MacPLas International - May 2022 by PROMAPLAST

MACPLAS INTERNATIONAL

Published by Promaplast Srl - Centro Direzionale Milanofiori - Palazzo F/3 - 20057 Assago (Milano, Italia) - ISSN 0394-3453 - Poste Italiane S.p.A. - Spedizione in abbonamento postale-aut. n°cn-ne/00788/02.2022 stampe in regime libero

INNOVATION IS ALWAYS IN OUR MIND.

TECLAN

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TECRIL

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PMMA

For over 20 years we’ve been oﬀering a large range of compounds and masterbatches suitable for any ﬁeld of application.

Via dell’Industria, 6 - 31020 San Polo di Piave (TV) - Italy Tel. 0422 856644

www.colortech.biz

extrusion

CONTENTS

25 18

13 10 MARKETING

25 MACHINERY AND ANCILLARY EQUIPMENT

10 13 16 16

25 Two new lines for the extrusion of compound ready for the market 28 Innovation, sustainability and productivity: the forces of recycling and compounding 30 More than a simple new model 32 A brand for flexibility and efficiency in welding 34 Diversification without disruption 37 Entry into the blown film sector 38 A sort of new paradigm for the packaging and converting 38 Containers for detergents and home care products 40 Blocking even the smallest contaminating particles 42 Care and attention as key of success

Editor’s letter - A new magazine for sustainability Two sectors in recovery Windows and roller shutters on the rise in 2021 APAC is projected to be the fastest-growing region for agricultural films market 17 Growing demand for a common but versatile polymer

18 PLASTICS AND ENVIRONMENT 18 Bioplastics in the limelight 22 Mechanical recycling exceeded 8 million tons in 2021 22 PET packaging moving steadily towards circularity 23 The first Mattel toys in materials from renewable sources are on the way

MACPLAS I NTER NATI ONAL | MAY 2022

S T O R Y

MACPLAS INTERNATIONAL

MAY 2022

Ultra Plast goes green

44 MATERIALS AND APPLICATIONS 44 Material solutions for a seamless, fully networked mobility 46 A real sustainable solution 48 A multitalented compound for the plastics industry 48 Compounds for a gentle, comfortable shave 49 Electric push for lots of driving fun 49 New recycled-based HPPA for household appliances

50 TRADE FAIRS AND CONFERENCES New dates for the triennial show Exhibitions & Trade Fairs Meetings & Congresses A conference dedicated to composites

Environmental protection and energy saving

50 50 51 51

C O V E R

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

Huge volumes of plastic resins are wasted every day due to product contamination and ineffective changes of resin and/or colour. This large amount of plastic scraps creates a significant negative effect on the environment. As a result, in all media, newspapers and TVs, we can read and hear about the problems of plastics waste. The carbon chemical bond, and the other chemical bonds on which a polymer is based, remain very strong and stable over time. As a result of this feature, polymers have a long life, and are also weather resistant and extremely strong; this is why we can find them almost everywhere in our daily life in the form of various objects. But, unfortunately, in addition to these positive features that make them suitable for use in industries, they have a very low degree of biodegradability and consequently a remarkable environmental impact. Due to this fact, it is very important that they are not simply thrown away but properly recycled and re-used. When changing from a dark colour to a clear colour, the first shots of processed pieces have the so-called “stripes”, “black spots”, or other kinds of pollutions originating from previous production. These shots cannot be reused for other clear colours and normally they will be regrind in order to produce black or very dark coloured pieces. As not all companies produce large quantities of dark pieces it is often necessary to recycle them. Ultra Plast purging compounds make it possible to reduce scrap production. The higher the efficiency of the purging compound, the lower will be the waste. Let us now analyse the use of purging compounds from an ecological point of view: a company which produces several tons of waste per month can avoid up to 95% of this waste through a proper use of an efficient purging cycle and careful recycling. We can state that Ultra Plast consists in a carrier material (polymers) and an active part which is made only of food and pharmaceutical components. It operates at temperatures between 120°C and 420°C, according to the grade and works by generating chemical reactions that remove the plastic residues from the cylinder wall and the screw. All what remains after use is a residual polymer material filled with inert minerals which can either be disposed of as plastic waste or recycled as mineral-filled plastic. The resulting purged material can even be considered biodegradable. All grades of Ultra Plast purging compound have internal chemical reactions which are activated by the heat of the plastic processing equipment, saving time and energy for production. Ultra Plast is safe for humans and environment and it has many benefits. Wouldnʼt it be cheaper to recycle all scrap production and wouldnʼt there be fewer problems if purging compounds were used regularly? Saving time is important for production and saving energy is not only an economical factor but, above all, an ecological duty for all of us. Everybody can do something to reduce plastic pollution. Plastic is fantastic. The important thing is to use a good and environmentally friendly purging compound. Take care… Ultra Plast will do the job! www.ultrasystem.ch

MAY 2022

MACPLAS INTERNATIONAL

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ASSOCIAZIONE NAZIONALE EDITORIA DI SETTORE

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photos: www.shutterstock.com ARTHA MILANO

BELIEVE IN COLORS

Vanetti s.p.a., founded in 1971, produces Masterbatches, Biomasterbatches®, Additives, MasterbatchRecy® for plastic materials. With almost fifty years experience in the industry, Vanetti specific products are used to color and additivate all thermoplastic resins and new biopolymers. Passion for color, experience and customers service are the company’s strengths. New high-tech systems and attention to quality and eco-sustainable raw materials guarantee high performance in the use of the products.

VANETTI S.p.A. - Italy

since 1971

www.vanettimaster.com

- Tel: +39.0331.389077 - Fax: +39.0331.389078 - vanetti@vanettimaster.com

On the road together towards sustainability: a new story An engineering polymer with reduced environmental impact made of recycled polyamide and featuring excellent technical performance. A safe and certified product according to the latest regulations: this is Renycle ®.

What about you? What will your Renycle® story be?

AUTOMOTIVE

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CONSUMER

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Bags Bagson onroll, roll,garbage, garbage,anti-drip, anti-drip, and industrial bags. and industrial bags. NON NON STOP STOP production production also also in in extrusion extrusionline. line. Automatic Automatic end-of-line end-of-line packaging packaging machines. machines.

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ELECTRONIC PERFORATOR PERFORATOR 1200 1200--1400 1400--1700 1700-2200 -2200 ELECTRONIC Independentmachine machineequipped equipped with with its its own own PLC PLC and and print print detection. detection. Independent canbe beinstalled installedininline linewith withextruders extruders or or in in line line with with aa bag bag making making ItItcan machine. machine. Continuousperforation perforationfor forholes holes from from øø 22 to to 80 80 mm. mm. Continuous

√ All BMTEK lines are equipped with control and management electronics, single-brand. √ All BMTEK lines are equipped with control and management electronics, single-brand. √ Each line consists of completely independent machines. √ Each line consists of completely independent machines. √ All the accessories we propose are “plug and play”. √ All the accessories we propose are “plug and play”. Via G. Matteotti, 26 – 40057 Loc. CADRIANO di Granarolo dell’Emilia (BO) Via G. Matteotti, 26 051 – 40057 Loc. CADRIANO di Granarolo dell’Emilia (BO) Phone.: +39 6926178 - sales@bmtek.it - www.bmtek.it Phone.: +39 051 6926178 - sales@bmtek.it - www.bmtek.it

The full-year report developed by Mecs - Amaplast/Ucima statistical studies centre shows double-digit growth in 2021 for the Italian plastics and rubber processing machinery, and a turnover above 8 billion euros (+8%) for packaging machinery

“A

ccording to our estimates”, states Amaplast president Dario Previero, “at the close of 2021 production should be a hair’s breadth

Amaplast president, Dario Previero, during the last annual assembly, held at Alfa Romeo Museum (Arese, Milan) on September 16, 2021 MAY 2022

from pre-pandemic levels, reaching 4.35 billion euros and an impressive +11.5% with respect to 2020”. The primary driver of recovery in the sector in Italy is the domestic market, which is forecast to close the year with growth of nearly fifteen points and a value of 1.35 billion euros. On the basis of the most recent economic survey of the first nine months of the current year, the surge in orders from Italian customers mainly regards machinery and complete processing lines. Exports are also playing a decisive role and are expected to return to a value on the order of 3 billion euros, giving a boost to the balance of trade. Indeed, 8 of the top 10 Italian export destination countries, collectively absorbing nearly 60% of the total, show strong growth in demand, with +17% from Poland and

+83% from China. Orders received in the first three quarters of the year, both from Italian and foreign customers, cover production for the next six months and mainly regard machinery. The replacement parts segment, while in the positive range, appears somewhat less dynamic. As regards applications, it is not surprising to see the highest and most sustained demand for technology from the packaging and medical sectors, while construction and automotive travel at more moderate speeds.

