Published by Promaplast Srl - Centro Direzionale Milanofiori - Palazzo F/3 - 20057 Assago (Milano, Italia) - ISSN 0394-3453 - Poste Italiane SpA - Spedizione in abbonamento postale - 70% LOM/MI/2363
MACPLAS INTERNATIONAL
THE MAGAZINE FOR THE PLASTICS AND RUBBER INDUSTRY
ITALIAN MACHINERY MANUFACTURERS -A DIFFICULT START FOR THE YEAR… BUT NOT TOO MUCH www.macplas.it A REVISED VIEW ON THE TURBULENT MARKET OF BIO-BASED POLYMERS KEEPING BUSINESS GOING IN THE CORONAVIRUS ERA NEW TRENDS FOR THE PACKAGING OF THE FUTURE www.ultrasystem.ch
Plastics Recycling Show Europe Amsterdam, Netherlands 27-28 October 2020 Booth E25
Kunststoffen
Veldhoven, Netehrlands 2-3 December 2020 Booth 334
ZPE and ZT cor with Alessandro Zambello
C
M
Y
CM
MY
CY
MY
K
The big
sizes
MNP3 with Elio and Alessandro Zambello
In Magnago (Milano) plant, headquarters of Zambello group, we design and produce large gearboxes with very high performance for Single screw extruders Corotating twin screw extruders Counter-rotating twin screw extruders, parallel and conical Injection moulding machines
a Family Company since 1957, made in Italy
ZAMBELLO
group
Advanced technology for extruders www.zambello.com
TAILOR-MADE INNOVATIVE SOLUTIONS We build high-performance injection
PERFORMANCE
molding machines, innovative systems and special solutions fully customizable, which cover the whole sector molding of elastomers
EXPERIENCE
CUSTOMIZATION
and plastics.
CONTENTS
19
27
13
10
MARKETING 10 13 16 16 17
19
PLASTICS AND ENVIRONMENT 19 24 24 25
27
BIO-BASED POLYMERS - A REVISED VIEW ON A TURBULENT AND GROWING MARKET STEERING THE PVC INDUSTRY TOWARDS THE CIRCULAR ECONOMY LCA STUDY FOR PVC COMPOUNDS AND CORES EUPC REQUESTS THE POSTPONEMENT OF THE SUP DIRECTIVE
MACHINERY AND ANCILLARY EQUIPMENT 27 30 37 41 44 46 48
6
EDITOR’S LETTER - SETTING A GOOD EXAMPLE! ITALIAN MACHINERY MANUFACTURERS - A DIFFICULT START FOR THE YEAR… BUT NOT TOO MUCH HIGH PERFORMANCE THERMOPLASTIC FILMS - GOOD GROWTH OPPORTUNITIES OVER THE NEXT FIVE YEARS ABOUT A QUARTER OF EUROPEAN ETHYLENE PRODUCTION THREATENED BY THE CORONAVIRUS BOPP FILM - OPTIMISTIC MARKET DESPITE TURBULENCE CAUSED BY COVID-19
KEEPING BUSINESS GOING IN THE CORONAVIRUS ERA EVEN IN TIMES OF CRISIS, FURTHER DEVELOPING INNOVATIVE TECHNOLOGIES KEEPING UP WITH THE TIMES BY REMAINING YOURSELF PRECISION AND VERSATILITY FOR GROWTH IN THE FOOD AND BEVERAGE SECTOR INNOVATION AND ENHANCED PERFORMANCE IN THE PRODUCTION OF MULTILAYER PIPES HOW TO GIVE AN ADDED VALUE TO RECYCLED MATERIALS GREAT TONNAGE FOR A GREAT RECOVERY
50 52 52 53 54 56 56 57 58 61 64 67 70 72 74 74 75 76 76 78 79 80 82 82
MICROWAVE-BASED TECHNOLOGY FOR ODOUR AND VOC REMOVAL RECYCLING OF PVC FROM ELECTRIC CABLES FLEXIBILITY AND VERSATILITY - A UNIVERSAL SOLUTION CO-ROTATING TWIN-SCREW EXTRUDERS FOR FOAM SHEETS AND PROFILES LOOKING TO THE FUTURE WITH OPTIMISM EXPLOITING OPPORTUNITIES TO CREATE VALUE FROM IRRIGATION SYSTEM MANUFACTURING TO SPECIAL EQUIPMENT A SUSTAINABLE BLOW MOULDING END-OF-LINE AUTOMATION FOR POLYPROPYLENE PIPES OF LARGE DIAMETER RESILIENCE: THE KEYWORD FOR A COMPANY AND ITS PRODUCTS TIMES CHANGE, RECYCLING CHANGES MORE THAN A QUARTER OF A CENTURY IN THE SCREW MANUFACTURING TAKE A… BREAK! INCREASING QUALITY IN CASCADE INJECTION MOULDING A HALL OF FAME OF GREATEST ACHIEVEMENTS BREAD AND BUTTER IN PVC MIXING IMAGE ALIGNED WITH THE TECHNOLOGICAL DEVELOPMENT THE ANSWER FOR GROWTH, COMPETITIVENESS AND INNOVATION TURNKEY PACKAGE FOR CONTINUOUS FLOW THE BEST MEANS OF REDUCING ENGINE SPEED RELIABILITY, SAVINGS AND QUALITY TOP-QUALITY CORONA TREATMENT 80 YEARS OF EXPERIENCE IN IR AND UV LAMPS FOR INDUSTRIAL APPLICATIONS AN INNOVATIVE SOLUTION FOR THE PLASTICS RECYCLING INDUSTRY MACPLAS INTERNATIONAL OCTOBER 2020
COVER STORY
Published by Promaplast Srl - Centro Direzionale Milanofiori - Palazzo F/3 - 20057 Assago (Milano, Italia) - ISSN 0394-3453 - Poste Italiane SpA - Spedizione in abbonamento postale - 70% LOM/MI/2363
MACPLAS INTERNATIONAL
THE MAGAZINE FOR THE PLASTICS AND RUBBER INDUSTRY
www.macplas.it
ITALIAN MACHINERY MANUFACTURERS -A DIFFICULT START FOR THE YEAR… BUT NOT TOO MUCH A REVISED VIEW ON THE TURBULENT MARKET OF BIO-BASED POLYMERS KEEPING BUSINESS GOING IN THE CORONAVIRUS ERA NEW TRENDS FOR THE PACKAGING OF THE FUTURE www.ultrasystem.ch
85
98
85
MATERIALS AND APPLICATIONS 85 NEW TRENDS FOR THE PACKAGING OF THE FUTURE 88 FIRST-OF-ITS-KIND POLYPROPYLENE TO EXPAND 90 92 93 94 94 95 96 96
98
3D PRINTING APPLICATIONS GREEN TECHNOLOGIES TO MAKE SOMETHING GOOD FOR THE EARTH THE REFERENCE POINT FOR HIGH QUALITY AND IMMEDIATE DELIVERY THE SUSTAINABLE EVOLUTION ADHESIVE SOLUTIONS FOR EFFICIENT LI-ION CELL ASSEMBLY RECYCLED GLASS FIBRES IN THE NEW ECO FAMILY OF POLYAMIDES GREEN RESEARCH AND INNOVATION IDENTITY UNDER THE MASK OPTIMUM QUALITY FOR SPECIFIC BOPE FILM STRUCTURES
TRADE FAIRS AND CONFERENCES 98 98 99 99
PLAST 2021, THE ORGANIZATION RESTARTS EXHIBITIONS & TRADE FAIRS CHINAPLAS - EMBRACING POST-PANDEMIC OPPORTUNITIES COURSES & CONFERENCES
MACPLAS INTERNATIONAL OCTOBER 2020
The benefits of a better purging The Swiss company Ultra System develops and produces high-quality purging compounds for the cleaning of plastic processing machinery since 2004. Known under the brand name of Ultra Plast, the sales of Ultra System’s purging compounds grew quickly and now its products are purchased and appreciated all over the world thanks to a tight network of agents and distributors. Strongly engaged in quality and innovation, Ultra System has constantly extended its product offer thanks to important investments in R&D and innovative technologies. Ultra Plast can be used in all sectors and with all types of machinery for cleaning operations during colour and/or material change at temperatures as high as 420°C, without generating unpleasant smokes and smells. In general, the use of purging compounds is spreading worldwide, as an increasing number of converters understand the clear benefits of purging. Firstly, Ultra Plast reduces the overall use of virgin resin for purging, as huge amounts can be replaced by a few kilograms of dedicated material. No more scraps will be generated, following also the new eco-green sustainability. Secondly, machine downtime for colour and/or material change operations has an effective cost as it means a direct reduction of machinery productivity. This can be drastically reduced only through the use of a good purging compound like Ultra Plast, which will speed up this purging time. Other benefits reside in the product formulation: with 100% food-grade components according to the strictest legislations, Ultra Plast products are compatible with all sectors, ranging from food packaging to technical tools used in the medical and pharmaceutical industries. Working only through chemical action, Ultra Plast does not damage metallic machine parts. Abrasive purging techniques, on the other hand, will encourage the reappearance of production defects such as black specks and, over the time, they may cause micro scratches on the metal surface of the machines, compromising the production itself. With the launch of the Ultra Plast “CS” line with Swiss Qualipurge technology, with the line “S” and lately with the SP/SP Plus universal grades, Ultra System has set a new threshold in purging operations standards, with some of the most innovative products on the market. The new strengthened formulas give the best results even in the most difficult situations. Tests performed in laboratories and in production lines confirm the benefits that derive from a regular use of the new Ultra Plast ranges, which allows a decrease in production costs up to 85%. From this year, Ultra System is also directly present on the Mexican territory with the company Purge Ultra Plast Mexico. www.ultrasystem.ch
7
MACPLAS INTERNATIONAL
ADVERTISERS’ LIST
95 AMAPLAST
2 AMPACET
Supplement of MacPlas August/September 2020
www.amaplast.org www.ampacet.com www.arburg.com
47 ATECO
www.atecosrl.com
12 BANDERA
www.luigibandera.com
Editor in chief Riccardo Ampollini
11 ARBURG
Editorial staff Luca Mei, Girolamo Dagostino, Stefania Arioli
22 BARUFFALDI www.baruffaldi.eu
Sales office Roberta Pagan
9 BIESSE www.biesse.com
18 BD PLAST
www.bdplast.com
60 BFM www.bfm.it Back Cover BMB
www.bmb-spa.com
23 BREAK POLYMER
www.breakpolymer.com
Editorial assistant Giampiero Zazzaro
84 CHINAPLAS www.chinaplasonline.com
Editorial committee Dario Previero, Gabriele Caccia, Massimo Margaglione
53 CIMBRIA
www.seasort.com
51 CM PRODUZIONE
www.cmevolutionplast.com
29 CMS www.cms.it
Contributors to this issue Amaplast, AMI, EUPC, European Bioplastics, FachPack, ICIS, Nova-Institute, Stratview Research, VinylPlus
73 EUROVITI
www.euroviti.com
35-36 FILIPPINI & PAGANINI
www.saldoflex.com
57 FIMIC www.fimic.it
Published by Promaplast Srl Centro Direzionale Milanofiori - Palazzo F/3 20057 Assago (Milano, Italy) Tel.: +39 02 82283735 Fax: +39 02 57512490 e-mail: macplas@macplas.it www.macplas.it
65 FRANCESCHETTI ELASTOMERI www.f-franceschetti.it 25 GAMMA MECCANICA
www.gamma-meccanica.it www.giurgolastampi.com
83 GREENSAN
www.greensan.it
66 HELIOS ITALQUARTZ
www.heliosquartz.com
5 HRSFLOW
www.hrsflow.com
Registration at the Court of Milan n. 68, 13/02/1976 Registration at the National Press Office n. 4620, 24/05/1994
34 GIURGOLA
4 IMG
www.imgmacchine.it
5 INGLASS www.inglass.it 55 IPM
www.ipm-italy.it
Managing director Mario Maggiani
79 LABORPLAST www.laborplast.net
Administration Alessandro Cerizza
17 MAST www.mastsrl.it
100 MACPLAS www.macplas.it www.mero.it
49 MIXACO
www.mixaco.com
Layout and prepress Nicoletta Albiero
75 ME.RO
www.mobert.it
33 PEGASO INDUSTRIES
www.pegasoindustries.com
97 PLAST 2021
www.plastonline.org
Printed by LOGO
40 MOBERT
Postal delivery: IFS Italy ISSUE PRICE: 8 euro if not sent with mother magazine The managing direction of the magazine declines any responsibility for possible unreliability of editorial articles and notes coming from various sources ASSOCIATED TO: UNIONE STAMPA PERIODICA ITALIANA ASSOCIAZIONE NAZIONALE EDITORIA DI SETTORE
101 PLASTIBLOW
www.plastiblow.it
33 PLASTIC SYSTEMS
www.plasticsystems.it
77 PLASTORE
www.plastore.it
15 PRESMA www.presma.it 59 PROFILE DIES www.profiledies.it 45 ROBOLINE SYTRAMA
www.sytrama.com
35-36 SALDOFLEX
www.saldoflex.com
43 SARA www.sarasrl.eu
63 SIPOL
www.sipol.com
39 STAR AUTOMATION EUROPE www.star-europe.com 26 TECNOMATIC
Cover ULTRA SYSTEM 69 VANETTI
3 ZAMBELLO
www.tecnomaticsrl.net www.ultrasystem.ch www.vanettimaster.com www.zambello.it
INSTITUTIONAL SPONSORS AMAPLAST ITA LI A N PL ASTIC S A N D RU B B ER PRO CES SIN G M ACHIN ERY A N D M O U L DS M A N U FACT U R ERS’ AS SO CI ATIO N
ASSORIMAP AS SO CI AT IO N O F ITA LI A N PL ASTIC S R ECYCLIN G A N D R ECL A IMIN G C O M PA NIES
SPE ITALIA SO CIE T Y O F PL ASTIC S EN G IN EERS
AIPE I TA L I A N AS SO CI AT I O N O F E X PA N D ED P O LYST Y R EN E
CIPAD C O U N CIL O F IN T ER N ATIO N A L PL ASTIC S AS SO CI ATIO NS D IR ECTO RS
UNIONPLAST AS SO CI ATIO N O F ITA LIA N PL ASTIC S PRO CES SIN G C O M PA NIES
IIP ITA LIA N PL ASTIC S INSTIT U T E
UNIPLAST ITA LI A N STA N DA R D ISATIO N BO DY FO R PL ASTIC S
ASSOGOMMA ITA LI A N RU B B ER, CA B L ES, WIR ES A N D SIMIL A R M A N U FACT U R ERS’ AS SO CI ATIO N
8
MACPLAS INTERNATIONAL OCTOBER 2020
EDITOR’S LETTER
“
SETTING A GOOD EXAMPLE! As some of our loyal readers will already have learned from news updates published on the MacPlas website, at the beginning of June I took over the direction of two more associations: Ucima (Italian Packaging Machinery Manufacturers’ Association) and Acimac (Association of Italian Manufacturers of Machinery and Equipment for Ceramics), while obviously remaining at the helm of Amaplast. So, what exactly prompted the chairman and the executive board to “share” the director? The answer is quite simple: the project of a network amongst our associations! But let me take a step back to give you some more details. For years now, I have been advocating greater collaboration amongst member companies, and indeed urging them to move in this direction: after all, in today’s globalised world, size has become fundamental. Moreover, I could hardly allow myself to fall into the trap of saying one thing and doing another. Accordingly, when the opportunity arose, I felt it was my duty to support the proposal made to our association. The model is both simple and highly effective: the three associations remain effectively independent, each with its own management bodies, service company and fair etc. Instead (replicating the system already in place for some years between Acimac and Ucima), the available professional expertise is pooled amongst the members of the three associations, thereby improving and completing the range of services each already offers. Furthermore, combined under the leadership of a single director, the political weight of the three combined sectors assumes an even greater value. In short, the difficulties linked to the coronavirus crisis have further strengthened the firm belief of the chairman, executive board and myself, that it is crucial, also at association level, trying to create critical mass. This challenge is exciting, but demanding to say the least. Good luck to all of us with this new job!
