - JEC Group & AVK (www.jec-dach.events) November 29-30 - Berlin: Silicone Elastomers World Summit Smithers Rapra (www.smithers.com/events) November 29 - December 1st Nuremberg: Thin Wall Packaging AMI (www.ami.international/events) November 30 - December 1st Berlin: European Bioplastics Conference - European Bioplastics (https://www.european-bioplastics. org/events)
Italy November 11-12 - Webinar: Advances in the Packaging Industry MCM Eventi e Congressi (www.apicongress.it)
Spain November 2-4 - Barcelona: Sustainability in Packaging Europe Smithers Rapra (www.smithers.com/events) November 8-10 - Barcelona: Agricultural Film Europe - AMI (www.ami.international/events) November 23-25 - Barcelona: Multilayer Flexible Packaging Europe - AMI (www.ami.international/events)
The Netherlands November 4-5 - Amsterdam: PRS Europe - Plastics Recyclers Europe (www.prseventeurope.com) November 22-23 - Amsterdam: Recovered Carbon Black - Smithers Rapra (www.smithers.com/events)
December 8-9 - Amsterdam: Digital Print for Packaging Europe - Smithers Rapra (www.smithers.com/events)
United Kingdom October 25-28 - Webinar: GPS + PEPP: Global Plastics Summit & Polyethylene-Polypropylene Chain Global Technology & Business Forum - IHS Markit (https://globalplasticssummit.com) November 17-18 - Manchester: European Biomass to Power Conference - ACI December (https://www.wplgroup.com/aci/ event/european-biomass-to-power) December 14-16 - Webinar: Smart Packaging Virtual Summit AMI (www.ami.international/events)
United States November 1-2 - Chicago (Illinois): SmartPack Smithers Rapra (www.smithers.com/events) November 2 - Cleveland (Ohio): The Global Plastics Industry - AMI (www.ami.international/events) November 3-4 - Chicago (Illinois): E-Pack - Smithers Rapra (www.smithers.com/events) November 9 - New York (New York): The Global Plastics Industry Seminar - AMI (www.ami.international/events) November 15-18 - Scottsdale (Arizona): Hygienix - INDA (www.hygienix.org) November 18 - Webinar: SPE Plastics Forum - SPE (www.4spe.org) December 9 - Webinar: Thermal Dependency of Plastics - SPE (www.4spe.org) NOTE: The event calendar could be subjected to change due to the health emergency caused by Covid-19. Therefore, we invite you to visit the websites listed to take note of all possible postponements. MACPLAS INTERNATIONAL OCTOBER 2021
EDITORIAL CONTRIBUTORS
THE FOLLOWING COMPANIES ARE MENTIONED IN THIS ISSUE: COMPANY/ASSOCIATION/INSTITUTE PAGE 10; 13
AMAPLAST
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Publisher Promaplast Srl Centro Direzionale Milanof ori Palazzo F/3 - 20057 Assago (MI) phone (+39) 02 82283775 - fax (+39) 02 57512490 macplas@macplas.it - www.macplas.it For advertising: lerner-media@t-online.de
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AMI
20
ASSOGOMMA
16
ATOS
61
BARUFFALDI
64
BINOVA
42
BMB
46
BOSCH REXROTH
52
BREAK POLYMER
66
CERESANA
21
CONAI
26
COVESTRO
76
DM INDUSTRIAL
50
DOW CHEMICAL COMPANY
26
FIMIC
68
GAMMA MECCANICA
44
GEFRAN
70
GREENPLAST
23
GUMMIWERK KRAIBURG
77
HAITIAN INTERNATIONAL HOLDINGS
28
HELIOS ITALQUARTZ
68
HERRMANN ULTRASCHALLTECHNIK
69
IMG
28
IPM
58
ITIB MACHINERY
66
LATI
77
MARFRAN
73
MARIS
38
MESGO
76
MURA TECHNOLOGY
26
PHT-PETRELLI
54
PLAST 2023
80
PLASTIBLOW
33
PLASTICS INDUSTRY ASSOCIATION
20
PRS (PLASTICS RECYCLERS EUROPE)
82
PRESMA
53
SALDOFLEX
52
SARA
52
TECNO SYSTEM
48
TURRA
50
UCIMA
13
ULTRA SYSTEM
78
UNIVERSITY OF BOLZANO
27
UNIVERSITY OF TRIESTE
27 MACPLAS INTERNATIONAL OCTOBER 2021
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