Amaplast president’s short-term forecasts “Naturally”, adds Previero, “various factors of instability that arose and worsened over the past year - from raw materials costs to difficulty in procuring

| MARKETING

ready in 2022. “This”, emphasizes Previero, “confirms the robust response capacity of companies in the industry, deriving typically from their flexibility. Faced with the challenges posed by the context and Matteo Gentili, chairman of Ucima, markets, the comthe Italian packaging machinery manufacturers’ association panies have again succeeded in decomponents, from an increase in ener- veloping tailor-made solutions in terms gy and transport costs to restrictions on of technological content, sustainability, personal mobility - are still unresolved and efficiency”. and continue to be sources of concern for companies”. Packaging machinery: However, the clear recovery recorded in a turnover above 2021 - with the first signs of an upswing 8 billion euros already observed in the last months of The Italian packaging machinery man2020 - gives us good reason to expect ufacturers have once again passed performance beyond pre-crisis levels al- the 8 billion euros mark. According to

the preliminary figures compiled by the Mecs studies centre, the sector has reached an overall turnover of 8.43 billion euros in 2021, 8% up on the result recorded in 2020. This figure is higher than the 2019 turnover and consolidates the industry’s position in the wake of the pandemic. Specifically, the Italian packaging machinery manufacturers’ domestic sales fell by 18% to 2.03 billion euros, while exports, which have always been the sector’s key strength, grew 5% year-on-year to 6.40 billion euros. However, the return of industrial plants to full capacity is accompanied by a 30% average increase in production costs. Companies face soaring raw materials costs, higher prices and delayed deliveries of components, more expensive land and sea transport, and a disproportionate rise in the cost of energy for operating factories. And despite the almost 7 months of assured production in 2022 estimated by Mecs, the current global situation is likely to have a negative impact on the sector as well as holding back the recovery of the Italian economy. “Ucima is monitoring the price increases of key commodities”, says Ucima chairman Matteo Gentili. “These market issues must be acknowledged and managed so as not to jeopardise the growth in production of our sector and of the country as a whole, especially during this delicate period of recovery. The orders already acquired for 2022 are higher than the historical average, so we are very optimistic about this year. However, we don’t want to have to slow down production and deliveries of our machinery due to the lack of a small number of components worth just a few hundred euros”. www.amaplast.org - www.ucima.it According to the preliminary figures published by the Mecs research centre, the packaging machinery sector is returning to growth. Both the domestic market (+18%) and exports (+5%) performed well in 2021

MACPLAS I NTER NATI ONAL | MAY 2022

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“Botanical” bioPE bricks from Lego

Discov ering bioplast ics

Lego, European Bioplastics

Bioplastics in the limelight A journey through the curious world of bioplastics. They may cause a revolution over the next few years, in fact they probably already have, just quietly BY ST E FA NO BE R TA CCH I

hat happens when you combine sustainability, technology, and science? Often new opportunities arise, leading to developing solutions for current and future problems. But what happens when all that is combined with legislation, marketing, consumers, and the Internet? A whole lot of confusion, and often the risk of spreading disinformation to the general public who can easily fall prey to misinterpretation or fall into intentional traps when they try to understand what nobody is explaining. The best way, then, to tackle this issue (whatever this issue might be) is to be properly informed. Even more so when it is regarding scientific issues. And bioplastics represent one such case. The introduction of laws in Italy to govern biodegradable bags for fruit and vegetable produce (Italian Law no. 123/2017, introduced on January 1, 2018) triggered an apocalypse on the Internet in the early days of that year. Political accusations, economic conjecturing, people at super-

markets who put the price label on every single tomato to avoid buying bags: anything, basically. And this disconnected reaction, though exaggerated, is also attributable to those who, from lawmakers to large-scale retail trade, did not hold the consumer’s hand through the transition, even though they had known about it since August 2017, resulting in an information gap full of fragmented or incorrect information. The upside is that everyone, all of a sudden, begun to be interested in the issue of biodegradable bags and bioplastics, despite, at least at first, there being one down side. Then, as is often the case for the discussion that pops up on the Internet, the talk went away in just a few weeks. The message remains, however, that consumers are not being informed, and it is very important for this not to happen, given that this technology then ends up in the hands of the consumers themselves. Indeed, if consumers don’t know that the item they are holding goes in organic waste, it is unlikely they will throw it in the right waste

bin, making all those efforts of producing a biodegradable material useless. The purpose of this article is, therefore, to lead the reader on a journey through the curious world of bioplastics, which might soon cause a revolution, one that has probably already begun in almost complete silence.

Plastics vs. bioplastics Definitions The European Bioplastics association defines bioplastic as a plastic material that is biobased, biodegradable, or that features both properties. This definition is the one lawmakers usually consider when drawing up various regulations, but it is unlikely to resolve many perplexities. Especially because it is taken for granted that the definition “biomass” and “biodegradable” leave room for interpretation. To simplify, biomass is intended to mean a renewable resource, in the majority of cases of vegetable origin, that can quickly regenerate, thanks to the free energy MACPLAS I NTER NATI ONAL | MAY 2022

Plastic is now a common material, especially in the food industry. Its extensive use in disposable items, such as water bottles, has accelerated accumulation in the environment

of the sun. The process by which plants grow is possible thanks to photosynthesis, which enables plants to capture the carbon dioxide present in the atmosphere and produce new biomass. Clearly, even the origin of crude oil lies in nature since it derives from living beings, however its regeneration time is not compatible with its use, because we cannot wait millions of years for it to reform. As a result, it is a depleting resource, which is actually considered non-renewable. It is important to clarify this concept for consumers, especially when they are convinced that oil is a “non-natural” substance, as opposed to a biomass, just for this reason. In any event, we well know how problematic the use of oil as a resource is from an environmental standpoint, because its extraction and refining have an important impact on ecosystems, despite, over the years, technology drastically reducing the direct anthropic effect. Therefore, in this case, bio-based bioplastics aim to resolve the problem of using fossil resources, replacing the origin of plastic itself. Another problematic aspect of conventional petrochemical plastic, as noted, is its build-up in the environment, because of the almost non-existent biodegradability of the material. The incredible resilience of plastic is paradoxically an anathema, like a new King Midas touch that turns everything touched into gold, but that then is cursed by its own power. This is where biodegradable bioplastics come into play, which, essentially, dissipate into the environment, as if by magic. Obviously, it is not magic, because microorganisms are behind their disappearance. In combination with atmospheric agents, temperature, and humidity, they decompose this type of bioplastic, literally “eating it for their own growth.” So, translated into practical terms, if you are very distracted and leave a biodegradable bioplastic item in the park after your picnic, you’ll not want to do it again, but at least you’ll know that it will MAY 2022 | MACPLAS I NTER NATI ONAL

disappear much more quickly than regular plastic. Exactly how long this will take depends on a number of factors, such as the type of bioplastic, its thickness and shape, as well as environmental factors, which vary according to the location. In any event, it takes decades, which is not however long when compared to the hundreds - if not thousands - of year conventional plastic takes to decompose. But at this point, quite rightly, some readers might wonder what biocompostable means. Contrary to what many people think, is not synonymous with biodegradable. Biocompostable, in fact, is that particular object that can be disposed of in the organic fraction of municipal solid waste (OFMSW, or FORSU in Italian). This is because, subsequently, organic waste is processed in the composter: a “machine” that speeds up the biodegrading process, fully disintegrating a small coffee cup in just a few months. The concepts of biodegradability and compostability have been greatly simplified here. In reality, they vary greatly in terms of time and environmental conditions, all described in standard EN 13432. It is necessary, therefore, to be careful to distinguish the two elements, because they refer to two different destinies for plastic. In any case, these messages must be correctly handled by the consumer in order for them to know where to dispose of the material. Also because throwing away a biodegradable item in the plastic container causes problems for plastic recycling. When it comes to recycling, because bioplastics are polymers, they can be recycled, but only when they are properly collected: obviously, once they are sent to the composter, they disappear (in the literal sense of the word).

Now the confusion stems from the fact that plastic derived from biomass is automatically biodegradable, while, on the other hand, plastic deriving from petrochemicals is naturally “ugly and bad” and pollutes the environment, without ever seeing a chance of redemption. If only it were that simple. In reality it is not, but, paradoxically, this makes the discussion very interesting. Unfortunately, all this creates confusion around bioplastics, especially in the consumer’s eyes. It is therefore necessary to analyse all possible combinations, unearthing properties and unique features.