Mario Maggiani, director of Amaplast
10
”
MACPLAS INTERNATIONAL OCTOBER 2020
FUTURE
CUSTOMER PORTAL
DIGITALISED BUILDER TIME MACHINE
arburgXworld NEW WORLD
DIGITAL TRANSFORMATION
NETWORKING
PIONEER
20 20 c tober 29 -31 O all 6 H 9 4 Stand F Italia Parma,
arburgXworld gives you the tools you need to fully digitalise your company. We can help you to achieve your goal with our Road to Digitalisation. Choose from a wide variety of products and services to improve your production efficiency. Start digitalising now with arburgXworld! “Wir sind da.” www.arburg.it
AMUT
MARKETING
ITALIAN MANUFACTURERS OF PLASTICS AND RUBBER PROCESSING MACHINERY
A DIFFICULT START FOR THE YEAR… BUT NOT TOO MUCH BRIEF LOOK AT THE PANDEMIC’S NEGATIVE IMPACT ON THE FIRST QUARTER OF 2020 (MITIGATED SOMEWHAT DURING “PHASE 2”) AND AT A NEW COLLABORATION PROJECT LAUNCHED, IN RESPONSE TO THIS, BY THREE ITALIAN ASSOCIATIONS - AMAPLAST, ACIMAC AND UCIMA - AIMED AT IMPROVING THE QUALITY OF THE SERVICES OFFERED TO THEIR MEMBERS
T
he import-export data published on cessing machinery exports have collapsed in still, also for plastics and rubber industries. last June by the Italian Institute of Sta- this part of the world (-27%), nearly matching The situation is particularly dire for automotive tistics (Istat) and elaborated by the losses in Asia (-28%). and building applications, where demand has Statistical Studies Centre of Amaplast (na- The current scenario sees the global econo- fallen to extremely low levels. On the other tional trade association, member of Confin- my in downturn, with investments at a stand- hand, healthcare and cleaning/personal-hydustria) points to declining foreign giene product containers are doing trade flows during the first three well (packaging sector is generally months of the year, with losses in holding steady). March reaching 7% for imports and Looking more closely at the trends in 13% for exports with respect to the the main sales markets in the above same period in 2019. geographical areas, the Americas These are probably only the first efshow a decline by 24% in the Unitfects caused by the Covid-19 paned States, 16% in Mexico and 37% demic. According to the forecasts, in Brazil, whilst Asia shows a decline they will peak in the coming months by 27% in China, 6% in India and and will be followed by long-last75% in Indonesia. ing aftereffects, since the worst of Concerning Europe, the decline is the pandemic is not yet behind us limited to -4%, with exports showing Despite the global economic recession, the medical and packaging medically speaking - especially in sectors seem to be holding up, recording positive performances the following trends in the main outlet the Americas. And it is not surprising related to the production of containers for personal care and markets: -3% for Germany, -40% for that Italian plastics and rubber pro- cleaning products Spain, -21% for France, counterbalMACPLAS INTERNATIONAL OCTOBER 2020
13
MARKETING
anced, however, by +8% for the United Kingdom, +40% for Poland, and an eye-catching +218% for Russia, where strong oscillations, both up and down, are nothing new. Again in the period January-March 2020, sales in Africa remained broadly constant, although the two main outlet markets recorded the following downturns: -20% for Morocco, major export destination in the Mediterranean region; -28% for South Africa, a prominent sub-Saharan market.
A NEGATIVE PICTURE… BUT WITH A SIGNIFICANT “REBOUND” IN MAY After the fallback in 2019, with 6% drops in production and exports (not surprising after eight years of growth), 2020 is not going to be a rebound year for the Italian plastics and rubber processing machinery industry, one of
the country’s mainstays in mechanical engineering. It is difficult to make forecasts, but most certainly the return to pre-crisis levels will not happen in 2021, a full recovery only likely in 2022. The drop in orders recorded in the past weeks had immediate consequences for auxiliaries manufacturers whilst providers of more complex and costly plants, with longer delivery times, will feel the main impact further down the line, even in 2021. The uncertainty of the duration and intensity of the pandemic in the various geographical areas (also considering the possibility of new waves in the coming months) is reflected in the highly uncertain outlooks of foreign buyers of Italian plastics and rubber processing machinery - an industry that exports roughly 70% of production, and even 90% for certain
Inter-association synergies
Amaplast, Acimac and Ucima start a threesome cooperation project The presidents and executive committees of Amaplast (Italian plastics and rubber processing machinery and moulds manufacturers’ association), Acimac (Association of Italian manufacturers of machinery and equipment for ceramics) and Ucima (Italian packaging machinery manufacturers’ association) have implemented a new project of collaboration, aimed to further increase the quality of their services to member companies. The project expands on synergies active between Acimac and Ucima since 2011.
Mario Maggiani pictured on July 8 at the Acimac annual meeting, which elected him director also of that association
14
The resources of the three associations will be pooled to provide greater support to members in various fields, ranging from trade fairs and technical regulations to market research, statistics, and finance. During their annual assemblies, on July 6 and 8 respectively, Acimac and Ucima officially voted to put their management in the hands of Amaplast director, Mario Maggiani. “It is a great challenge for me”, commented Maggiani, “and for the staff of the collaborating associations, who will share their competencies and experience. But in a continuously evolving global context - with the pace increasing in recent months with the Covid-19 pandemic - it has become vital to achieve critical mass at all levels. This is what prompted our decision, with the goal of giving more complete and specialized services to the member companies in the three sectors through the active pooling of consolidated professionalism”. This new cooperation - where each association will formally maintain its independence - represents more than one thousand companies, with 55,000 employees and over 14 billion euros of revenue, of which 70% destined to exports.
types of plants. The contraction in orders is compounded by personal travel restrictions, resulting in slower or deferred installations and repairs and hence delays in payments. The domestic market is also suffering. It does not currently appear to benefit to any great extent from the emergency measures implemented by the Government to counter the crisis. Fortunately, on July 10, the Italian Institute of Statistics was able to report signs of an upturn in Italian industry. Linked to the resumption of operations permitted in so-called Phase 2 of the crisis, this trend exceeded expectations. Indeed, Istat documented a 42.1% rise in the industrial production index in May as compared with April. This is a figure that should be considered in the light of the 25% and 20% increases previously predicted by economists from, respectively, Intesa Sanpaolo and Unicredit. Istat stresses that its figure refers to a comparison with April, a “month characterised by closures in many production sectors following the introduction of measures related to the health emergency”. This explains why May saw “a significant recovery of operations, with all sectors except the food, beverage and tobacco industries (which experienced slight declines), recording economic growth”. A quick look at the table prepared by Istat reveals positive three-digit changes for sectors such as textiles (+142.5% from April to May 2020) and transport (+140.2%), as well as sizable rebounds in other areas, such as metallurgy (+72.7%) and, last but not least, Italian plastics and rubber processing sector, which recorded a remarkable +75.9%. www.amaplast.org MACPLAS INTERNATIONAL OCTOBER 2020
MARKETING
High-performance thermoplastic film market
Good growth opportunities over the next five years As it is now well known, all major end-use industries, such as electrical & electronics, automotive, aerospace, and construction, have already started portraying huge shortfalls with many manufacturing facilities being temporarily shut down for an undetermined timeline due to the outbreak of Covid-19. The high-performance thermoplastic film market is also not untouched with such severity owing to the halt of operations of many manufacturing facilities of the major markets, such as China, the United States, Italy, and France. Currently, the assessment of the real impact of coronavirus on each industry is unpredictable as the disease is continuously spreading and imprinting its dreadful impact on mankind. However, analysts expect the market to gradually recover in the coming years with long-term market outlook to be favourable. According to the last Stratview Research report on the high-performance thermoplastic film market in the period 2020-2025, this market remains salubrious with consequential growth opportunities in the long-term scenario. It is estimated to reach 802.8 million dollars in 2025, expecting a healthy rebound from 2021 onwards after registering a steep fall in 2020. The growing interest towards the use of thermoplastic films on account of their recyclability, trend of miniaturization in the electronics industry, superior injection moulding properties assisting in the reduction of part cycle time, and films’ suitability as an insulator in the electrical & electronics industry are some key factors fueling the growth of these films in the ma-
At least 6.6 million tons/year, or 26%, of Europe’s ethylene production capacity is threatened by oil refineries running at reduced rates or ceasing production, according to new analysis by Icis. The ethylene is produced by crackers attached to refineries hit by collapsing demand for petroleum products including jet fuel as coronavirus-linked restrictions cut road and air transport; aviation has come to a standstill across the region. These ethylene crackers may be forced to reduce operating rates or close because they rely mainly on naphtha or liquified petroleum gas (LPG) feedstocks sourced from the refineries to which they are linked.
16
High-performance thermoplastic films are ideal for applications in the electrical and electronic field
Covestro
NEWS
jor end-use industries. Further, the leading players are also forming longterm contracts in the market to smoothen their supply bottlenecks. For instance, in 2019, Solvay and Safran underwent a long-term agreement for the supply of Halar high-performance film based on ECTFE for Safran’s LEAP aircraft engine acoustic panels. Based on the material type (PPS, PAEK, PSU, LCP, PEI, HPPA and others), high-performance polyamide (HPPA) is expected to remain the most dominant material type over the next five years. The high share is attributed to the huge demand from the automotive and electrical & electronics end-use industries, owing to properties of HPPA films such as good flexibility, excellent insulation, and superior heat resistance. LCP films also hold a significant share of the market, as they are a preferred choice for flexible electronics applications, such as flexible solar cells and electronic circuit boards for computers as well as mobile phones, owing to their superior electrical characteristics, dimensional stability, low moisture absorption, and excellent heat resistance. Based on the end-use industry type, E&E segment is likely to remain the biggest demand generator during the forecast period. High-performance thermoplastic films are preferably used in printed circuit boards as they fulfil key requirements, such as thermal conductivity and low moisture absorption. There is also an urge in the market demand for high-performance films from flexible electronics applications, especially from consumer electronics such as computers and mobile phones. Further, there is also a continuous shift of the electronics industry from the developed western economies to the developing Asian economies. The outbreak of Covid-19 in major Asian economies may fade the growth trajectory temporarily, especially in 2020, but the region’s attractiveness amongst all regions remains ubiquitously in terms of market growth and size. www.stratviewresearch.com
European Chemistry
About a quarter of European ethylene production threatened by the coronavirus Icis analysis suggests the 6.6 million tons/year represent about 50% of the refinery-linked steam cracking capacity in Europe, and 26% of the region’s steam cracking capacity. For propylene, 5.9 million tons/ year of capacity is linked, while for benzene the figure is 4 mil-
lion tons/year. The analysts are aware of around 6.5 million barrels/day of oil refining capacity that is not operating at typical capacity. There are some planned stoppages, but most are due to reduced fuels demand from coronavirus and associated
lockdowns. The experts believe that at least 2.2 million barrels/day of reductions are in place, versus the expected forecast throughput of 12.2 million barrels/day for Europe. The refineries are operating in the range of 50-60% utilisation, which reflects the typical minimum turndown for most distillation units. However, the crackers that are directly linked are probably able to run at higher utilisation rates than this. wwww.icis.com
MACPLAS INTERNATIONAL OCTOBER 2020
Fig. 1 - Additional capacity and average global utilisation rates for BOPP films between 2014 and 2020 (estimation)
Source: AMI Consulting, 2020
BOPP Film
Optimistic market despite turbulence caused by Covid-19 According to AMI Consulting, the BOPP film industry is facing a number of challenges creating significant trading turbulence; resin price fluctuations, trade tariffs, trade barriers and currency shocks all affect working capital and business planning. Therefore, companies are acting more cautiously than in previous years. The Covid-19 pandemic has exacerbated this, with disruption to raw materials supply and distribution logistics. Even with this multitude of factors being present, the BOPP film industry has seen an improvement in margins overall since its low point of two years ago thanks to a reduction in overcapacity and more favourable raw materials prices. Investment in capacity continues apace. While for much of the 21st century the main focus of investment has been in China (by far the largest market), the fastest growth in investment in recent years has been in India. This country has seen capacity nearly double over the past five years, driven by the opening up of its retail sector, growth in middle classes and associated consumer spending on packaged food and other goods. Recent BOPP investments are in large high-speed lines, averaging above 45,000 tons/year nameplate capacity. According to AMI, sustainability is the main “new” story of the last two years. Downgauging continues, and recyclability is key to future business planning in every region. However, huge disparities exist between regions in terms of concrete actions: Europe and North America are the most advanced in their
approach to sustainability, with the implication that enterprises which export to these regions need to adapt and innovate to trade effectively in the future. Simpler films (mono-material or with 2-3 layers) are now perceived to be advantageous and many BOPP suppliers are reacting to capitalise on this in an environment which has widely felt growing negative consumer sentiment towards plastics in general. Demand for BOPP film continues on a growth trajectory, despite Covid-19 slowdown experienced in other plastics markets, given its important role in primary food packaging and its core functional characteristic as a cost-effective barrier protection. Packaged foods are largely considered to be recession-proof, and growth in packaged foods markets around the world will continue to be a key driver for future demand. This is particularly so in emerging markets experiencing population growth, urbanisation and rising incomes. The five-year (2014-2019) compound annual volume growth rate for the global BOPP film market was 4.6%, which added just over 1.5 million tons of demand and increased the global market to over 9 million tons. E-commerce is expected to continue expanding share over traditional retail channels. This is resulting in rising demand for tapes and label films and has been further accelerated by the Covid-19 pandemic. www.ami.international
C
M
Y
CM
MY
CY
CMY
K
VIA COMO, 5 LOC. CAGNO - I – 22043 SOLBIATE CON CAGNO (CO) T. +39 031 806021 - T. +39 031 807801 - F. +39 031 807695 - info@mastsrl.it
MACPLAS INTERNATIONAL OCTOBER 2020
www.mastsrl.it 17
PLASTICS AND ENVIRONMENT
Michael Carus, founder and managing director of nova-Institute, at the last annual conference of European Bioplastics
THE GLOBAL BIO-BASED POLYMER MARKET
A REVISED VIEW ON A TURBULENT AND GROWING MARKET UNCERTAIN TIMES FOR BIO-BASED POLYMERS IN 2019: PLA SOLD OUT DESPITE EXPANSION, AS DID PHA. BIO-BASED PP AVAILABLE FOR THE FIRST TIME, INCREASED PRODUCTION OF PBAT, PBS, BIO-BASED PE, STARCH-CONTAINING POLYMER COMPOUNDS AND EPOXY RESINS. LOWER PRODUCTION IS SEEN PARTICULARLY IN BIO-BASED PET. AT THE SAME TIME, THERE IS A LACK OF SUPPORT FROM POLICY MAKERS, WHO ARE TAKING BIO-BASED AND BIODEGRADABLE PLASTICS INTO COLLECTIVE PUNISHMENT WITH FOSSIL PLASTICS BY NOVA-INSTITUTE AND EUROPEAN BIOPLASTICS
T
he market and trend report “Bio-based Building Blocks and Polymers - Global Capacities, Production and Trends 2019-2024” published by nova-Institute (Hürth, Germany), shows capacities and production data for all bio-based polymers in the year 2019 and a forecast for 2024. The production of bio-based polymers has become much more professional and differentiated in recent years. A large number of different producers and suppliers came into play to create bio-based alternatives for practically every application. The already large number of players in the bio-based polymer field, many situated in Asia, makes it difficult to verify each announced and installed capacity and their actual production. MACPLAS INTERNATIONAL OCTOBER 2020
Detailed research, including interviews with international experts and players in the bio-based polymer field, made it possible to draw a verified and realistic view on the market. The results look at an even smaller bio-based polymer market than formerly assumed: its share in the total polymer and plastics market is 1% (3.8 million tons in 2019). The capacities and production of bio-based polymers will continue to grow with an expected CAGR of about 3% until 2024, which is almost the same predicted growth rate as for fossil-based polymers and plastics (figure 1). The increase in production capacity from 2018 to 2019 is mainly based on the expansion of PBAT (poly butyleneadipate-co-terephthalate) produc-
tion in Europe, worldwide epoxy resin production and European production of starch-containing polymer compounds. Also, increased and new capacities of polybutylene succinate (PBS) and copolymers, bio-based polyethylene (PE) and polypropylene (PP) - for the first time commercially available - were reported in 2019. Especially epoxy resins and PP will continue to grow significantly until 2024. Additionally, polyhydroxyalkanoates (PHA) capacities will increase in the same period. In 2019, detailed research on the bio-based structural polymer market unveiled significant changes and a former misinterpretation of available, but non-transparent market numbers. Therefore, the actual global production volume for bio-based
19
PLASTICS AND ENVIRONMENT
Not included PET, PA and polyacryl-fibres
Source: nova-Institute
The second advantage is offered by more than half of the produced bio-based polymers: they are biodegradable. Depending on the environment, they can biodegrade without leaving behind microplastics. Only a few countries such as Italy, France and probably Spain will politically support this additional disposal path. In 2019, the European Union’s single-use plastic ban was adopted. It will enter into force in the second half of 2020. Biodegradability and biobased origin are not recognised as grounds for exemption from the ban. Almost all bio-based and biodegradable polymers are put under “collective punishment” together with fossil plastics and are banned as well. Only so-called “natural polymers”, polymerised by nature, are exempt. WHEN POLITICS ENTERS THE GAME Under the microplastics restriction currently beOverall, the market environment remains chal- ing worked on in the REACH regulation, PHBs lenging with low crude oil prices and little polit- will probably be exempted from a microplastic ical support. So far, the two major advantages ban. The final regulation is expected by the end of bio-based polymers have not been politically of this year. rewarded. The first advantage is that bio-based The most important market drivers in 2018 and polymers replace fossil carbon in the produc- 2019 were brands that want to offer their custion process with renewable carbon from bio- tomers environmentally friendly solutions and mass. This is indispensable for a sustainable, critical consumers looking for alternatives to petclimate-friendly plastics industry and is not yet rochemicals. If bio-based polymers were to be politically rewarded. accepted as a solution and promoted in a similar way as biofuels, annual Fig. 2 - 5,0 mln t biomass feedstock for 3,6* mln t bio-based polymers growth rates of 10 to 20% (with a 43% bio-based share) in 2019, worldwide could be expected. The same applies if the price of oil should rise significantly. Based on the already existing technical maturity of biobased polymers, considerable market shares could be gained in these cases.
BIO-BASED POLYMERS
*excluding fossil-based PBAT and PBS
20
Source: PlasticsEurope, Consultic and nova-Institute
Fig. 1 - Plastics production from 1950 to 2018
Production (million tons)
polymers in 2018 is much smaller than the one reported in the previous report (figure 1). Considering the future steady increase of biobased polymers, the biomass feedstock requirement is a necessary factor to consider. This is especially true for the recurring debate on the use of food crops for bio-based polymer production. Figure 2 shows the percentage distribution of the 5 million tons biomass needed for the worldwide production of 3.6 million tons of bio-based polymers. The major biomass feedstock used for biobased polymer production are biogenic by-products (47%), especially the by-product glycerol from the biodiesel production, which is mainly used for epoxy resin production via epichlorohydrin as an intermediate. 37% of the required biomass are made up by starch and sugars, 9% by cellulose (mainly for cellulose acetate) and 8% by edible and non-edible plant oils, such as castor oil. From the 3.6 million tons of produced bio-based polymers (fully and partly bio-based, excluding fossil-based biodegradable PBAT and PBS) only 1.6 million tons are actual bio-based parts of the polymers (43%). Considering this fact, 3 times more feedstock is needed than used for product formation. This amount of over 3.4 million tons (68%) of feedstock that is not ending up in the product is due to high number of conversion steps and related feedstock and intermediate losses.
The global polymer market includes functional and structural polymers, rubber products as well as man-
made fibres. nova-Institute’s report focuses on the bio-based part of the structural polymers, analysing potential pathways from biomass to bio-based polymers, via different intermediates and building blocks. Those pathways consist of bio-based “drop-in”, “smart drop-in” and “dedicated” inputs within the chemical production chain, and the different derived bio-based polymer groups are subject to different market dynamics. While drop-ins (like EPDM, PET, PE, PP) have direct fossil-based counterparts and can substitute them, the dedicated ones (PEF, PUR, biodegradable CA, PHA, PLA and starch-containing polymer compounds) have new properties and functionalities that petrochemistry does not provide. Both have their own advantages and disadvantages from a production and market perspective. Figure 3 summarises the results of the report and shows the development of capacities from 2019 to 2024 on the basis of forecasts by current and some additional producers. Here an increase is shown from an installed 4.3 million tons capacity, resulting in 3.8 million tons of production in 2019 to 4.9 million tons capacity in 2024, which indicates an expected compound annual growth rate (CAGR) of about 3%. Despite the main drivers for capacity increase in 2024 - epoxy resins and, presumably, PHA and PP - also the capacities for bio-based polyamides (PA), bio-based polyethylene (PE) as well as polylactic acid (PLA) will increase.
BIO-BASED BUILDING BLOCKS Figure 4 illustrates the development of capacities for the main bio-based building blocks used for the production of polymers from 2011 to 2024. These 18 building blocks are utilised for the synthesis of structural and functional polymers as well as ingredients in various other applications such as food, feed, cosmetics or pharmaceuticals. The overall production capacity of bio-based building blocks increased about MACPLAS INTERNATIONAL OCTOBER 2020
Fig. 3 - Bio-based polymers production capacities in 2019 and 2024
Production capacities (million tons)
8% (230,000 tons/year) in 2019, although some pioneers went bankrupt. This increase is mainly based on epichlorohydrin (ECH) and the production of the newly added building block bio-based naphtha. The overall forecast for bio-based building blocks worldwide indicates a growth by 5% (CAGR) until 2024, with 1,4-butanediol (1,4BDO), different furan derivatives, L-lactic acid, naphtha and 1,3-propanediol (1,3-PDO) being the main drivers.
GLOBAL PRODUCTION CAPACITIES BY REGION After Asia as the leading region, which has installed the largest bio-based production capacities worldwide with 45% in 2019, Europe follows with 26%, North America with 18% and South America with 10% respectively. In the next five years, the share of Europe will rise to 31% - all other regions will face decreasing shares (figure 5). With an expected CAGR of 7% between 2019 and 2024, Europe displays the highest growth of bio-based polymer capacities compared to other regions of the world. This increase is mainly due to higher production capacities for bioPE, bioPP, bioPA, PHA, PEF and newly added casein polymers that are only produced in Europe.
MARKET SEGMENTS FOR BIO-BASED POLYMERS Today, bio-based polymers can be used in almost all market segments and applications, but the applications per polymer are very different. Figure 6 shows a summary of the applications for all bio-based polymers covered in the report. In contrast to 2018 (not shown in the figures of this report), where consumer goods make up the largest share of actually produced bio-based polymers, in 2019 textiles - including woven, non-woven and fibres (mainly polytrimethylene terephthalate, PTT, and cellulose acetate, CA) have the highest share with 22%. The decreased
Source: nova-Institute
“The data showed once more that there is no competition between renewable feedstock for food and feed, and the use for bioplastics”, said Francois de Bie, chairman of European Bioplastics. “94% of all arable land is used for pasture, feed and food”
share in the consumer goods market segment is due to the correction of the large reported number for bio-based PUR in 2018. This leads also to a more balanced and equal distribution of the production shares within the different market segments: the textiles segment is followed by automotive and transport with 15%, building and construction with 13% (both mainly epoxy resins, PA and PUR), consumer goods with 13% (mainly epoxy resins, PA and PUR), flexible packaging also with 13% (mainly starch-containing polymer compounds, PBAT and PE) and rigid packaging with 11% (mainly PET, PLA and PBAT). The market segments electrics and electronics, func-
Production capacities (million tons)
Fig. 4 - Evolution of worldwide production capacities of bio-based building blocks from 2011 to 2024
Source: nova-Institute
MACPLAS INTERNATIONAL OCTOBER 2020
tional as well as agri- and horticulture and others have a market share of under 10%.