Fossil or alive? As we have already seen, one of the characteristics for defining bioplastic is that it is derived from renewable biomass, whether or not it is biodegradable. In fact, contrary to what one might think, there are some bio-based bioplastics that are not biodegradable, for example, bioPET, bioPP and bioPE. You read that correctly: the acronyms stand for polyethylene terephthalate, polypropylene and polyethylene, products we are all familiar with. “Bio” used as a prefix indicates the fact that they derive from biomass and not from petrochemical processes. To synthesize the monomer of polyethylene, or ethylene, a chemical process of

The biodegradability of some bioplastics facilitates the dissipation of abandoned manufactured items in the environment, reducing their impact. This should not make us want to starting throwing bags in the street!

| PLASTICS AND ENVIRONMENT

PlantBottle logo and, in particular, the version presented by Coca-Cola at the Milan Expo in 2015

dehydrating the ethanol can be done. And how to obtain ethanol? Very easily, just think of a wine glass you drank from at dinner, or the beer glass from the other evening with friends: both are alcoholic and contain ethanol. The starting point for its production can be from biomass, such as grapes or barley, whose sugar components are transformed into our favourite drinks. Even in this case, the “magic” is done by invisible conjurers, namely microorganisms: in particular yeast is able to ferment the above-mentioned sugars to produce ethanol, which is why it is called bioethanol. In fact, it is identical to ethanol obtained by petrochemical processes, but the prefix reminds us that it comes from biomass. Bioethanol is used as biofuel for socalled “flexi fuel” motors to replace petrol, but in this case, it can also be used as the initial base for plastic. It is mandatory, therefore, to thank yeast not only for beer, but also for other chemical substances that are not limited to polyethylene, because propylene and, as a result, bioPP, can be obtained from ethylene (at this point bioethylene). Similarly, as you can imagine, you can also “put your hands on” PET, as ethylene is one of the two monomers it is made from. This is how the PlantBottle brand (brand registered by The Coca-Cola Company) came about, a material made up of bioPET and The author

Stef ano Ber tacchi PhD in Industrial biotechnology and post-doctoral researcher of the University of Milano Bicocca, Stefano Bertacchi develops bioprocesses based on residual biomasses, using natural or engineered microorganisms to synthesize molecules for industry, such as bioplastics. Science communicator, speaker and author of the books “50 grandi idee. Biotecnologie” (Dedalo, 2021), “Piccoli geni - Alla scoperta dei microrganismi” and “Geneticamente modificati - Viaggio nel mondo delle biotecnologie” (Hoepli, 2021 and 2017).

used for some products by big global names, such as Coca-Cola and Ford. Currently, 30% of the most common bioPET is made up of bio-based material. Why 30%? Because, no surprise, it is the ethylene which we talked about before. Its “polymer companion” or terephthalic acid, is more complicated to obtain from renewable sources because of the presence of the inconvenient aromatic ring, which in nature is a bit of a double-bladed sword. One of the ways to synthesize it from renewable sources is to start with isobutanol, which in turn can be obtained by fermenting the sugars, similarly to ethanol. In this case we obtain bioPET that is 100% derived from renewable sources, and this is certainly a goal of the companies involved in the project. The first PlantBottle 100% was introduced during Expo 2015, in Milan. However, despite deriving from biomass, this bioPET is still a PET and its identification code remains 1; as a result, it can be thrown into plastic bins. This is despite being to all intents and purposes a bioplastic. It is impossible to distinguish between PET and bioPET, because it is literally the same molecule. The only way to do it is to analyse and date the atoms, which will determine if they derive from freshly synthesized biomass or from the organisms that died millions of years ago. For this reason, bioPET, bioPE (code 2 or 4), bioPP (code 5) can be recycled, but are not biodegradable. And here is where the confusion lies for the consumer who, thinking about “green” plastic derived from plants, automatically associates this element with being biodegradable. And they risk throwing a bottle in the organic waste bin that will not be broken down in the composter.

“ Fa’ balà l’oeucc” This Milanese saying basically means “be careful”, and it is what must be done with bioplastics. The warning is for everyone, not just the consumer but also the producer, who does need to rethink their marketing to underline the virtu-

ous use of renewable biomasses in place of oil, but also to provide guidance on the correct disposal of the product post consumption. Non-biodegradable bioplastics like bioPET, bioPP and bioPE are indistinguishable to insiders, so it is no surprise that consumers cannot tell the difference. In any event, these bioplastics have the purpose of resolving one of the two problems of petrochemical plastics, namely the relative use of fossil resources. This is very important both for the environmental reasons mentioned as well as because of the socio-economic instability of oil. In addition to this, oil is a resource that is not distributed in a uniform manner, making it hard to source on a global scale. Biomasses, on the other hand, are available in a more or less uniform manner on all continents, facilitating local production of plastic, where necessary. The problem of final disposal is, however, unresolved. Despite this, we have filled the world up so much with PET that some microorganisms have become very quick at disposing this polymer, providing a valid starting point for developing new disposal systems. But this argument will be addressed in more detail in a future article. For now, we are only at the first act of the bioplastics show, appearing on the market and in the lives of people. In the second act, we will address biodegradable bioplastics, deriving from biomasses and/or oil. As is often the case, to fully understand the value of what we are about to see, it is best to first get to really know the leading actors. www.macplas.it MACPLAS I NTER NATI ONAL | MAY 2022

| PLASTICS AND ENVIRONMENT NEWS A new st udy on PET r ecy cling in Eur ope

R ecy cled plast ics in Eur ope

PET packaging moving steadily towards circularity

Mechanical recycling exceeded 8 million tons in 2021

identifies, it is expected that 19 EU According to the new study “PET Member States will have Deposit Markets in Europe: State of Play”, Return Schemes (DRS) in place for commissioned by Plastics Recyclers PET bottles, which shows, along with Europe (PRE), Petcore Europe, NMWE the increased recycling capacities, and Unesda Soft Drinks Europe, new a strong move of the PET sector data for collection, recycling capacity towards circularity. Today, seven EU and production for 2020 show Member States with established DRS increases in all measured factors, achieve sorted for recycling rates of indicating a steady move towards 83% or higher. This implies that with circularity of the PET industry in the EU Single Use Plastics Directive Europe. (SUPD), collection rate targets already Major growth is observed, in in place, the collection figures, as particular, within the PET recycling well as quality, are likely to increase market, with an overall 21% increase substantially in the lead up to 2025. in the installed capacity and totalling 2.8 million tons in EU27+3 (figure 1). EUNOMIA I P E T M A R K E T I N E U RO P E : S TAT E However, O F P L AY some challenges remain. For EUNOMIA I P E T M A R K E T I N E U RO P E : S TAT E O F P L AY E U N O On M I AtheIrecycled P E T Mfigures, A R K E T I1.7 N Emln U ROtPof E : S TAT E instance, O F P L AY to meet the 90% collection flakes was estimated to be produced rate and the mandatory recycled in 2020. There is a steady growth content targets, Europe will require within trays and sheets application, an expansion in recycling capacity of which with a 32% share remain the at least one third by 2029. Moreover, largest outlet for rPET in packaging, further innovation, support from the Following washing, some PET flake bottles is sent forwith further reWhen comparedand withmore the previous of the report followed by food contact EU policymakers, robustiteration Following PET flake is sent forcapacity further reWhen compared on with previous iteration of the capaci report cycling by washing, extrusionsome into pellets. Total input for an improvement thethe data available for recycling Following washing, some PET flake is sent for further reWhen compared with the previous iteration of the capaci report a 29% share. data sources are needed in all areas cycling by extrusion into pellets. input capacity improvement theresulted data available for recycling PET extrusion is estimated to be Total approximately 736ktfor in an ty and productionon has in increases in all measure cycling by extrusion into pellets. Total input capacity for an improvement on the data available for recycling capaci PET extrusion is estimated to be approximately 736kt in ty and production has resulted in increases in all measure Driven by producers’ pledges, who of the packaging value chain to the to respondents to the Annual PET This can be clearly seen Figure 9inwhere overal PETEU27+3According extrusion is estimated to be approximately 736kt in factors. ty and production has resulted inin increases all measure the EU27+3According toinrespondents to the utilisation Annual PET factors. This can be clearly seen Figure overal Recyclers Survey (PRE), 2020 the average of capacity has increased bythe 21% in in two years.99 where have made a range of commitments ensure progress towards targets the EU27+3According to respondents to the Annual PET factors. This can be clearly seen in Figure where overal Recyclers Survey (PRE), in 2020 the average utilisation of capacity has increased by 21% in two years. extrusion capacity was estimated to be 86%, resulting in Recyclers (PRE), in 2020 the average of capacity has by 21% in will two years. andSurvey goals to incorporate is achieved andincreased measured. This extrusion capacity was estimated torecycled be 86%,utilisation resulting in approximately 632kt of pellet output. extrusion capacity was estimated to be 86%, resulting in approximately of pellet content632kt within theiroutput. bottles, and with require further harmonisation and approximately 632kt of pellet output. the mandatory recycled content implementation of best practices Figure 9 : PET Recycling Capacity, Input and Output, 2018 versus 2020 targets the share of food-grade rPET for collection, sorting and design for Figure 9 : PET Recycling Capacity, Input and Output, 2018 versus 2020 Source: Annual PRE Recyclers Survey (PRE, 2020) Figure 9 : PET PET Recycling Capacity, Input and Output, 2018 versusrecycling 2020 Source: Annual PRE Recyclers Survey (PRE, 2020) in beverage bottle production to facilitate more rPET being Source: Annual PRE Recyclers Survey (PRE, 2020) is 3000 set to continue to grow rapidly. used within its own application cycles. 3000remainder of recycled PET, on The The significant increase in PET Following washing, some PET flake is sent for further re- When compared with the previous iteration of the report, 3000 by extrusion into pellets. Total input capacity for an improvement on and the datarecycling available for recycling capacithe othercycling hand, is used in fibres collection sends a 2500 PET extrusion is estimated to be approximately 736kt in ty and production has resulted in increases in all measured 2500 strapping the EU27+3According toand respondents to the Annual PET factors. This cansignal be clearly seen in Figure 9 where overall 208 (24%), (8%) in injection positive to the market and Recyclers Survey (PRE), in 2020 the average utilisation of capacity has increased by 21% in two years. 2500 208 extrusion capacity was estimated to be 86%, resulting in 208 moulding (1%), followed by other will boost confidence in further 2000 approximately 632kt of pellet output. 53 2000 53 applications (2%). accelerating PET’s circularity. 2000 53 Figure 9 by : PET 2025, Recycling Capacity, Inputreport and Output, 2018 versus 2020www.plasticsrecyclers.eu Additionally, as the 1500 385 EUNOMIA