A DYNAMIC GROWTH ALSO ACCORDING TO EUROPEAN BIOPLASTICS The results of the European Bioplastics’ annual market data update, presented in Berlin on last December 4 at the 14th annual conference of the association, confirm a dynamic growth of the global bioplastics industry. As those data have been compiled in cooperation with nova-Institute and are based on the market study already summarised in the first part of this article, below are reported only other interesting data that emerged during the conference. The global bioplastics production capacity is set to increase from around 2.1 million tons in 2019 to 2.4 million tons in 2024. Innovative biopolymers such as bioPP and PHAs are driving this growth. Production capacities of bioPP are set to almost sextuple by 2024. This is due to the widespread application of PP in a wide range of sectors. Bio-based, non-biodegradable plastics, including the “drop-in” solutions bio-based PE, PET and PA, currently make up for around 44% (almost 1 million tons) of the global bioplastics production capacities. The production of bio-based PE is predicted to continue to grow as new capacities are planned to come on line in Europe in the coming years. Intentions to increase production capacities for bio-based PET,
21
however, have not been realised nearly at the rate predicted in previous years, but actually declined over the years. Instead, the focus has shifted to the development of PEF (polyethylene furanoate), a new polymer that is expected to enter the market in 2023. PEF is comparable to PET, but is fully bio-based and furthermore features superior barrier and thermal properties, making it an ideal material for beverage bottles. Packaging remains the largest field of application for bioplastics with almost 53% (1.14 million tons) of the total bioplastics market in 2019. The data also confirm that bioplastics materials are already being used in many other sectors, and the portfolio of application continues to diversify. Segments, such as automotive & transport or building & construction, significantly increased their relative share. The land used to grow the renewable feedstock for the production of bioplastics is estimated to be 0.7 million hectares in 2019, and continues to account for only around 0.02 percent of the global agricultural area of 4.8 billion hectares. Despite the market growth predicted in the next five years, the land use share for bioplastics will remain at only around 0.02 percent. www.nova-institute.eu www.european-bioplastics.org
22
Fig. 5 - Global production capacities of bio-based polymers by region in 2019 and 2024 (excluding cellulose acetate, epoxy resins and polyurethanes)
Fig. 6 - Shares of the produced bio-based polymers in different market segments (2019 and 2024)
Source: nova-Institute
MACPLAS INTERNATIONAL OCTOBER 2020
Source: nova-Institute
PLASTICS AND ENVIRONMENT
“Over the last 20 years, VinylPlus has worked tirelessly to tackle the challenges of circularity. We continuously aim to improve our sustainability performance embracing the European Green Deal, the Circular Economy Action Plan and other policy initiatives impacting the plastics sector”, stated Brigitte Dero, managing director of VinylPlus
PLASTICS AND ENVIRONMENT NEWS VinylPlus progress report
Steering the PVC industry towards the circular economy In 2019, VinylPlus, the voluntary commitment to sustainable development of the European PVC industry, recycled 771,313 tons of PVC - more than 96% of the programme’s 2020 target. The PVC industry is well on track to meet VinylPlus’ ever more challenging recycling targets for 2025 (recycling at least 900,000 tons of PVC per year), in line with the circular economy and the ambition of the Circular Plastics Alliance and EU policy initiatives to encourage recovering, recycling and reusing plastics. VinylPlus’ results are presented in its 2020 progress report. Through this voluntary commitment, the European PVC industry has recycled 5.7 million tons of PVC since 2000, preventing the release of 11.4 million tons of CO2 into the atmosphere. The European Chemicals Agency (ECHA) has confirmed recently that the recycling of end-oflife PVC products is the best waste manage-
In a global context where there is a growing focus on environmental issues, the concept of recovering and recycling materials, breathing new life into materials currently treated as waste, plays a central role in the management of future strategies across all industries. The Italian company Laborplast has operated for more than 60 years in the field of regenerated rigid PVC, giving a new life to a material that is still perfectly usable in the industrial system. In a far-sighted way, Laborplast made very specific choices in the development of products made of recycled PVC, in order to be ready to face the challenges imposed by the changes of recent years. The production of recycled PVC compounds (for pipes and profiles extrusion, and for injection moulding) and the extrusion of regenerated PVC cores (intended for wrapping
24
ment option from both an environmental and human health point of view (ECHA’s Annex XV report). Recycling of PVC significantly reduces potential greenhouse gas emissions as for each kilo of PVC recycled, two kilos of CO2 are saved. To guarantee maximum transparency, participation and accountability, a Monitoring Committee, composed of representatives of the EU Parliament, the EU Commission, trade unions, consumer organisations and academia, supervises VinylPlus’ achievements and progress. But VinylPlus goes further than the circular economy, addressing other sustainability topics such as energy and climate change, sustainable material sourcing and production and the responsible use of additives. Such key issues have been integrated into the VinylPlus Product Label, the sustainability certification scheme for PVC products in the building and construction
sector delivering the highest sustainability performance and contribution to the circular economy. To date, ten companies have received the VinylPlus Product Label for more than 110 PVC products manufactured at 18 European sites. Workers’ health and education are also an integral part of the programme. VinylPlus cooperates with the European chemical sectoral social partners (made of European Chemical Employers Group and industriAll Europe) to implement action plans for workers’ safety and for the digitalisation of SMEs that were defined in the framework of the renewed cooperation agreement signed in 2017. The new VinylPlus programme towards 2030 will be launched in May 2021. www.vinylplus.eu
Industrial ecology
LCA study for PVC compounds and cores industrial flexible packaging, agricultural films, geotextile and non-woven fabrics) represent Laborplast’s main business. So much so that we can safely state that the principle of the circular economy or, as Laborplast’s technicians like to call it, “industrial ecology”, is embedded in the DNA of the company, which processes approximately 16,000 tons of regenerated PVC every year, with characteristics that are completely comparable to virgin PVC. On the other hand, the production of recycled PVC products significantly reduces energy consumption, the use of water and the emissions of harmful
substances, compared to the production from virgin PVC. In order to quantify the impact on the environment through measurable data, in 2020 Laborplast has started a Life Cycle Assessment project. The LCA study analyses the amount of harmful substances for the environment saved for each kg of processed product, considering the entire life cycle and continuously improving the company’s ecological footprint. Another interesting element of an LCA analysis is the possibility of directly comparing the impact of the production of regenerated PVC compound with its equivalent produced
Faced with the challenges arising from the ongoing ecological revolution, Laborplast is an experienced and reliable partner, who applies the principle of industrial ecology tangibly and operationally in all of its everyday manufacturing and business activities
through the use of virgin resin. The first available data show how the transition from virgin PVC to recycled PVC leads to a significant reduction (more than 100%) on all the impact categories analysed in the study. www.laborplast.net
MACPLAS INTERNATIONAL OCTOBER 2020
Open letter to the European Commission
EuPC requests the postponement of the SUP Directive In an open letter sent to the European Commission, EuPC advocates for a postponement of the implementation of the Single-Use Plastics (SUP) Directive in view of the current Covid-19 crisis in Europe. Single-use plastics are not easily substitutable and offer unique advantages when it comes to ensuring hygiene, safety as well as preservation from contamination to protect consumers. The signatories underline that since the beginning, the Single-Use Plastics Directive 2019/904 has proven to be a difficult piece of legislation to follow and implement both at commercial level and at national
level by member states. Some crucial categories of items have been completely banned or reduced in their availability due to the (alleged) existence of a valid alternative. The Directive also hinders the single market and the free circulation of packaging and goods amongst European countries. The letter stresses that from today to tomorrow the world will be completely different and hygiene and consumer health will be the number one priority for all, so it is time to reflect on adjusting strategies for Europe and the world in particular related to the use of plastics. The term single-use plastics is com-
MACPLAS INTERNATIONAL OCTOBER 2020
Renato Zelcher, president of EuPC and Crocco’s CEO
pletely wrong and not justified. To reduce littering an anti-litter regulation will be needed to impact both consumers and force industry in circularity thinking and keep going in this direction. The bashing on plastics followed by many politicians is now backfiring and its time to work together to rebuild the economy and safeguard consumer health whilst driving the circularity of the plastics industry. It continues stating that unfortunately, the coronavirus has shown us that not all materials are the same. Many independent studies repeatedly show that plastics is the material of choice for ensuring hygiene, safety as well as preservation from contamination. Therefore, the European association of plastics converters asks the Commission to inform all European Union member states of the postponement of the deadline for the
implementation of the SUP Directive for at least an additional year at national level and to lift all bans on some of the single-use plastics items. Industry will continue to work on the circularity aspects with all value chains and maintain the objectives to reach 10 million tons of use of recycled materials between 2025-2030. For this, support will also be needed from the European Commission by clearly accepting both mechanical and chemical recycling as complementary technologies to the common objectives in the CPA. The implementation postponement will give all European Union member states more time to focus on more urgent measures in the fight against Covid-19 by distributing also SUP in emergency situations, whilst the industry will have the possibility to continue to produce all those plastic products and others that are needed and will be needed in the future. www.plasticsconverters.eu
25
THINK OUTSIDE THE BOX Approaching problems in new and innovative ways; conceptualizing problems differently; and understanding a position in relation to any particular situation in a way never thought before are the basis of the companies that want to stay relevant and inventive. Starting from our customer’s experience and working backwards to technology, Tecnomatic partnerships all the pipes companies, which are aiming at development and leadership, cultivating the ability to look at things differently from the common thinking.
TECHNOLOGIES FOR PLASTIC PIPES PROCESSING
Tecnomatic Srl | Bergamo | Italy | tel. +39 035 310375 | tecnomaticsrl.net
PROCESSING MACHINERY
AN INTERVIEW WITH BRUNO DAL LAGO OF IMG
KEEPING BUSINESS GOING IN THE CORONAVIRUS ERA
SPEAKING STRICTLY BY PHONE, IN ORDER TO RESPECT THE PHYSICAL (MORE THAN SOCIAL) DISTANCING THAT IS REQUIRED NOWADAYS, SALES MANAGER AT BRESCIA-BASED COMPANY IMG TOLD MACPLAS HOW THE COMPANY FARED DURING THE LOCKDOWN AND HOW IT IS GETTING READY TO RELAUNCH ITS OPERATIONS BY LUCA MEI
“D
on’t fear difficult moments, the best comes from them”. “In the middle of difficulty lies opportunity”. These two quotes, from two equally great scientists (respectively Rita Levi Montalcini and Albert Einstein), refer to a concept that, put concisely, sounds rather paradoxical: in other words, the idea that to give the best of yourself, you need to be struggling. But leaving aside this apparent paradox, both remarks are a way of encouraging, stimulating even, people to adopt an active rather than a passive outlook, to act rather than wait, this being seen as the best means of overcoming the adversities that they, as individuals or communities, may encounter. Never has all this seemed more apt than it does today, in the midst of a global pandemic and in the wake of the lockdown it necessitated - a period that has seen us forced to draw on our own resources and our best attributes in order to work out and accept a new way of behaving and living. And as their focus has shifted from the public health emergency to the economic MACPLAS INTERNATIONAL OCTOBER 2020
one, these efforts to find a new way of living and doing things have been led, primarily, by the protagonists on the economic stage: the entrepreneurs and companies that, despite being perfectly used to giving the best of themselves, have suddenly found this mindset to be absolutely imperative. These actors have also recognised that being able to seize even the smallest opportunity offered by the crisis is the only way of overcoming it. One of the many companies in Italy that have had to make a virtue of necessity and use this uncertain time to rethink their business through smartworking, focusing i n c re a s i n g ly on research and the development of technological solutions and new market
strategies, is IMG of Capriano del Colle, in the province of Brescia. This company manufactures rubber processing machines and is the sole distributor in Italy of the injection moulding machines produced by Haitian and Zhafir. We interviewed sales manager Bruno Dal Lago, speaking to him by phone in order to GUM is one of the latest machines developed by IMG for the injection moulding of elastomers
27
PROCESSING MACHINERY
ensure the necessary social distancing. Actually, we prefer to talk of physical distancing, given that this article stems from the personal relationships that, albeit now conducted differently, have remained constant throughout the months of lockdown, representing one of the cornerstones of the Brescia-based company’s activity. Thus we learned about how IMG fared during the lockdown, about the preparations made to relaunch its operations, and about how things are going now.
“As a practical solution, we at IMG also resorted to this particular way of working, especially for employees who could easily do their work from home, such as back office staff. We responded quickly to the emergency and coped with it well by making good use of all the tools provided by the company to our sales team. The members of the technical staff, for their part, continued to carry out their activities as normal, as these obviously do not lend themselves to smartworking”.
OUR FIRST QUESTION MAY SEEM A BIT OF CLICHÉ NOW, BUT IT IS ONE THAT WE CAN’T AVOID ASKING: HOW DID YOU MANAGE TO OPERATE DURING THE LOCKDOWN?
PRODUCTION ACTIVITIES HAVE NOW RESUMED AT FULL CAPACITY, ALBEIT IN COMPLIANCE WITH STRICT HEALTH SAFETY REGULATIONS. HOW DID YOU GET ORGANISED FOR THIS, AND HOW EXACTLY ARE YOU OPERATING?
“During the lockdown, IMG tried to develop a strategy capable of supporting a market that, as we all know, has been particularly hard hit. By offering an extremely diversified product range and practically just-in-time deliveries, we have been able to meet requests for new machines to replace old ones that, having been idle for varying lengths of time as an effect of the lockdown, were found to be having problems. I am talking about certain machines that, more than others, suffered reboot problems after long periods of inactivity. On the other hand, while we have to acknowledge that the protracted crisis within the automotive industry has unfortunately led to a sharp reduction in sales, it must also be pointed out that Haitian, with its highly diversified product range, has been able to compensate for the decline in demand in the automotive sector with solutions for the food, medical and industrial sectors in general”.
HOW MANY MEMBERS OF STAFF DID YOU HAVE COMING INTO WORK DURING THE LOCKDOWN? DID YOU RESORT TO SMARTWORKING, NOW LAUDED IN THE PRESS AS THE NEW WAY OF WORKING?
Injection moulding machine model Mars III Plus, by Haitian
28
“Although, for our company, things never came to a complete standstill, the lockdown nevertheless forced us to review how we operate. With day-to-day interaction on the market no longer a possibility, we managed to support the weak level of demand with tailor-made promotional initiatives based on the different priorities of our customers. Our sales operations, albeit somewhat reduced, was able to carry on, and was never completely suspended”.
GENERALLY SPEAKING, HOW ARE THINGS GOING NOW (AT THE END OF JULY 2020)? “Up until March our performance was substantially in line with the brilliant results recorded by IMG in the same quarter of 2019. Everything suggested that we were on track to play a leading role in 2020, too. The pandemic, however, has had the effect of accelerating downturns that were already beginning to loom on the horizon. Unfortunately, from March to May, we recorded a sharp slowdown in sales. That said, since the start of June we have been seeing a gradual increase in requests for quotations linked to the closure of existing orders. This bodes well, allowing us to hope that we might manage to end the year with results in line with our expectations.
Bruno Dal Lago, sales manager at IMG
I say this also bearing in mind the strength and expertise of Haitian, a world leading company for which IMG, since 2009, has served as the official distributor in Italy and Romania”.
HOW DID YOU EXPLOIT THE LOCKDOWN PERIOD FROM THE TECHNOLOGICAL AND APPLICATION RESEARCH AND DEVELOPMENT PERSPECTIVE? “Haitian reacted to this wholly unexpected situation in a very timely manner, since it is well aware of the fundamental importance, in our sector, of research and development of new technologies. In my view, this represents the only way forward if you want to be able to grasp any opportunities that might come along even in difficult times, like the ones we are living through. Because, while on the one hand it is certainly true that some sectors are really struggling at the moment, it is equally true that there are others that have never really experienced a drop in demand. So, based on our signature Zeres range by Zhafir, we have developed new applications for the packaging (Zeres Fast) and two-component injection sectors, in the latter case offering not only vertical secondary injector solutions, but also injectors positioned laterally, parallel and at an angle of 45° to the main injector. As IMG, we have continued with the technological and application development of solutions that we were already working on even before the lockdown. We have continued to work without interruption on these new projects, and this work will continue over the coming months, with the aim of ensuring that we are ready for the next major trade fairs, primarily Plast 2021. These are developments that will allow machines to be customised according to the desired application, starting from the basic version. Both through Haitian-Zhafir and as IMG, we have done, and continue to do, everything possible to turn the current situation into an opportunity to constantly improve, where possible, our range. This approach is allowing us to be all-round suppliers of technologies both for all plastic materials and elastomers, offering solutions and expertise that allow us to meet processing needs right across the board”. www.imgmacchine.it MACPLAS INTERNATIONAL OCTOBER 2020
PROCESSING MACHINERY
ARBURG DURING AND BEYOND THE PANDEMIC
EVEN IN TIMES OF CRISIS, FURTHER DEVELOPING INNOVATIVE TECHNOLOGIES THE GERMAN MANUFACTURER ARBURG HAS RESPONDED TO THE CORONAVIRUS CRISIS VERY EARLY ON WITH GREAT PRUDENCE AND EXCELLENT KNOW-HOW. THANKS TO THAT, THE MACHINE MANUFACTURER BASED IN LOSSBURG CONSIDERS ITSELF WELL-POSITIONED FOR THE FUTURE AFTER THE PANDEMIC, IN TERMS OF TECHNOLOGY, KNOW-HOW AND ORGANISATION: PRODUCTION CONTINUES TO PROGRESS AND THE DEVELOPMENT OF INNOVATIVE SOLUTIONS FOR INJECTION MOULDING, INDUSTRIAL ADDITIVE MANUFACTURING AND PROGRESS IN DIGITALISATION IS BEING DRIVEN FORWARD
D
uring the coronavirus crisis, Arburg has been and continues to be able to provide its customers with unrestricted delivery, competence, reliability and solution orientation. Despite or even because of the coronavirus pandemic, innovative firstclass technologies are still being developed. In recent months, Arburg has very quickly initiated several specific projects to contain the pandemic. Since spring, four injection moulding machines and turnkey systems have been producing high-quality safety goggles and multifunctional LSR masks at the Lossburg headquarters. The protective equipment were distributed to employees as well as to nursing staff in charitable and medical facilities in the region.
30
SAFETY GOGGLES “READY TO WEAR” The German machinery manufacturer implemented the “safety goggles” project within a very short time together with the Swiss speciality chemicals group Ems-Chemie and the German protective and safety glasses manufacturer Uvex. Because it was possible to build on the experience of the K trade fair, Arburg had already presented the fully automated production of sunglasses there as a trade fair demonstrator. Thanks to first-class and unbureaucratic coordination between the parties involved, the sunglasses could also be used to produce safety goggles quickly, using the same tools and thus the same design. The goggles are produced in one piece on an electric Allrounder 570 A with the Gestica con-
trol system, in a cycle time of about 50 seconds. Handling and depositing are carried out with a six-axis robot. The packaging is done manually downstream via a packaging station. In the comparable trade fair application, it was shown by way of example how processes can be visualised using the Arburg Turnkey Control Module (ATCM) and how all relevant process and quality data can be merged for specific parts. With the help of this Scada system for turnkey systems, individual parts or installed assemblies can be 100 percent traceable.
FROM THE PROTOTYPE TO THE CERTIFIED HIGH-TECH MASK Arburg also started production of LSR and PP mouth and nose masks for everyday use. The MACPLAS INTERNATIONAL OCTOBER 2020
project shows how “time-to-market” can be accelerated in exceptional cases. The companies involved in this project are Sigma Engineering (LSR component and mould simulation), Polar-Form, Foboha and Wilhelm Weber (mould), Ewikon (cold runner), Männer and Günther (hot runner technology), Mechanik (grippers), Wacker and Borealis (materials), Karl Küfner (filters), Herrmann Ultraschall (welding technology) and Packmat (packaging technology). Arburg developed the high-quality and sustainable masks made of flexible LSR and PP itself and produced the first prototypes with its Freeformer for additive manufacturing. The flexible multifunctional masks consist of a soft LSR mask, which is put over the nose and mouth, and a fixed holder made of PP with eyelets for fastening elastic bands. To prevent infection in everyday life, the mask opening is closed with a cover so that the breathing air is discharged downwards. To reliably protect the carrier themselves from the coronavirus, a disposable filter can be placed on the opening.
MASK PRODUCTION SET UP IN RECORD TIME The injection moulds for the LSR and PP components were built in a record time of only five weeks. Since mid-May, an Allrounder 570 A with a clamping force of 2,000 kN has been producing the LSR masks with a 4-cavity mould from Polarform in the Arburg Training Center, while a Allrounder 520 E Golden Electric, with a clamping force of 2,000 kN and a 2-cavity mould from Foboha, has been simultaneously producing the associated PP shields in the Customer Center. The larger injection moulding machine operates with an LSR dosing unit from Elmet and a six-axis robot from Kuka, which removes the flexible masks from the mould in a demanding moulding removal process and places them on a conveyor belt. In the second machine, a linear Multilift Select robotic system takes over the easier handling of the PP shields. Finally, the PP label is manually placed on the silicone mask with form closure, the mask is completed with the corresponding elastic straps and packed. As a next step, it is planned to produce the disposable filter, which can be placed on the opening, also at Arburg. The company is in contact with the partners Karl Küfner (nonwovens) and Wilhelm Weber (mould) for this purpose.
In April, a trade fair demonstrator became an application for safety goggles - distributed to nursing and medical staff during the coronavirus pandemic. The glasses are manufactured on a turnkey system around an electric Allrounder 570 A
ly manufacture high-quality products. Arburg does not want to earn money with the masks and safety goggles project; they are therefore not sold individually to end customers. The aim is rather to use the know-how and machine fleet to support hospitals and care facilities with protective clothing and equipment in the fight against the coronavirus as well as to show the injection moulding market the huge amount of know-how available at Arburg that allows them to design and supply highly complex systems for economically efficient and technologically advanced production in the shortest possible
MACPLAS INTERNATIONAL OCTOBER 2020
DIGITALISATION INCREASES PRODUCTION EFFICIENCY As an industry pioneer, Arburg works intensively and practically with the question of how to use digitalisation to increase production efficiency when processing plastics. In the program arburgXworld, the company has intelligently and clearly collected all of its digital products and services as well as the customer portal of the same name. Besides “smarter” machine technology and innovative solutions in the service area, the central customer portal arburgXworld, with its numerous apps, is given a key position. There are now four packages to that end, which contain various apps and configuration levels. Arburg sees great potential in digitalisation and offers manifold added value with its digital products and services. These days, many customers use the digital platform worldwide arburgXworld. The customer portal has been well received, and the basic version is free. Practically anyone, from machine operators to managing directors, can individually benefit from the numerous apps during their daily work.
CUSTOMER PORTAL: ARBURGXWORLD BUNDLES DIGITAL SERVICES
WITH KNOW-HOW AND TURNKEY SOLUTIONS AGAINST CORONAVIRUS The application shows how complex turnkey systems can be implemented within the shortest possible time, if necessary, in order to efficient-
time, even in high-wage countries.
The high-quality LSR and PP mouth and nose mask was developed by Arburg itself and realised with partners
The customer portal makes work easier all along the value chain of injection moulding. Employees from purchasing, work preparation, and maintenance profit the same as production managers, machine setters, and machine operators. The digital services of arburgXworld come in four packages.
31
PROCESSING MACHINERY
Basic The free basic package includes central apps like MachineCenter, ServiceCenter, SelfService, Shop, and Calendar. They offer an overview of machine fleets, service history, and approaching maintenance dates, for example. Service tickets and spare parts can be ordered round the clock. With the “Configuration” app, the hydraulic Allrounder 270 S Compact can be ordered online under specified conditions. Premium With the services of the premium package, which incurs a fee, Arburg offers valuable tools to increase machine availability. Thanks to the app “VirtualControl” the user can simulate the machine controls on a PC or tablet to create data sets, optimise workflows, or train employees. The premium versions of the apps “MachineCenter” and “SelfService” include an expanded digital machine file, as well as a guided solution dialogue and the “video telephone services” feature. Premium Plus The configuration level “Premium Plus” offers access to Arburg’s interesting calculation tools and detailed knowledge databases, thus significantly reducing the time expenditure for production planning, work preparation, and quality assurance, as well as for product development and sales. The “MachineFinder” helps to select the right clamping and injection unit based on data concerning processes and material technology. “DataDecoder” can be used to display machine data sets legibly and save them as scv or xlsx files.
Connect The “Connect” package offers machine-related expansion options for digital data integration. The optional “MachineDashboard” displays detailed status information and key indicators regarding individual Allrounders. It also includes the visualisation of production workflows using graphic trend diagrams. Based on the production protocol, the data for this are collected and continually processed in the machine via an IIoT Gateway. Customers who use the host computer system ALS will receive along with the ALS dashboard a cross-location overview of the machine fleet and key production indicators that is also mobile and extends outside one’s own company.
SMART MACHINE: BASIC STANDARD CONNECTIVITY Beyond the digital solutions of the customer portal, Arburg is continually refining the “smartness” of its machines. All new Allrounder come equipped with an IIoT Gateway and have basic connectivity so they can be interconnected with the customer portal or Arburg Remote Service. Digital tools that support the operator when working on the machine include four assistance packages for all new Allrounders in the clamp design and, optionally, Arburg’s filling and plasticising assistant.
SMART PRODUCTION: COLLECTING AND TRACING DATA Digitised production and online organisation are in demand so that plastic parts can continue to be manufactured efficiently also in the future. Arburg offers solutions for designing series production flexibly, using resources
With remote machine acceptance, an Arburg sales expert will go through all requirements with the customer one by one with an iPad
32
The customer portal arburgXworld makes it easier to work with injection moulding on a daily basis. Arburg has now bundled four packages that combine free and paid apps and services
sparingly, and increasing productivity, quality, and availability. The Arburg host computer system ALS is one of these solutions. This MES, proprietary to Arburg, is designed for detailed production planning and for data acquisition and tracking in injection moulding production. Besides the injection moulding machines of other manufacturers, metalworking machines and peripheral devices can be integrated. With a production cell around an electrical Allrounder 570 A, Arburg demonstrated at the trade fair K 2019 how glasses can be manufactured “ready-to-wear” in a way that is fully automatic and traceable. To that end, Arburg “Turnkey” Control Module (ATCM) collects all process- and quality-relevant data.