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P E T M A R K E T I N E U RO P E : S TAT E O F P L AY

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2000

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Figure 1 - European plastics recycling rate in 2021

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Recycling Capacity, ktpa

Recycling Recycling Recycling Capacity, Capacity, Capacity, ktpa ktpa ktpa

The waste plastics value chain is a complex and dynamic sector, with an evolving operating environment. New legislation and targets for the recycling of plastics and the use of recyclate are changing the way the whole plastics industry must operate. The mechanical plastics recycling industry, therefore, has become the focal point for investments, acquisition, and expansion. Although the volume of commodity plastic entering the waste stream on a yearly basis is extremely large, estimated by AMI as 35.6 million tons in 2021, feedstock availability should not be taken for granted. Much of this waste is currently uncollected for recycling or “lost” at the sorting stage and ends up in landfill or used by EfW plants. Feedstock is therefore a finite resource, characterised by bail price fluctuations and variable quality and supply. Plastics recyclate production was 8.2 million tons in 2021 and is forecast to grow at a rate of 5.6%/year to 2030. To put this figure into context, one must review it in tandem with the 35.6 million tonnes of commodity plastic entered the waste stream in 2021. This implies that Europe achieved an overall plastic recycling rate of 23.1%, far lower than one might have assumed. The coronavirus pandemic has had an impact on both the volume of waste being collected for recycling as well as simultaneously reducing the demand for recyclate, as factories close or reduce production. However, to date it has not seemed to have had a long-lasting effect, as the industry has in general bounced back. Moreover, within the 2030 timeframe of its last report on mechanical plastics recycling, AMI sees additional absorption of recyclate volumes into applications that to date absorb negligible levels, particularly in Western Europe. Uses for recyclate are becoming more diverse, and the ability to absorb recyclate into higher value applications is also increasing, creating added value for the industry. AMI expects the commercialised and scaled production of food grade rPP and rPS within the timescale of the report, creating new closed loop systems, as we already see for rPET. www.ami.ltd/recyclingandsustainability

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1 083 1 083 1 083 264

1 318 1 318 1 318

2 229

1 083

2020 2020 2020

1 318

Recycler Capacity Input to Recycler (Bottle Bales) Recycler Capacity2018 Input to Recycler 2020 (Bottle Bales) Recycler Capacity(Trays) Input torPET Recycler Bales) Input to Recycler Output (high(Bottle viscosity) Input to Recycler (Trays) Output rPET (high viscosity) Recycler Capacity Input to Recycler (Bottle Bales) Input torPET Recycler Output rPET (high viscosity) Output (low (Trays) viscosity) Input to Recycler (Trays) Output rPET (high viscosity) Output rPET (low viscosity) Source: Annual PREviscosity) Recyclers Survey (Plastics Recyclers Europe, 2020) Output rPET Output(low rPET (low viscosity)

Figure 1 - PET recycling capacity, input and output, 2018 vs. 2020

385 385

385

2 804

1 819

2018 2018 2018

2 229 2 229 2 229

Given the greaterGiven level of data granularity available for 2020, alongside the total rPET production, Figure 9 includes th the greater level of data granularity available for 2020, alongside the total rPET production, Figure 9 includes the Given the greater level of rPET dataproduced granularity available for 2020, alongside the total rPET production, Figure 9 includes th split between and destined for low applications, and that which is destined for high viscosity split between rPET produced destined for lowviscosity viscosity which is destined for high viscosit Givenbetween the greater level of data and granularity for 2020, applications, alongside theand totalthat rPET production, Figure 9 includes th applications. split rPET produced and destinedavailable for low viscosity applications, and that which is destined for high viscosit applications. split between rPET produced and destined for low viscosity applications, andNATI that ONAL which is destined MACPLAS I NTER | MAY 2022for high viscosit applications. applications. PAG E 1 8

A new applicat ion f or Sabicʼs cer t ified r enew able poly mer s

The well-known company Mattel will use Sabic’s Trucircle plastic materials, obtained from renewable resources, to produce some of its new toys. The first Mattel toy products to enter the market in 2022 using certified renewable Sabic PP polymers will be from Mega and Matchbox series, with more to follow. Heading the initiative will be Mega Bloks Green Town, the first-ever toy line available at mass retail to be certified CarbonNeutral. These new construction playsets, including the Grow & Protect Farm and the Build & Learn Eco House, embrace the sustainable material choice and help teach kids green behaviours. From the Matchbox brand, all Action Driver playsets and the Matchbox Recycling Trucks contain Sabic materials, which supports the brand’s Driving Toward a Better Future initiative, to make all Matchbox die-cast cars, playsets and packaging with 100% recycled, recyclable or bio-based plastic materials by 2030, in line with Mattel’s corporate goal. Mattel is the first company in the toys market to work with Sabic in a mass balance approach designed to return secondgeneration renewable feedstock into high-quality new plastic applications. The partnership directly supports Mattel’s goal to

MAY 2022 | MACPLAS I NTER NATI ONAL

achieve 100% recycled, recyclable or bio-based plastic materials in its products and packaging by 2030, and is an important step forward in their transition towards a circular economy. “The collaboration with Mattel is an important step in providing our customers with materials that can help lower their carbon footprint across a wide range of consumer markets, and Mattel serves as a pioneer in the toy industry. Our materials from renewable sources facilitate the change-over from existing fossil-based applications without compromise on purity and quality”, said Lada Kurelec, general manager for PP & E4P Business, Sabic. “As global leaders in the toy sector, we strive to develop innovative products that are better for our planet by integrating sustainable materials and principles of product stewardship and circular design. Aligned with our strategy, this new partnership with Sabic will allow us to be first to market with products made from ISCC certified renewable feedstock that has a lower carbon footprint but the same quality and safety as products made with traditional virgin plastics”, added Pamela Gill-Alabaster, head of Global Sustainability at Mattel. www.sabic.com

The first Mattel toys in materials from renewable sources are on the way

Matchbox Series toys by Mattel, Earth Day Group, Lifestyle

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In a period of international crisis and great difficulties in terms of the availability of raw materials and high prices, which lengthen production and delivery times of technological products, Bandera focuses on the possibility of offering readyto-deliver systems

MAY 2022

n a market where purchasing times are increasingly extended due to the difficulties in finding raw materials, Bandera offers two machines for compound extrusion ready for delivery.

Single or cascade extrusion? The two extrusion lines can be used individually or in tandem, in cascade mode. Intended for the production of compounds (polypropylene with the addition of fillers), the Revotech Twin line can process waste from the processing of rigid films for obtaining a result more refined than the initial one. The two machines are able to maintain the mechanical characteristics of the original granule, performing an upcy-

cling that improves its properties. Thanks to an increased resistance, the machines are able to process abrasive materials, such as calcium carbonate contained in fillers, necessary for the production of the compounds, without deteriorating.

Technological pluses for the compound production The plants, able to produce new raw material from second raw material, represent an opportunity for the market not only for their technological innovation, but also because, being already available for customers for tests and sale, bring in these terms another real competitive advantage.

| PROCESSING MACHINERY

Rendering of a Revotech system in tandem configuration

The introduction in the market of these new plants comes after the last great successes in the recycling area for Bandera, which has supplied to a Dutch company a futuristic line for the extrusion and recycling of second raw material.

Test and lead the market The appointment is set, in Bandera laboratories, at THOE - The House of Extrusion, where the interested processors will be able to personally see several plants

of Bandera recycling division, Revotech. The company extends the invitation also to visitors of the K 2022 show (scheduled in Düsseldorf on October 19-26): the fairground is very well connected to Bandera Italian headquarters in Busto Arsizio (Varese), so the international event will offer a perfect opportunity to visit the company and discover its technology, with the possibility to see several plants of Bandera different technological divisions, Recycling, Blown Film and Flat Die.