SMART SERVICES: LESS STANDSTILL, MORE PRODUCTIVITY The digital services of the customer portal arburgXworld include the Apps Shop, SelfService, and ServiceCenter; customers can use the “Configuration” app to configure and order the Allrounder 270 S compact online; and the Arburg Remote Service (ARS) facilitates time-saving online support. In light of the coronavirus effects, Arburg has also created the option for accepting machines remotely. To that end, its sales experts go through the requirement specifications with the customer using an iPad. The customer sees exactly what’s shown on the iPad. This allows all requirements to be checked one by one through a visual approval test. In conclusion, the customer receives an extensive written record along with image documentation before his Allrounder is finally put into operation on site. This is a timeand cost-efficient alternative and an intriguing option for the future, although it cannot fully replace personal contact and an on-site visit. www.arburg.com MACPLAS INTERNATIONAL OCTOBER 2020
ONLY ONE GOAL:
ACHIEVING NEW HEIGHTS
Our companies assure client success in the PLASTIC-CHEMICAL and FOOD processing sectors through the development of new and emerging technologies. Our proven and innovative solutions provide single source results exceeding your most challenging applications. One goal in common: achieving new heights TOGETHER.
pegasoindustries.com MacPlas '20(Pegaso).indd 1
23/09/20 15:43
FLEXO PRINTING MACHINE FFS SUPERFLEXOL 4 COLOURS GEARLESS - 1000MM.
Production line for Industrial bags – Heavy Duty (FFS) Automatic unwinder and revolver winder for up to 1500 mm. diameter reels 2-band embossing & gussetting unit Printing speed up to 300 mt/min.
Since 1961
FLEXOL 6 COLOURS GEARLESS - 2200MM. Inking through closed chamber doctor blades Automatic pre-register at machine start and printing unit motorized forwarding with job memorization and recall Printing width 2200 mm. Printing speed up to 300 mt/min.
Via IV Novembre, 153 - 21058 Solbiate Olona (VA) Italy - Tel. +39 0331 64 90 12 info@saldoflex.com - www.saldoflex.com
AUTOMATIC BAG MAKING MACHINE MODULA SERIES: 800 -1100 -1300 -1500 MM. High speed production of bottom seal bags, T-Shirt bags and Block Notes NON STOP production for bags up 700 mm. and with PAUSE operation up to 2000 mm. Stacking table for up to 8 lines bags collection (with or without pins) Film feeding speed up to 180 mt/min.
Since 1961
ROLL-FLEX R-3000 | 1100 – 1300 – 1500 MM. High speed production of pre-cut bottom seal rolled-up bags, taped with gummed paper Production for bags up to 2000 mm. long Automatic winder unit with taping devices up to 4 tracks Film feeding speed up to 180 mt/min
Via IV Novembre, 153 - 21058 Solbiate Olona (VA) Italy - Tel. +39 0331 64 90 12 info@saldoflex.com - www.saldoflex.com
PROCESSING MACHINERY
CMS PLASTIC TECHNOLOGY
KEEPING UP WITH THE TIMES BY REMAINING YOURSELF WITH AN IDENTITY THAT STRENGTHENED THROUGH THE YEARS, TODAY THE COMPANY BASED IN ZOGNO (BERGAMO) IS A UNIQUE AND RELIABLE PARTNER FROM THERMOFORMING TO TRIMMING, RIGHT UP TO THE PRODUCTION OF MODELS AND MOULDS, ALWAYS GRANTING PRODUCTIVITY AND QUALITY
T
he origins of CMS Plastic Technology - the division of CMS dedicated to plastic manufacturing - date back to 1973. That was the year that Villa was founded, the long-standing company based in Varese (Italy) and specialising in the construction of thermoforming ma-
chines which, in 2000 (after years of partnership with CMS) became an integral part of the Zogno (Bergamo, Italy) company, bringing with it its know-how, skills and highly qualified professionals. In 1991, thanks to its lengthy experience matured in milling and routing, CMS produced its
first machining centre for plastic cutting. A winning synergy between two successful companies that led to the creation, expansion and success of CMS plastic division, focusing on a highly specialised objective, engraved in the entire company’s DNA: to work with customers, learn and expand their production process and come up with the solution that best suits their needs. “This is what has always distinguished CMS”, explains the business unit manager of the department, Massimo Guerra. “We aim to present ourselves as a unique partner for the entire process, from thermoforming to cutting, to the creation of models and moulds, so we can optimise the process stages, reduce operating times and increase productivity”.
NEW FEATURES AND INNOVATION Evotech is a range of 3 and 5 axis machining centres with mobile gantry structure MACPLAS INTERNATIONAL OCTOBER 2020
The last three years have been an abundance of new features and innovation: “As well as standard products”, Guerra contin-
37
PROCESSING MACHINERY
ues, “over the last few years we have delivered thermoforming machines of a unique size. To mention but a few, we manufactured the largest thermoforming machine for packaging in Europe (8 x 2.5 metres) for a Danish customer, or, talking about depth, we delivered a 4 x 3 metres thermoforming machine with a surprising and wholly stimulating performance, that rates us among the very few manufacturers capable of completing a similar project. 2019 was undoubtedly the year of our exclusive CMS Thermo-Prophet software that we launched and which plays a fundamental role: monitoring the production of the machine in real time and intervening on machining parameters in order to maintain the highest standards of quality. In terms of range, we have added a complete line of panel sizing machines and 3- and 5-axis machining centres specifically for flat plastic machining”. “There is no need to underline”, Guerra points out, “that 2020 has been, and continues to be, an unusual year. The pandemic completely changed our outlook and, after lockdown, we all had to find ways to reinvent ourselves, both in how to interact with our customers, which, up until a short time ago, could not receive visits or come to CMS, and to promote our products, considering that all the trade fairs had been cancelled. At CMS we were ready and equipped. We have the best platforms for interacting with our customers remotely, whether for simple sales meetings or to conduct virtual tours of the company and provide demonstrations on how machinery works. Thanks to our digital systems we can offer a remote demo and explanations of the machine’s functions as though the customer were here with us”.
A PLASTIC LIVE SHOW IN COMING From a trade fair point of view the situa-
Helix: automatic beam saws for plastic materials processing
tion is completely different but, even on this front, CMS has shown itself ready to react and within a structured organisation. The second CMS live show of 2020, the first one for the plastic department (a live show specifically designed for composite material processing was held in July), is due to be held on November 9. It will be entirely streamed live in eight languages and accessible from all over the world thanks to the super technological platforms. This will ensure all participants to be present in CMS remaining comfortably in their own office or home and having the opportunity to watch demos of specific technologies, webinars and live talks dedicated to the world of plastics, with the possibility of interacting live with CMS experts. “The event will be a unique experience”, Guerra adds, “and I firmly believe in it. We are working towards creating a format that will completely change the way we communicate. Furthermore, and from a sales point of view, the most important part, during the plastic live show, will be the
The exclusive Thermo-Prophet software monitors the production in real time and intervenes on machining parameters in order to maintain the highest standards of quality
38
launch of our two new prize machines: a machining centre and a revolutionary thermoforming machine that we had hoped to present at the Fakuma trade fair but will instead present on this special occasion, simultaneously across the globe. We could wait no longer. Innovation at CMS is a daily occurrence and I am extremely proud of what we will be launching. But I shall say no more; you will see for yourselves on November 9 during our CMS live show”.
A PARTNER FOR THE ENTIRE PROCESS CMS Plastic Technology produces numerically controlled machining centres, panel sizing machines and thermoforming machines to machine plastics and offer technologically advanced solutions. The brand is the result of a successful union between technical-industrial experience in thermoforming at the historical Villa company, founded in 1973 and CMS’ long-standing know-how in milling and routing. Thanks to constant investments into research and innovation, CMS Plastic Technology is recognised as a unique partner throughout the entire process: from thermoforming to trimming, right up to the production of models and moulds, guaranteeing maximum productivity. CMS Plastic Technology plays a key role in a number of sectors such as the car industry, aerospace, earth moving machinery, caravans, buses, the railway industry, signing and the production of bathtubs. www.cms.it MACPLAS INTERNATIONAL OCTOBER 2020
Sole partner for all operations beside the IMM
star-europe.com - eins1.eu
tel. +39 (0)41 578 5311 - fax +39 (0)41 578 5312
PubblicitĂ Star A4.indd 1
19/03/20 15:20
PROCESSING MACHINERY
A CASE HISTORY BIESSE-CROSA
PRECISION AND VERSATILITY FOR GROWTH IN THE FOOD AND BEVERAGE SECTOR THE ITALIAN COMPANY CROSA HAS A 50-YEAR HISTORY IN THE DISTRIBUTION OF INDUSTRIAL TECHNICAL COMPONENTS AND IS KNOWN FOR HIGH QUALITY SERVICE. THE COMPANY FROM PIEDMONT IS CONSTANTLY GROWING AND INNOVATING AND IS A STRATEGIC PARTNER IN VARIOUS INDUSTRIAL MANUFACTURING SETTINGS, ESPECIALLY THE FOOD, BEVERAGES AND PACKAGING SECTOR
A
s a brand, Crosa (originally Crosa & Sassernò) dates back to 1897 and initially operated in the transportation sector; the business survived World War II by providing repairs and serving as a spare parts retailer and eventually shortened its name to Crosa (Commercio Ricambi Ogni Specie Auto). In 1962 Piero Sartore, father of current owners Giovanni and Francesca, acquired the historic brand. Over time, Piero’s three children joined the family-owned company, which expanded in new directions. Driven by attention to its staff and emphasis on growth, the company took the elevated skills it had developed over the years and its reputation for service in the vehicle spare parts sector and, at the dawn of the millennium, transitioned from being a parts dealer for cars to selling industrial components. In 2008 the company inaugurated a new machining operations department dedicated to plastics: a new business and the beginning of a long-term partnership with Biesse. With MACPLAS INTERNATIONAL OCTOBER 2020
over 15,000 customers across e-commerce and traditional sales channels, the Crosa warehouse provides more than 100,000 industrial spare parts and counts 32 customer service specialists. “These days Crosa mainly operates as a sales company, but that’s not all we are. We also have a manufacturing unit dedicated to the
production of plastics for the mechanical sector, and the food and beverage sector accounts for 90% of our activities”, explained Crosa owner Giovanni Sartore. The company purchased two Biesse machines in 2018: a 3-axis machining centre, the Rover Plast A FT, and a 5-axis machining centre, the Materia CL. “Purchasing these two machines boosted our machin-
Technical parts (in this and in the opening picture) processed by Crosa with Rover Plast A FT and Materia CL technologies
41
PROCESSING MACHINERY Francesca and Giovanni Sartore, owners of Crosa
ing capabilities and helped us respond to the needs of our customers. The new technology also allowed us to create even more complex components”, Sartore continued.
CHALLENGES AND OPPORTUNITIES Precision machining, versatility and the capacity to cover every step in the creation of industrial technical components are some of the main advantages offered by the two Biesse machining centres. “We are able to handle the following machining operations for our customers: supplying the raw materials, supplying cut materials and supplying items processed from sheets of raw material. More specifically, thanks to the Rover Plast A FT we are able to achieve advanced nesting, while our pride and joy, the Materia CL, has opened us up to the processing of advanced materials, especially for the food sector”, explained Lorenzo Pavon, Crosa Production Manager. The company provides precise
machining, milling and tapping for components used in the food and beverage sector. “Ever since we started using the Biesse machines, we have been able to offer higher quality and greater flexibility for our customers”, Pavon stated in closing. The industrial technical parts sector is full of challenges and opportunities: the production of complex industrial parts requires ultimate precision, a distinctive trait of Biesse technology. “I consider Biesse a partner for the coming future. The challenges will be increasingly complex, but I believe that we will have no trouble rising to the occasion together”, Sartore explained. “By opting for Biesse machining centres, we have introduced extremely innovative technology capable of taking on requests that entail the machining of parts with very complex shapes, sizes and materials, ensuring elevated precision, quality and reliability for our customers”, Sartore concluded. www.biesse.com - www.crosa.it
The Biesse Innovation Lab is born
A new vision of research and development The Biesse Innovation Lab launched by Biesse Group is a major new project in the field of research and development, and innovation, which is set to serve as an accelerator for new ideas and startups of the highest quality. A stimulating and dynamic environment in which to cultivate links with the world of academia, universities and research centres, and with other accelerators, venture capital firms and companies, with a view to further enhancing the group’s innovation ecosystem. The Biesse Innovation Lab was created in accordance with a number of objectives based upon high-level innovation, with the intention to seek solutions not only within the organisation but also outside of it, through interaction with its points of reference in Israel and Italy. Indeed, the Biesse Innovation Lab boasts a dual identity: in Israel it will be developed in cooperation with the AdlerInlight Technology Observatory, an organisation created in order to bring together industry and innovation on the Italian territory; in Italy it will be developed with the support of Manifaktura, a company with expertise in the implementation of open Innovation initiatives, and with expeManagement of Biesse, AdlerInlight Technology Observatory, and Manifaktura
42
rience in managing innovative projects in the manufacturing sector. “To open our company boundaries in order to broaden the horizons of our minds: this is the two-way principle according to which Biesse Group seeks to lead the Biesse Innovation Lab. The process of digital transformation we are currently experiencing involves change at all levels, and it is only by seizing every opportunity that this revolution offers that we can continue to be innovators”, explained Roberto Selci, CEO of Biesse Group. “When it comes to innovation, we really have our foot on the accelerator, and this is something that has been made possible not only by our internal expertise, but also - and above all - by the fact that we are able to look outwards, allowing opportunities and solutions to flow both ways, from the outside to the inside of the company and vice versa. Our goal is to become an accelerator of innovation and research, creating a fertile, flexible environment from which all those involved can benefit”, added Paolo Tarchioni, director of Innovation at Biesse Group. The new organisation, created by Biesse Group in collaboration with the other players involved in the project, will integrate technological, business and organisational themes via a team focused on multi-functional development, consisting of staff from both inside and outside the organisation, with the participation of managers, analysts, creatives, engineers and experts in marketing and sales. At the heart of the project is a strategic approach which embraces interaction and the exchange and dissemination of knowledge, with an understanding of the value of fostering a synergy between different organisations and of exchanging skills. www.biessegroup.com
MACPLAS INTERNATIONAL OCTOBER 2020
PROCESSING MACHINERY
ADVANCED DIE-HEADS AND LINES
INNOVATION AND ENHANCED PERFORMANCE IN THE PRODUCTION OF MULTILAYER PIPES T
he market for polyolefin pipes is constantly evolving with more demanding customer and application requirements. Despite the constant improvement in polyolefin properties, single-layer solid wall pipes are still not able to always fulfil certain customer or application requirements. For such situations, multilayer pipes may be a solution. The key to producing a good multilayer pipe is the die-head. This is the reason why Tecnomatic, an Italian manufacturer of processing equipment for polyolefin and PVC pipes based in Azzano San Paolo (Bergamo, Italy), continues to improve technolo-
Coextrusion of HSCR PE100 using a coating die-head on a standard PE100 pipe
44
DESPITE THE CONSTANT IMPROVEMENT IN POLYOLEFIN PROPERTIES, MULTILAYERS PIPES STILL REPRESENT THE BEST SOLUTION, IN COMPARISON TO THE SINGLE LAYER ONES, TO FULFIL HIGH PROCESSORS AND APPLICATIONS REQUIREMENTS. TECNOMATIC DESCRIBES WHY AND HOW
gy and performance for the production of complex multilayer pipes with functional layers. Developed on the basis of the Venus monolayer concept, Tecnomatic currently has a full range of die-heads with multi-helical spirals, for the production of two, three or four layers polyolefin pipes, even for large diameters, building on years of experience supplying reliable and high performing lines for multilayer pipes. A recent delivery of an extrusion line to Authentic Production in Myanmar, for the production of multi-layer pipes up to 630 mm, shows that the Asia Pacific market is embracing innovations that may provide higher levels of performance. Authentic Production, part of the Authentic Group, which started its PE pipe production several years ago, has rapidly gained market share and reputation because of its focus on quality. They benefited from running Tecnomat-
ic lines capable of producing pipes up to 1,200 mm that offered production efficiency, reliability and reduced scrap rates when producing their recently-launched multilayer product. The new product featured the BorSafe HE3494-LS-H PE100 High Stress Crack Resistant (HSCR) material in the outer layer to offer maximum security against point loads and surface damage that may occur during installation. Such multilayer pipes have been used extensively in Europe for installations either using trenchless techniques or where no imported backfill is used. By using the same material dug from the trench, the installers were able to reduce the costs and environmental impact of bringing sand or other backfill materials to the site. HSCR PE100 pipes can now offer contractors and installers such options in Asia as well. The wall of the multilayer pipe produced by MACPLAS INTERNATIONAL OCTOBER 2020
Authentic Production is made up of two layers equal to 10% and 90% of the total thickness. The outer layer is produced from HSCR PE100 material and the core from standard PE100. This requires two separate extruders, which was achieved by a main extruder from the Zephyr series in L/D 40, which offers extreme output performance and lower melt temperature and energy consumption, while the inner layer is produced from an Atlas series in L/D 30. Both extruders are synchronised using gravimetric feed on each extruder to maintain a continuous raw material feed and to record variations in mass throughput, thereby ensuring perfect control of the weight per meter and wall thickness distribution.
INNOVATIVE FLOW CHANNEL GEOMETRY The Venus Multi pipe head series have been designed to achieve excellent processing using a wide range of materials at very high output. The spiral geometry has been optimised for the latest generation of PE and PP raw materials, while achieving improvements in reducing its overall length, volume and operating pressure. The heart of the Venus Multi heads consists of an innovative flow channel geometry, which has been calculated to take into consideration the
MACPLAS INTERNATIONAL OCTOBER 2020
current raw materials. This geometry ensures the same behaviour for pressure and distribution of the melt, in all the pipe heads in the range even at very high output rates. This new feeding system, as well as for the matching ranges and the small die sets contributes to the reduced working pressure. This reduces the energy consumption during extrusion since up to 10% of the extruder power is usually required for pumping capacity. Lower pressure results in a lower melt temperature and, together with lower residence times, ensures improved pipe characteristics such as its OIT (oxidation resistance) and reduction of thermal and shear stresses. Authentic Production has expressed a high degree of satisfaction for the quality of the multilayer line since its commissioning. The new product will offer project owners additional security for pipelines that are installed in demanding conditions. Additional features can be added to the pipe such as a peelable outer skin which provides further economic and environmental benefits for water and gas distribution pipelines. This peelable outer jacket, frequently made from specially modified polypropylene, further protects the pipe surface against potential notches and cracks when using installation methods such as pipe bursting or wash-boring.
M.H. Aung (left), from Authentic Production, and Massimiliano Vailati, from Tecnomatic
Potentially deep scores in the protective jacket will not be transferred to the inner pipe when it is eventually exposed to service-related stresses. The peelable jacket that is adhered to the outer wall of the core PE pipe is typically 0.6-0.7 mm thick for all current dimensions of this new multilayer pipe and the skin is added by a cross-head positioned before the last cooling bath. Tecnomatic has a full range of die-heads, based on spiral or radial technology suitable for plastic or metal pipes coating ranging from 5 to 800 mm and up to 4 layers. The die-heads are based on a typical spiral technology for large and single layer co-extrusion, or a mixed solution with radial distributors or short path spiral alternative depending on the characteristics of materials such as PA, EVOH, PVDF or adhesive bonds. www.tecnomaticsrl.net
45
PROCESSING MACHINERY
GAMMA MECCANICA TANDEM PLUS TECHNOLOGY
HOW TO GIVE AN ADDED VALUE TO RECYCLED MATERIALS THE ULTIMATE TANDEM PLUS LINE OF THE ITALIAN MANUFACTURER GAMMA MECCANICA RESULTS THE IDEAL SOLUTION FOR THE PRODUCTION OF COMPOUNDS FROM RECYCLED MATERIALS FOR SPECIAL APPLICATION, THANKS TO ITS REGENERATION AND UPCYCLING PROCESS
C
an a recycled packet of chips or snacks become a high performance technical component? It may be possible with the latest recycling technology of Gamma Meccanica, an Italian company specialized in the design and construction of lines for the regeneration of plastic materials. The new series of GM Tandem lines, born to give more “added” value to waste materials, is the result of the constant evolution of a technology characterized by higher level of automation, maximum quality of the recycled product (granules) and improved energy savings. With Gamma Meccanica’s classic Tandem technology it is possible to recycle heavily printed, extremely humid and very contaminated materials. The ultimate Tandem Plus line improves characteristics during the upcycling process, so it is ideal for the production of compounds from recycled materials for special applications. There are numerous advantages for processors with the possibility to
46
obtain maximum quality of the recycled product (granules).
INCREASINGLY ADVANCED RESEARCH The recent case of the Tandem Plus line is a GM180 delivered to a North American company. The customer’s need was to recycle heavily printed and contaminated post-con-
sumer PE waste obtaining granules with specific technical characteristics to be used in the pipe production. This GM180 Tandem Plus is the result of increasingly advanced research by technical staff of Gamma Meccanica and the collaboration of selected partners in the industry. The first part of the line consists in the Com-
The assembling of a Tamdem Plus line with dosing units
MACPLAS INTERNATIONAL OCTOBER 2020
LDPE scraps
pac feeding system and a single-screw extruder with a diameter of 180 mm. Connected to the first extruder is a self-cleaning screenchanger installed to remove the contaminants present in the melted polymer. The patented Gamma Meccanica high performance vacuum system is installed at the exit of the screenchanger and allows for removal of up to 10 times more gas and humidity in the melted material compared to other systems. The high performance vacuum chamber is connected to a second corotating twin-screw extruder, with 90-mm screw diameter, 44 L/D ratio, two standard degassing sections, two lateral inlets for mineral fillers and additives and a dosing section for liquids. The fillers and additives are fed into a gravimetric dosing system. At the end of the twin-screw extruder is installed the TDA water ring pelletizer developed and produced by Gamma Meccanica which, in addition to guaranteeing high production performance, makes cleaning operations simple and quick during the changes of production and startup of the system.