Visits are aimed at knowing, but, above all, at testing and experimenting, with the customer materials, safety and performance of Bandera plants. Private appointments and one-to-one sessions conducted in security and with the discretion of specific NDA (Non-Disclosure Agreement) will allow interested parties to verify, well before the purchase, operation and objective performance of the plants, which will be certified with the use of the designated material. www.luigibandera.com

A Revotech plant in tandem configuration at the Bandera facility

MACPLAS I NTER NATI ONAL | MAY 2022

Precisely because it is a consolidated reality despite its relatively young age, Binova today results an agile and smart company able to propose plants capable of treating plastic waste to obtain advanced materials to produce sustainable and performing articles according to the circular economy model

he business initiative of Binova Plastic Machinery started in 2006, focused on the construction of plants to process thermoplastic materials. Whilst it may appear to be a relatively new reality, Binova represents a consolidated productive project, in which many professionals, with over 30 years’ experience in the field of plastics, have come together to form a highly competent team and use their expertise for the design, implementation and installation of

plants in the field of plastic processing. More specifically, Binova deals with the recycling and compounding of production and/or post consumer scraps. The company aims at meeting the high demand for innovative solutions in the recycling field, at a time when improved recycling has become a matter of urgency. So, Binova intends to turn plastics into an opportunity rather than a problem through a process of virtuous, sustainable and highly productive transformation. Aware of living in a very demanding society, more and more interested in recycled products that are able to maintain the same characteristics of the starting material, the manufacturer has come up with solutions that do not compromise on the high quality standard of the final product.

Machines and processes of high level Every detail of the lines is taken care, so that the result is always devoted to innovation, sustainability and productivity

The high level of effectiveness of its process allows the company to maintain a relevant position in a market where competition is fierce and competitors have been in the business for decades. These characteristics and its innovative push allow the company to develop projects not only in Italy, but also in France, Spain and other countries, in and outside Europe. MAY 2022

Binova bets on R&D as the right path to take in order to increase productivity and come up with high-tech solutions. For the last few years, the company’s next-generation plants have been equipped with software able to control the whole production also remotely. Binova’s innovation is oriented to the increase of competitiveness. The company has recently developed a line able to process in one single step what normally is done in two: recycling and compounding are carried out thanks to a corotating twin-screw extruder which guarantees up to 30% of energy saving, compared to the traditional single-screw extruder. From a strategic point of view, it is a competitive line that reduces costs, optimizes production time and improves the distribution of resources.

Ambition for excellence The company ambition for excellence respects the principle of flexibility. It designs ad hoc plants with highly personalized configurations, representing the perfect solution for any necessity. Binova has a close relationship with customers, acting more like a partner rather than a supplier. It offers all round support, thanks to its highly qualified personnel offering technical advice and expertise, post-sale assistance and a professional maintenance service for standard and specially-made plants. Today more than ever, in a constantly evolving market, are the bravest choices that make the difference. In the last two years, Binova has gained full strategic financial and industrial autonomy to face present and future challenges with a strong responsibility in decision making and in full control of its process. The company has recently invested in the acquisition of machine tools to guarantee much more rapid deliveries and become even more competitive. Binova’s constant and consolidated growth leads its ambi-

Assembling of a Binova line

tion to seek advanced solutions for the future, eager to move forward in the diversified world of plastics, which it will not stop exploring. www.binovapm.it

As shown in this picture and in the opening one, at Binova the production departments are always in operation and the construction of the lines continues unabated MAY 2022 | MACPLAS I NTER NATI ONAL

MacPlas International

Issue May/2022 ET: 29.04.2022 DUS: 08.04.2022

Plastics have improved the world.

GRAFE improves plastics. www.grafe.com

HIGH QUALITY MASTERBATCHES

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| PROCESSING MACHINERY NEWS

BMB ex pands it s applicat ion range

Diversification without disruption The change currently taking place in terms of procurement, prices of raw materials and supply of goods and products often leads to situations that are not easy to cope with, so that companies are pushed to make complex choices and take difficult decisions. For several years now, BMB has significantly expanded its export share, trying to supply as many markets as possible, with the aim of diversifying international sales, reach a certain stability and escape the effects of crises or unrest at a local and a global level. Following the same philosophy, recently the company has also turned its attention to application areas such as the moulding of syringes and PET preforms, investing in research and development activities to improve the performance and energy efficiency of its machines and cooperating with industry specialists to optimise the entire production cell or even the entire production department. The medical industry requires compliance with stringent production standards and the production of articles such as disposable syringes implies in-depth

knowledge, as well as the ability to aptly prepare the injection moulding machine for the type of item to be produced. Engineering a production line for syringes means starting from ergonomic design for perfect functionality, and, in addition, guaranteeing above all minimum waste of materials and then optimising the assembly and control steps after moulding. Often injection moulds have to be “as precise as a Swiss watch”, so to speak, while ensuring high output and no scrap. Nothing can be left to chance and a 64-cavity mould can incorporate up to 3,000 components (and the corresponding bill of materials may include up to 3,000 codes). The materials to be processed must be certified and supplied exclusively by leading producers. Behind every player in the medical supply chain there are enormous responsibilities, because devices such as syringes cannot accept compromises in terms of quality. The eKW-Pi series of fully electric injection presses by BMB is offered as the best solution for this type of production; multi-cavity moulds,

high productivity and energy efficiency are the main benefits deriving from their use. Everything that contributes to the manufacture of these presses is designed and developed strictly for use in a clean room, with proven assembly automation systems supporting very high output rates and eliminating any bottleneck. An expensive post-packaging sterilisation system completes the production line. The capacity of the syringe contributes to identifying the press model used, that can range from 0.08 to 50 ml and more, with unit weights of 0.15 g and moulds featuring up to 288 cavities. This is an application sector that can be subject to various requirements, yet quality is a constant need. For this reason, BMB has committed many of its resources to research, optimisation and pursuit of total quality. www.bmb-spa.com The eKW-Pi full electric series is offered by BMB as the ideal solution for medical applications. In the picture: an eKW 16Pi/700 injection machine

MACPLAS I NTER NATI ONAL | MAY 2022

STAMPANTI FLESSOGRAFICHE FFS SUPERFLEXOL 4 COLORI GEARLESS - 1000MM.

Linea produzione sacchi industriali (FFS) Svolgitore e Avvolgitore automatici per bobine diametro 1500 mm. Unità di goffratura a 2 bande e soffiettatura laterale Velocità di stampa fino a 300 mt/min.

Since 1961

FLEXOL 6 COLORI GEARLESS - 2200MM. Inchiostrazione con racla a camera chiusa Pre-registro automatico a partenza macchina e avanzamenti motorizzati Larghezza di stampa 2200 mm. Velocità di stampa fino a 300 mt/min.

Via IV Novembre, 153 - 21058 Solbiate Olona (VA) Italy - Tel. +39 0331 64 90 12 info@saldoflex.com - www.saldoflex.com

TERMOSALDATRICI AUTOMATICHE SERIES MODULA: 800 -1100 -1300 -1500 MM. Produzione di sacchi stesi Shopper, Bocca Aperta e Block Notes Produzione NON-STOP per sacchi lunghi fino a 700 mm. e con PAUSA fino a 2000 mm. Tavolo impilatore per la raccolta dei sacchi in mazzette fino a 8 piste (con o senza spilli) Velocità avanzamento film 180 mt/min.

Since 1961

ROLL-FLEX R-3000 | 1100 – 1300 – 1500 MM. Produzione di sacchi a bocca aperta avvolti in rotolo con pretaglio e nastrati Produzione per sacchi lunghi fino a 2000 mm. Gruppo avvolgitore automatico con dispositivi di nastratura fino a 4 piste Velocità avanzamento film 180 mt/min.

Via IV Novembre, 153 - 21058 Solbiate Olona (VA) Italy - Tel. +39 0331 64 90 12 info@saldoflex.com - www.saldoflex.com

NEWS PROCESSING MACHINERY |

Colines launches Polyblow n

Entry into the blown film sector The year 2021 registered a new milestone for Colines, as the Italian company launched its Polyblown lines, the new generation blown film technology family. The lines are available in configurations from 3 to 11 layers, able to perform the widest possible range of products. For decades Colines has mainly focused on the engineering and production of cast extrusion lines, even though occasionally built blown film lines for selected customers. Over the last two years Colines has hired high level technicians, with long-term experience in blown-film extrusion technology, hence investing a great deal in the research and development department. This brought about the engineering of a brand-new family of extrusion lines with blown film technology. The company unveiled the “Polyblown” family in a 3-day open house event in its Marano Ticino facility, from November 23 to 25, 2021. “We have been working for this for two years now and have decided to launch our new lines with a special in-presence event. We know very well that the blown-film market is highly competitive and demanding, nevertheless as a team we are extremely confident about the technologies we have developed and engineered. We are back in full force in this market, and we are extremely proud about our brand-new blown film lines”, said Anthony Michael Caprioli, Colines CEO. The line showcased is a 2,600-mm 7-layers Polyblown

multipurpose one: as a matter of fact, the line ran three different productions over the three days in order to prove its extreme versatility. The result was amazing: Colines was positively impressed by the number of customers that attended the open house: over 160, including those who attended in person and those who got in touch with dedicated online one-on-one meetings. “We are very happy about the success we are having on the market. We were able to show the extreme versatility and flexibility of our Polyblown lines by making three different products over the three days which we were much appreciated by our customers. As a proof of that, the line has been immediately sold. I would like to thank all those people who contributed to the success of our event, including our staff, partners and guests. Even though we have not been investing in full force in this market for several years, our Polyblown lines are achieving an amazing success: after having sold the first lines in 2021, now we are strengthening our presence in the market. Our goal is to keep growing and become an excellence in this field, as we have been for years already in cast line production. This will allow us to offer a widest range of technologies, both blown and cast, to our customers”, added Colines marketing and communication director and sales area manager, Gabriele Peccetti. www.colines.it

With Polyblown family Colines enters the blown film sector MAY 2022 | MACPLAS I NTER NATI ONAL

| PROCESSING MACHINERY NEWS Leaf -S8: an ambit ious pr oject

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 setup 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 is 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 analysis conducted by the Saldoflex 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 and the IndraDrive drives, with onboard safe motion functions. www.saldoflex.com Compact but performing: a particular of the Leaf-S8 machine

A PB26ED-900 Deco machine equipped with E120/25 and E70/25 extruders

Ex t r usion blow moulding machine

Containers for detergents and home care products Due to the forced confinement and the fear of the virus, during these two years of pandemic the consumption of cleaning and disinfection products has recorded, according to recent data, growth rates of around 30% and led to a big demand in blow moulded containers. Plastiblow did its part to supply equipment for this purpose. In addition, today consumer good companies are reducing the environmental impact of their products, for example by increasing the use of recycled plastics or creating easily removable labels, to make it easier the packaging recycle. Moreover, they are cutting down on packaging, improving its recyclability. The move to lightweight packaging has also led to replace glass containers with plastic ones. Plastics contribute to sustainability, preserving products from deterioration and being at the same time also light and flexible. In the cleaning sector, therefore, plastic packaging continues to dominate. Plastiblow has for many years proposed electrically operated blow moulding machines, allowing: repeatability of movements; faster cycles and regular and precise movements, and therefore increased productivity and reduced production waste; energy consumption reduced to a minimum, and therefore lower operating costs; lower maintenance costs; reduction of environmental impact. The manufacturer has created many blowing machines for such a sector, where lighter coextruded multilayer containers are required, and eco-sustainable, using an important percentage of recycled plastic polymers. Among its recent projects, the company has supplied two blow moulding machines for producing trigger spray bottles, with two layers and various sizes, using post consumer material. They were equipped with 2 moulds, each with 6 cavities, to reach an hourly production of over 6,000 bottles. Other projects have concerned the production of bottles for bleach, with machines with 6+6-cavity moulds for 2-litre containers, and machines with 5+5- or 4+4-cavity moulds for 4-litre mono and multi-layer containers; or for bottles for house cleaning and maintenance products, requiring inclined neck to make it possible to reach the most difficult points. www.plastiblow.it MACPLAS I NTER NATI ONAL | MAY 2022

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| ANCILLARIES AND COMPONENTS NEWS

Cor ona and other t r eat ment s accor ding to MeR o

Care and attention as key of success Tuscany-based company owned by the Mennucci family, MeRo has successfully built up over the years an excellent reputation in the field of systems for corona treatment, specialising in the production of corona treatment machines for a wide range of applications and supplying system manufacturers like the German company Brückner. One of the sectors on which MeRo has focused on is that of lines for biaxially oriented films, and it is the official supplier of corona treatment to Brückner, with whom it has established a thirty-year plus partnership. Moreover, MeRo also works directly with users, deploying its expertise to identify and roll out the most suitable solution. The BOPP films core business is complimented by the converting sector with applications on printing and lamination machines, extrusion coating and coating machines. Other historic sectors for MeRo are the cast field, especially cast polypropylene films, where the company can draw on the expertise recognised by major European manufacturers, and the blown films. In addition to corona treatment, the company offer also includes vacuum plasma and atmospheric plasma treatment systems. The latter is a variation of the corona treatment which achieves better results on certain types of films, guaranteeing a longer duration of the surface tension and, thus, better adhesion of inks, glues etc. The vacuum plasma treatment systems operate in high vacuum conditions and the surface treatment takes place between the unwinder and metallisation phase. This makes it possible to achieve better adhesion on metal or other coatings of aluminium or silicon oxides, resulting in better barrier properties. Recently, there has been a trend, especially in the food packaging sector, to create a transparent coating as an alternative to the aluminium one, using aluminium or silicon oxides specifically to obtain transparent barriers. Another application in the packaging sector

is the use of induction cap sealing machines, employed in the bottling sector. MeRo is one of just a handful of companies in Italy that produces this type of machinery which places a seal under the cap to create a barrier and prevent leakages, which is used, for example, in packaging for milk, fruit juice and sauces, as well as engine oil and fertiliser. The Italian company has opted for an approach centred on the constant updating of its offer, immediately applying the latest innovations in components and electronics to its production line. In corona treatment, the company efforts have always focused on ensuring quality, reliability and robustness of generators and discharge stations. Another of the company strong points is the wide selection of generator powers available, ranging from 1 to 125 kW (over 25 sizes), together with the possibility of choosing from over 40 different discharge stations depending on the application (cast, blown, converting, extrusion coating etc.). By combining different size generators with the most suitable discharge station, it is, therefore, possible to offer a customised and “made-to-measure” solution for the specific application. Furthermore, the company has always focused on electronic management. It was the first company to integrate the recipe corona treatment management system on rotogravure and laminating machines, thus avoiding the need to periodically adjust the various parameters based on the film and treatment required, which has proved particularly useful in converting processes. Another advantage offered by MeRo is the company flexibility in adapting the configuration of its devices to existing machinery layout; a capability that is highly appreciated by manufacturers. www.mero.it

3850-mm-wide corona treater suitable for metalized films at a speed of 1000 m/min

MACPLAS I NTER NATI ONAL | MAY 2022

people technologies perspectives

| MATERIALS AND APPLICATIONS

As the classic function of the driver’s seat is no longer required, the car interior can be completely redesigne

The automot iv e interior of the f ut ur e: f r om 3D mult if unct ional display s to v egan seat cov er s

Material solutions for a seamless, fully networked mobility

Working with its industry partners, Covestro has developed a new concept for the car of the future, with a seamlessly integrated, multifunctional 3D display; more privacy thanks to sound-absorbing acoustic foams; high quality PU seat covers for low environmental impact; and a new modular table

he car of the future will be fully networked and will integrate seamlessly into everyday life as trends of electric mobility, connectivity and car sharing start to redefine vehicle utility. Vehicle interiors, especially, will undergo groundbreaking change, becoming multifunctional living and working spaces. In order to meet these demands, Covestro has worked alongside its partners to develop a premium concept with material solutions. Highlights of the concept include among others multi-sensory infotainment systems, innovative seating concepts and a sound-insulating dome. High-tech materials from Covestro open up a kaleidoscope of new possibilities for many different components. The company is a leading player in this area.

The reinvention of the display The car of the future will be a mobile multifunctional living and working space. Displays and indicator instruments will take on a whole new meaning. They will become infotainment systems that will connect passengers with the outside world and provide them with information or entertainment, depending on their use. The interaction between people, cars and the environment will drive innovation in this field.

Seeing this challenge as an opportunity will require new concepts in display design and optimal integration in the car cockpit. Together with an industry partner, Covestro has developed a display concept that should meet the increased requirements in terms of optical quality, durability and design standards. The result of this cooperation is the largest three dimensional OLED display to date, which will serve as a seamless interface between humans and cars. Two Covestro materials were used in the display concept: the polycarbonate Makrolon Ai and the polycarbonate film Makrofol. Both thermoplastic products make it possible to fabricate geometrically challenging components that are of good quality and very durable. The high optical purity of the polymers ensures that the OLED display (organic light emitting diodes) provides vibrant colors without distorting the image due to its curved surface. For the production of such highly complex components, Covestro was able to draw on its many years of experience in process development. An ingenious combination of manufacturing technologies ensures the surface design and durability. The surface, shape, haptics and appearance of the component can be individually adapted to the customer’s wishes. MACPLAS I NTER NATI ONAL | MAY 2022

Peace and privacy in a small space Low-noise mobility was introduced with the electric drive. But the passenger in an electric car will not be able to drive acoustically shielded from his environment either. The quieter engine means that the noise of road traffic reaches his ears all the more loudly, and at a speed of 30 kilometers per hour or even lower the rolling noise of the tires is so loud that the noise level inside an electric vehicle is comparable to that of a car with a combustion engine. As a result, the need for noise reduction remains a central element in a car. To achieve this, Covestro has developed a new concept for noise reduction in the interior. The so-called PrivacyDome is an automatically retractable dome over the head of a passenger that protects him or her from noise and disturbing sounds. The Baynat polyurethane system from Covestro was used in this dome, which has proven highly effective in sound-proofing car interiors. This means that the passenger enjoys peace and quiet independently of other passengers – exactly when he or she wants it. Integrating loudspeakers into the PrivacyDome even allows individual music selection and, in addition, passengers can relax to calming sounds such as the soothing sound of waves on the beach.

Vegan seat covers Only a few years ago, reference to a “full leather interior” was an indication of a high quality vehicle, and genuine leather was an expression of quality and extravagance. However, this picture has now changed: when making purchasing decisions, today’s customers are focusing more attention on sustainable products with the smallest possible CO2 footprint. So, Covestro developed its water-based

Insqin technology in order to create a sustainable, efficient and permanent polyurethane coating for textiles and to produce high-quality synthetic materials, especially for car interiors. Conventional synthetics are often produced using organic solvents. For years, such volatile organic compounds (VOCs) have been subject to emission reduction measures. This is why Covestro is relying on a water-based coating technology that does not require solvents. Compared with the previous solvent-based coagulation process, this efficient technology not only saves up to 95% water and up to 50% energy, but the vehicle interior is also significantly less polluted by VOC emissions. As an alternative to animal leather, Insqin products offer several advantages: due to their lower weight, they increase the efficiency of a vehicle and thus reduce its fuel or electricity consumption. Thanks to modern production methods, they are durable, sustainable and recyclable. Insqin products are already well established in the textile coating industry and have impressed in many application areas. In vehicle interiors, they now provide an opportunity to completely redesign and reuse surfaces. Designers and drivers both benefit from this, as the color, feel and light permeability of surfaces can be customized. Because translucent effects can be achieved even with dark colors, indicator lights or buttons can be easily installed under the surface – a glance or the push of a button becomes an experience.

Modular table concept for the car of the future

Many things will change in the car of the future. New forms of mobility will turn the car into a multifunctional, mobile living and working space, that also need to be comfortable and appealing. Covestro takes things one step further by using Maezio: a continuous fiber-reinforced thermoplastic composite (CFRTP), extremely robust and lightweight, which also provides opportunities for high-quality and aesthetic design. One such current example of what is posIn the PrivacyDome, an automatically retractable sible is a space-saving, modular dome, the Baynat polyurethane system from table concept for autonomous Covestro ensures effective sound absorption MAY 2022 | MACPLAS I NTER NATI ONAL

vehicles, developed by Covestro in cooperation with Engel Austria and Dr. Schneider Unternehmensgruppe as a direct supplier to the automotive industry. The objective was to construct a normal-sized table that is as thin as an Ultrabook, and can be stowed just as easily, for instance between the back seats, but is mechanically extremely durable. This table measures 41 cm in length and 32 cm in width, with its thickness increasing from 5 mm on the outer edge towards the inside to 10 mm – which is less than half the thickness of conventional car tables. The later fitting of hinges, already accounted for in the molding process, and ready-molded trays for pen and tablet reduce the number of components and save weight. An initial version featuring a sandwich construction is shown in the interior concept. The upper and lower sides each consist of 1 millimeter thin layers of the polycarbonate composite material. The sandwich core is a rigid low-density polyurethane (PU) integral skin foam based on Baydur 20. Weighing just 690 grams, the table is twice the size of a conventional one and can even be loaded with 50 kg instead of 5 kg. The manufacturing process was developed with partners at the LIT Factory of the Linz Institute of Technology (LIT) at Johannes Kepler University (JKU) in Linz, Austria. Here, with the help of digitalization, potentials ranging from product development to reuse can be optimally identified and leveraged. The second step of the project aims at enabling a smooth and economic large-scale production of the table with series-proven processes and to transfer the know-how gained to other applications of CFRTP composites. www.covestro.com

The result of the new concept is the largest three-dimensional OLED display to date, which can act as a seamless interface between people, cars and the outside world

Vegan water-based Insqin technology for textile coating offers the same attractive appearance as leather, but at a lower cost and with reduced solvent emissions. Furthermore, it allows light to shine through the coated surface, creating an all new kind of ambient lighting

DROP LINE

Linee automatiche di estrusione per la produzione di tubi di irrigazione a goccia Automatic extrusion lines for the production of drop irrigation pipes

Profile Dies s.r.l. via delle Industrie n. 2 Gornate O. (VA) ITALY +39 0331 855 010 info@profiledies.com www.profiledies.com

| MATERIALS AND APPLICATIONS NEWS Univ er sal TPE w ith 40% of r ecy cled material

A multitalented compound for the plastics industry The world of plastics and rubber is currently experiencing a surge in sustainability values - faster, higher, greener is what the desired material is expected to be. But quality is an issue that must not fall by the wayside. The most sustainable solution is the one that can continue to be used for a long time. That saves time, energy and resources and scores points with consumers. In way to support all these trends, Kraiburg TPE has developed its new multitalented compound Universal PCR TPE, containing up to 40% post-consumer recyclate (PCR), and especially dedicated to consumer and industry applications. In accordance with ISO 14021, the manufacturer recycles materials that end consumers from households and industry can no longer use for their intended purpose. With its Universal PCR TPE, the competence leader is supporting customers and end users in implementing their sustainability targets and applications and is presenting a tough plastic that provides plenty of possible applications and is suitable as an alternative for established market solutions. “The development process focused on Kraiburg TPE’s desire to offer customers a sophisticated alternative to our most-requested

compounds. Universal PCR TPE is our multi-tool in the field of compounds, with a proportion of recycled materials ranging between 13% and 40% that come from households or commercial and industrial waste streams”, explained Jan Bothe, Product Development Scientist at Kraiburg TPE. “We’ve spent a lot of time on developing a product that can make a real difference. This series enables us to offer customers and prospective clients a useful, high-quality alternative to established products”. Universal PCR TPE also has strong points in colour and mechanics. Designers and developers appreciate the various colour and tone options designed to meet people’s needs; compounds are available in natural colour as a basis for customerspecific colour solutions as well as in a grey colour characteristic for recycled plastics. Another feature worth emphasizing is the compound’s processability, which is in no way lower to that of standard solutions and sets new standards for PCR compounds. Product managers will benefit from constant and high quality as well as from availability in Europe. When needed, certificates of conformity with Reach and RoHS can be issued on request. www. kraiburg-tpe.com

The latest solution from Kraiburg TPE makes a post-consumer recycling proportion of 40% possible

Compalen Slip Strip conditioning compounds are perfect for the manufacturing of wet razor lube strips

Quick to mark et w ith a customized pr oduct

Compounds for a gentle, comfortable shave Amongst last products by German company Grafe, Compalen Slip Strip conditioning compounds are ready-to-process for the manufacturing of the lube strips that enable wet shaving particularly gentle and comfortable. Carrier resins are polystyrene (PS) or thermoplastic elastomers (TPE) for injection moulding or extrusion. When it comes to compounding Compalen Slip Strip, Grafe can draw on its long and wide-ranging experience of thermoplastic additivation in order to combine the base material with freely selectable colouring pigments and functional fillers, which are purely physically incorporated without coupling agents. Individual formulations are developed in close partnership with the customers, which can choose between proven active ingredient formulations and the development of individually tailored compounds. Supplied as free-flowing pellets, all compounds are suitable for direct co-extrusion or twocomponent injection moulding together with compatible thermoplastics such as PS or ABS that provide mechanical stability. Due to the high filler contents, a certain proportion of the additive formulation remains on the surface of the resultant lube strips, which means that, on contact with water, these components can dissolve, swell and so show the expected effect. The soaps, fats and oils present in these components provide a pleasant lubricating effect that protects the skin from irritation. Further conditioning and fragrance components can also be incorporated and combined with the desired ontrend colour. The range of potential combinations is virtually unlimited. As Danny Ludwig, head of Product Management at Grafe explains, “Our selection of carrier polymers and processing technologies available for Compalen Slip Strip compounds results in a modular system allowing design to be optimally adapted to function and, in this specific case, to fitting to the razor head. Our development team can also advise on the selection of additives and reconcile customer wishes with processing realities, so eliminating potential problems at an early stage on the road to serial market application”. www.grafe.com MACPLAS I NTER NATI ONAL | MAY 2022

Composite materials f or moder n sk ateboar ds

Hig h-per f or mance poly amide

Electric push for lots of driving fun

New recycled-based HPPA for household appliances

manager Application Development at the High Performance Materials (HPM) business unit at Lanxess. Despite the thin walls, the electric and electronic components in the deck are safely protected against impact as well as moisture. The trough-shaped composite part is manufactured in a single hybrid moulding process step. First of all, a robot inserts the metal base plate used to attach the truck axles into an injection moulding tool. It then places a heated and plasticized Tepex section in the tool. In one operation, the section is then formed and the entire structure overmoulded with a short-glass-fibre-reinforced plastic compound. “The process is very efficient and highly integrated, meaning that not only can the base plate be fixed in place, but fastening elements, wire ducting and the battery holder can also be mounted in the same operation. That means that, unlike many conventional electric skateboards, the latter does not have to be screwed in separately”, explained Jules Staedelin, manager for research and development at EMI. The composite section is made from polyamide-6-based Tepex dynalite 102-RG600(6), which is reinforced with six layers of continuous-glass-fibre rovings. The deck cover is also made from this material. Lanxess polyamide 6 Durethan BKV30H2.0EF is used for overmoulding. www.lanxess.com

Electric skateboards are an effortless way to get around and offer their fans a thrill that is quite different from conventional skateboarding. They are also extremely challenging to design. The electric components, such as the battery and the motors that drive the wheels, need to be housed in very confined spaces to keep the board light, compact and easy for the rider to handle. The Tepex dynalite continuous-fibre-reinforced thermoplastic composites from Lanxess open up new opportunities in that regard. One example is provided by the Okmos SL-01 electric skateboards from EMI, a family business based in France. Conventional skateboards usually consist of a relatively flat wooden board where the rider stands, also known as the deck. Under the deck on electric versions is a plastic box containing equipment including the battery. The EMI design, however, has a trough-shaped deck. With the exception of the motors, which are mounted on the back of the skateboard, this houses all the electric and electronic functions, including the battery. The trough is enclosed by a cover. Thanks to Tepex, the trough can be manufactured with a wall thickness of just three millimetres. “Tepex is extremely resilient thanks to its high torsional and bending strength, and very lightweight into the bargain. The deck weighs just 2.5 kg”, said Jean-Marie Olivé, technical

The Tepex dynalite continuous-fibre-reinforced thermoplastic composites from Lanxess have been used to create ultra-thin and lightweight electric skateboards MAY 2022 | MACPLAS I NTER NATI ONAL

The leading global supplier of specialty polymers, Solvay, has introduced a new Omnix high-performance polyamide (HPPA) compound family based on a minimum of 33% recycled content, consisting of 70% PIR/ PCR recycled resin which is highly secured and has a controlled process by the supplier. The Omnix ReCycle combines innovative Omnix ReCycle HPPA technology follows the company’s the outstanding mechanical properties of virgin semiOne Planet roadmap towards aromatic HPPA with better continuously improving the flow, lower water pickup and environmental footprint and best-in-class surface aspect circularity of its product portfolio. “As Solvay’s first-ever recycled-based HPPA with 50% glass fibre reinforcement, Omnix ReCycle is a real breakthrough in the market of polyamides for household appliances”, said Claire Guerrero, Global Marketing manager for Packaging Segment and Sustainability at Solvay. “It combines the outstanding mechanical properties of virgin semi-aromatic HPPA with better flow, lower water pickup and best-in-class surface aspect. In addition, its unique performance and sustainability profile offers an attractive material solution for brand owners and manufacturers who seek to increase the recycled content in their products without compromising dimensional stability, high stiffness, impact resistance and processability”. The recycled content of Omnix ReCycle saves resources and results in a significantly lower carbon footprint compared to virgin HPPA, thus showing a 30% lower global warming potential (GWP). At the same time, it has an ideal fit for replacing lower-performing polyamides (PA) as well as metals. In household appliances, for instance, it delivers higher durability than provided by standard PA6 or PA66 polymers. This helps OEMs to reduce breakage and damage returns while meeting the growing awareness of consumers for longevity and lower environmental impact in their product choices. With its excellent surface appearance, the new recycled-based HPPA can also eliminate the need for painting, which adds to its overall sustainable benefits and facilitates the end-oflife recyclability of applications in an increasingly circular plastics economy. Another target is wear and tear resistance for lightweight interior components in transportation and automotive. Solvay’s Omnix ReCycle can be processed on standard injection moulding equipment, including the use of water-heated moulds. Following the successful sampling and approval by selected customers, the new sustainable HPPA material is commercially available, worldwide. www.solvay.com

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MEETINGS & CONGRESSES 2022 Austria

May 23-25 Vienna: Pipeline Coating - AMI (www.ami.international/events)

Belgium

May 19-20 Brussels: A Circular Future with Plastics - EuPC (www.plasticsconverters.eu/events) May 25 Webinar: VinylPlus Sustainability Forum - VinylPlus (www.vinylplus.eu/events) June 14-15 Brussels: Petcore Europe Annual Conference Petcore (www.petcore-europe.org)

France

May 5-6 Paris: World Pultrusion Conference at JEC World Epta, Acma (https://pultruders.com/wpc2022)

Germany

May 11-12 Frankfurt: Masterbatch - AMI (www.ami.international/events) May 24-25 Munich: PLA World Congress - Polymedia Publisher (www.pla-world-congress.com)

June 7-8 Cologne: Compounding World Congress - AMI (www.ami.international/events) June 14-15 Cologne: Chemical Recycling - AMI (www.ami.international/events)

Italy

May 3-6 Rho-Pero (Milan Fairgrounds): Packaging Speaks Green, International forum about sustainable packaging - Ucima & Amaplast (www.packagingspeaksgreen.com) May 12 Naples: National conference about rigid polyurethane foam - Anpe (www.conferenzapoliuretano.it) June 23-24 Cologno al Serio (BG): Injection moulds: types, features, advantages and disadvantages Plastinnova (www.plastinnova.it)

Singapore

June 7-9 Singapore: Sustainability in Packaging - Smithers Rapra (www.smithers.com/events)

Spain

May 10-12 Barcelona: Plastic Pouches - AMI (www.ami.international/events) June 7-9 Barcelona: Plastic Closure Innovations - AMI (www.ami.international/events)

The Netherlands

June 8-9 Amsterdam: Biobased Coatings Europe - ACI (www.wplgroup.com/aci/events) June 14-15 Amsterdam and webinar: E-Pack Europe - Smithers Rapra (www.smithers.com/events)

United States

June 13-15 Chicago (Illinois): Thin Wall Packaging - AMI (www.ami.international/events) June 16-17 Chicago (Illinois): Multilayer Flexible Packaging AMI (www.ami.international/events) 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 on this page to take note of all possible postponements.

JEC For um I taly

A conference dedicated to composites JEC Group and Assocompositi, the Italian association of composite materials, are organizing JEC Forum Italy, the first event in Italy dedicated exclusively to composite materials in all their different applications, which will be held for the first time next year in Bologna, at the Bologna Congressi exhibition spaces, on June 6 and 7, 2023. The event wants to replicate the successful formula inaugurated a few years ago by JEC Group in the German-speaking area (JEC Forum Dach) in collaboration with the German Association of Reinforced Plastics (AVK). This new, not-to-be-missed event focused to the Mediterranean area will take place annually in a different location to highlight the dynamics and variety of the composites industry in Italy. JEC Forum Italy is an event that promotes dialogue between professionals through organized meetings between suppliers and qualified buyers with the support of workshops and technical conferences organized by Assocompositi. 2023 will also be the occasion to launch for the first time in Italy the JEC Composites Startup Booster competition, the most important competition for startups in the

MAY 2022 | MACPLAS I NTER NATI ONAL

world of composites and advanced materials designed to evaluate, reward and promote the best innovations. The main purpose is to promote the already very dynamic Italian composites industry: thanks to the agile format, it will be possible to focus each year on a different application area according to the specific needs of the industry, as well as the local peculiarities related to composites. The final goal is to create business opportunities, connecting and involving the local industrial apparatus and its main players such as universities, research and development centres and companies of all sizes in a spirit of growth and innovation. “JEC Group mission is to promote the composite materials industry by sharing knowledge, developing networking and celebrating innovation. This concept of event, developed in partnership with Assocompositi here in Bologna, will activate business, bring together experts and customers, but also highlight the local dynamic ecosystem of composites in Italy”, Eric Pierrejean, CEO of JEC Group, commented about this strategic decision. “We are very pleased to create this new

composites event in Italy in alliance with our strong partner JEC Group. This important geographical region represents a large number of SMEs as well as some large companies across all industries. This event represents a very important platform for networking, supporting the industry with new impulses, particularly in the key markets for mobility, marine, building and construction and also aerospace“, Roberto Frassine, president of Assocompositi, added. www.jeccomposites.com www.assocompositi.it

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DID YOU KNOW THAT AN ICE CREAM TUB CAN BE RECYCLABLE AND COMPOSTABLE? There is an increasing tendency to use biodegradable and compostable raw materials obtained from natural fibers for the production of food containers. This great opportunity, combined with the high possibilities of total recycling of the most used polymers, gives the transformation of plastic materials the leadership in the production of containers for food and medical use with a low environmental impact.

THE INJECTION MOULDING MACHINE

BMB HP, the new Series of BMB machines, a perfect synergy of speed and precision.

ULTRA HIGH INJECTION SPEED. In a world where large quantities of food and medicines need increasingly to be preserved and transported anywhere, BMB has created the high productivity machine par excellence. The hybrid nature of the HP Series favours reduced consumption thanks to the electric drives with direct motors and at the same time offers very powerful injections controlled by a servo valve under accumulator. Specific pressures of 2500 kg/cm2 and injection speeds of over 1500 mm/s are the guarantee of high productivity and great quality for thin-walled containers, sometimes deep and difficult to be injected, such as food or medical containers.

MacPLas International - May 2022

Articles inside

A real sustainable solution

Material solutions for a seamless, fully networked mobility

Twonewlinesfortheextrusionofcompound readyforthemarket

Careandattentionaskeyofsuccess

ThefirstMatteltoysinmaterialsfromrenewable sourcesareontheway

Bioplasticsinthelimelight

Innovation,sustainabilityandproductivity:the forcesofrecyclingandcompounding

Blockingeventhesmallestcontaminating particles

Twosectorsinrecovery

Entryintotheblownfilmsector