REGENERATION AND UPCYCLING The regeneration and “upcycling” process be-
MACPLAS INTERNATIONAL OCTOBER 2020
gins with nine gravimetric dosing stations to feed the materials in a more precise and accurate way to the Compac system which has the function of shredding and densifying the waste material to be recycled. From the Compac unit, the material is pushed with constant flow from the feeding screw into the extruder. The melt obtained during the extrusion phase is filtered by the automatic screenchanger, which removes even the smallest particles of contaminants (down to 80 micron). At the exit of the screenchanger, the melt is “degassed” by the high performance vacuum chamber to avoid defects in the granules such as “air bubbles”. At this point, the polymer is “enriched” with masterbatches, carbonate and various additives inside the twin-screw extruder. The fillers and additives are introduced by the dosing system, which guarantees maximum precision. The upcycling process ends with the cutting of the melted material inside the TDA pelletizing system. Installed on the system is an inline measurement of the viscosity and the Gamma Meccanica UPC digital scale control for the real - time measurement of the productivity and energy consumption of the unit. The complete system has an average
production capacity of 1300 kg/h of enriched PE compound. This technological solution gives a much higher value to the product from waste with the upcycling process. Much like other solutions developed by Gamma Meccanica the Tandem Plus allows for contributions to the protection of the environment, both for the type of application and for better energy savings and minimum environmental impact. www.gamma-meccanica.it
47
PROCESSING MACHINERY
NEWS BMB during and after lockdown
Great tonnage for a great recovery No one could have imagined what would happen, but after the great uncertainty commonly experienced, in particular between March and April, which made BMB close the production plants for a couple of weeks (as a precaution measure), for the Italian machinery manufacturer the requests have now spread beyond expectations and fortunately it has collected enough orders to face a very hot autumn! The year 2020 will remain in the history of BMB as the year in which the new 6,400 m2 production site had to be inaugurated softly, in the lockdown period, directly with the production of the first 4500-ton injection moulding machine. Despite the current general difficulties, with partially closed suppliers and restrictive measures to be respected in every environment, the company managed to simultaneously complete a big size machine and a large plant. Thanks to the commitment and dedication of all the BMB staff, who worked continuously in sub-optimal conditions, but respecting all the safety rules, the new headquarters is now 100% working, fully equipped and complete with an independent painting department. The new production reality will allow to optimize flows and reduce delivery times, also thanks to the distribution of space, re-
The new KX 4500/2x68000 is the largest machine so far built by BMB
48
BMB 4, the new great plant
serving a larger area for the internal processing department, with working centres operating 24 hours a day, 7 days a week, and the incoming warehouse. The production of the new KX4500/2x68000 two-platen machine is BMB’s flagship of 2020, since it is the largest built to date and another with the same size will be shortly completed. The BMB’s technical staff designed the 4500-ton machine with the same meticulousness and typical accuracy of its Full Electric or Hybrid Series, with extremely
high performance in thin-walled components moulding, where speed, precision and reliability must be guaranteed without compromise. The end result is a huge high-tech masterpiece, featuring: Euromap classification 45000-2x68000 Clamping force 45000 kN Moving platen max stroke 4100 mm Distance between tie-bars 2500x2000 mm Maximum daylight 5400 mm Injection volume 39.914 + 39.914 cm3. www.bmb-spa.com
MACPLAS INTERNATIONAL OCTOBER 2020
PROCESSING MACHINERY
NEWS Developments at Bandera
Microwave-based technology for odour and VOC removal The Italian manufacturer Bandera has developed and fine-tuned a virtuous response to the circular economy with a 360-degree impact on the entire lifespan of polyolefins and PET, from the raw material to its processing into end products, up to the recovery and transformation of post-consumer recyclables into secondary raw material for extrusion, injection moulding and blow moulding. Amongst the existent systems for polyolefins - following the exclusive recycling/ upcycling process by twin-screw technology which aims at obtaining “high added-value granules” while minimizing residual odour and VOCs - a microwave-based technology is already available. Operating directly on the granule with no additives, it contributes to the removal of VOC residuals and odour in quick time. Odour removal is certainly a crucial aspect in order to promote a wider use of recycled plastics and can be particularly beneficial to the HDPE and PP market. Bandera exploits a microwave-based technology as the main vehicle to achieve an innovative extraction system able to reduce residual odours from different sources. As prolonged treatment times mean a reduction in productivity and energy efficiency, Bandera’s aim is to keep such times to a minimum so as to maximise profits, custo-
mers’ success and the concept of circular economy in itself. The best way to deal with odour is to properly process post-industrial and post-consumer materials from the very beginning. The final target is, ultimately, to obtain “premium” secondary raw materials, excellent from every point of view, which is what multinationals and retailers are mainly asking for today. For this reason, traditional single-screw extruder pelletizing, a favourite with converters until now, finds its natural evolution in Bandera HVTSE technology. Co-rotating twinscrew extrusion systems which feature high vacuum, minimum shear stress, large surface for degassing, shorter residence time, offering enhanced process performance from
the very beginning and ensuring the extrusion of high-quality materials also in terms of VOC and odour removal. Moreover, the twin-screw technology, thanks to the particular screw design developed by Bandera, offers several advantages, well beyond the high level of homogeneity (due to the excellent mixing performance), the reduction in polymer degradation (minimum MFI loss, reduced shear stress and relevant cross-linking effect), the controlled thermoregulation, the dilution, the integration of additives, minerals and fibres, which include the effective removal of VOCs and odour (thanks to the exclusive degassing process). Twin-screw technology - including both cascade and single systems - developed by Bandera is intended for working post-consumer polyolefins (HDPE, PP, LDPE) as well as styrenic resins and polycarbonate. Bandera 360-degree recycling technology can be either introduced gradually by manufacturers - who can integrate it into their existing plants to improve performance - or fully adopted for a complete revamp of their lines, with the possibility to validate results with materials supplied by the customer using the industrial machinery available at The House of Extrusion at Bandera, Italy. www.luigibandera.com
A recycling line by Bandera
50
MACPLAS INTERNATIONAL OCTOBER 2020
Luca Corti Communication
EVOLUTION PLAST
Via Grigna 9 - 20027 Rescaldina (Mi) ITALY -Tel. +39 0331 545704 - Fax. +39 0331 590961 www.cmevolutionplast.com - info@cmevolutionplast.com
PROCESSING MACHINERY
NEWS Rotary injection moulding machines
Recycling of PVC from electric cables The multi-station Roto PVC model was developed by Presma for the processing of PVC recovered from simply ground electrical cable after its separation from copper and other metal components. This range of injection moulding machines allows to process this “ground material” in a direct way, without the need to separate it from the other thermoplastics and rubbers often present in this kind of products. These units are particularly used to manufacture PVC products for road construction and road safety, as an alternative to cement and cured rubber, with excellent results
in terms of strength, durability, recyclability, safety and, of course, with a good economic return. This technology has successfully replaced the previous one based on compression moulding, ensuring higher productivity and better quality products, less waste and a reduction in labour costs; in this regard, the simplicity of the machine, which facilitates the introduction of automation, has made it possible to obtain, in some cases, a completely automatic process. PVC parts of this kind usually require very long cooling times and high plasticizing capacity. Depend-
The Roto PVC 16 injection moulding machine
ing on the required productivity, the carousel, equipped with modular clamping units, is offered with configurations of 4, 6, 8, 12, 16 and (starting from 2021) also 20 stations, with clamping forces from 100 to 300 tons. The use of special and complex rotary joints allows the clamping units to be connected to all the utilities required for the moulding process (cooling, hydraulic and pneumatic jack movements, hot runners and sensors). Each station is controlled independently with the possibility to run different products. The increasingly current demand for higher productivity led to develop plants with extruders combined with particular injection units that allow to fully exploit the plasticizing capacity as well as higher outputs (up to 30,000 + 30,000 cm3 and 1000/1200 kg/h). This was the reason why, in order to take advantage of this possibility, machines with a
greater number of mould-holder stations are offered. The possibility of applying a degassing system also allows the partial elimination of humidity and gases, present in some compounds. The plasticizing unit is electrically driven with vector asynchronous motor and frequency converter. The double accumulation piston allows to carry out the injection phase with constant volumes for each station. Thanks to this, the whole hydraulic system has been completely redesigned, eliminating accumulators. Adoption of drives with variable speed pumps has also made it possible to further reduce both energy consumption and maintenance of the hydraulic system. This range of “rotary injection moulding machines” is controlled by a new dedicated software that makes the process easier, more flexible and more efficient. www.presma.it
Bag-making machines
Flexibility and versatility - A universal solution The historical company Mobert, based in Castellanza (Varese, Italy), puts the versatility of its machines as the cornerstone of its strategy to address to the new market needs. Amongst the several models manufactured by the company, Roller SHP 6M, produced in the model 110 or 130 (sealing width 1100 or 1300 mm) stands out of the crowd, at a global level, for versatility in bags on roll production. Strong of its three-patented system, it grants fast production changes, lower production waste and a constant monitoring of the production quality: 1) The exclusive punching unit system with loop cut does not require any adjustments of the blade for the pre-cut, thus granting a perfect cut even with biodegradable films. Moreover, the knife life spam is way above the average. 2) The special vision system controls and rectifies automatically the puncher of the T-shirt bags’ handle. Thanks to a sophisticated software, images coming from the HD camera (placed on the punching unit) are processed by means of an algorithm developed internally, which controls the correct width of the handles and rectifies the positioning of every working track. Moreover, the system controls the constant scrap removal.
52
3) The exclusive winding system with pliers (with movable flap) allows a fast switch from the production with carton core to the one without carton cores, even while working on 3 or 4 tracks. Roller SHP 6M line can produce: T-shirt bags on two tracks with or without carton cores for fruits and vegetables; T-shirt bags on 3 tracks for the household waste; bottom welded bags up to 4 tracks with or without carton core; T-shirt bags on 3 tracks with star sealing. The machine works with the latest generation industrial PC, which allows the constant monitoring of the working process also from remote. www.mobert.it
The Roller 110 SHP bag-making machine
MACPLAS INTERNATIONAL OCTOBER 2020
Processing of expanded polymers
Co-rotating twin-screw extruders for foam sheets and profiles Highly specialized in the manufacturing of extrusion lines for expanded products such as profiles, pipes and sheets, Sara recently launched on the market the new Rs80 co-rotating twin-screw extruder for expanded PS, PE and PET, with output ranging from 30 to 160 kg/h (30% higher than the old range), centre distance of 75 mm, screws with diameter up to 98 mm, L/D ratio equals to 25 and a main drive delivering 30 kW. Thanks to their design, the co-rotating twin-screw extruders manufactured by Sara generate a very small amount of heat from mechanical work, and achieve a high level of mixing with low power consumption. So that it is possible to obtain a finished product with excellent foaming properties and enhanced cell and lambda structures. The screws (oil cooled) can be powered by an independent mechanism so that their adjustment does not affect productivity, while friction values are kept at an extremely low level thanks to the addition of outside heat, which is much easier to adjust. The positive feeding of the melt eliminates any fluctuations and facilitates the dimensional control of the extruded product. Mixing is also positive and is done without overheating. The system ensures better dispersion and homogenization. The automatic cleaning cycle is fast and complete and is achieved without overheating the material. In addition, less horsepower is required in order to reach the rated power, reducing the stress on the machine. Energy consumption is also reduced because actual consumption is very close to the technical values required. To improve the quality of the foam extruded product, a new series of melt coolers is available with output ranging from 300 to 2000 kg/h. Thanks to the perfect homogenization and cooling of the melt, the quality of the foam extrusion greatly improves. Therefore, Sara extruders are particularly suitable for processing delicate polymers that require low temperatures, dry mixes and materials which are difficult to feed or that need to be totally degassed. Last but not least, the Italian company presented a new series of co-rotating twin-screw extruders for laboratory applications: Lab Extruder RS - 0 (4 -12 kg/h) and Lab Extruder RS - 1 (6- 15 kg/h). www.sarasrl.eu
Launched on the occasion of the last K exhibition, in DĂźsseldorf, the new extruder Rs80S can reach a maximum output of 160 kg/h
MACPLAS INTERNATIONAL OCTOBER 2020
53
PROCESSING MACHINERY
NEWS BFM introduces a new Sirio model
Looking to the future with optimism In the field of plastics machinery for over forty-five years, today BFM is acknowledged as one of the leading companies in the “made in Italy” for the production of take off and automatic winders to suit extrusion lines for blown film (the company is a official partner of Bandera), and flexo printing machines with central drum, up to 10 colours, and stack type, with 2, 4, 6, and 8 colours. This year, also in the occasion of its 45th anniversary, the company will celebrate the inauguration of a new building, adjacent to the existing one. A new production area of 1,500 m2, housing a new R&D area, is in fact operational since the first half of 2020. It is an opportunity “to make a point” on the future of the company, that is heavily investing in terms of resources and technology, to always be at the forefront in an increasingly competitive commercial context. The company looks to the future with confidence, sure that the anniversary of 45 years of activity and the inauguration of the new production facility can become a new starting point. At the next Drupa, which will be held in Dusseldorf in April 2021, BFM will propose a novelty in its range of stack type flexographic printing machines: Sirio 6/8 Colours S Plus. It is a 6/8 colours stack type machine designed
Since the first half of 2020, at the BFM headquarters is operational a new facility of 1,500 m2, housing a new R&D department
for printing various plastic materials for the packaging market but also suitable for paper materials, in line with the extruder or reel to reel systems. The printing unit is equipped with a closed chamber doctor blade with the possibility of self-alignment; it is able to print from a minimum length of 350 mm up to a maximum of 1200 mm, with printing widths up to 1800 mm. The line is composed of an unwinder with different solutions (fixed, shaftless or revolver), a 6/8 colours printing group with motorized counter-printing axis, electric grinding and pneuma-
An 8-colour Sirio S-Plus
54
tic inking. The drying group is composed of an inter-colour system and a drying box, with electric or gas heating and a winder with different winding options. The maximum production speed reaches 250 metres per minute. This printer is the “right compromise” between costs and performance: in this case the use of IndraDyn T (MBT) torque motors, which move the colour group composed of counter-roller-clichè-anilox, guarantees great dimensional compactness and the right printing precision. The use of the IndraDrive M digital series guarantees constant position synchronism between the different printing elements, with consequent register maintenance both at high speeds and during acceleration and deceleration. Initial registration is very quick and can also be done when the machine is stopped, significantly reducing energy and material waste. To complete the Sirio stack lines, today the Sirio S-Plus model is born, even more flexible through the adoption of a full electronic positioning system. Each colour group can be moved longitudinally in a completely independent way thanks to the adoption of Indradrive Cs servo axes and MSM motors equipped with absolute multiturn encoder: the results consist in a most accurate set point, the management of storable recipes, the reduced reconfiguration times. Amongst the novelties of S-Plus, there is the new 21-inch graphic interface, simple and intuitive but at the same time complete for the management of all machine functions. www.bfm.it MACPLAS INTERNATIONAL OCTOBER 2020
PROCESSING MACHINERY
NEWS A welding machine for polyethylene gloves
Exploiting opportunities to create value “Focus on opportunities and not problems. Often in meetings the priority is to discuss how to solve problems. Of course the problems must be solved but we must not forget that their resolution does not create value; at best it prevents damage. Instead, it is the ability to exploit existing opportunities that creates value and it is therefore on these that we need to focus. Indeed, value nestles where opportunities nestle. Every business should look at what opportunities are in the market to understand where the value lies. Where the opportunities lie, there is the value, so the equation that everyone should keep in mind is value = opportunities. But where do the opportunities arise? As economist Peter Drucker teaches us, even an unexpected and
dramatic event such as Covid-19 can be a source of opportunity”. With these words Marco Filippini, Saldoflex project manager & sales operations, wanted to summarize the process that led his staff to implement the latest innovation brought to light in the company. “Last spring, during the complicated period of the lockdown, we saw how difficult it had become to procure the disposable polyethylene gloves that we normally use at supermarket fruit and vegetable counters. These have quickly become unavailable on the market (like sanitizing gels, masks, nitrile gloves, and so on) because in a few weeks the demand has reached 10 times the supply”, continues Marco Filippini. “Historically, it was at least a decade that the demand for disposable PE gloves was met with the import of the finished product
Extrusion lines
From irrigation system manufacturing to special equipment
A complete extrusion line by Profile Dies
56
from Far East countries (where labour costs are obviously lower). “A grapefruit is just a lemon that has seen an opportunity and has taken advantage of it”, said Oscar Wilde”. “The final result obtained is the result of the seized and pursued opportunity”, adds Filippini. “A servo-drive automatic bag-making machine capable of combining the classic high-speed production of T-shirt bags with that of disposable PE gloves (embossed and not). The guidelines of the new project led us to the creation of a high performance machine capable of realizing different finished product outputs. Reliability, flexibility and speed: these are the drivers that, as always, have pushed us to search for the final solution”. For the production of polyethylene gloves, the welding machine has been configured with a double overlying unwinder (capable of processing reels with a maximum diameter of 1100 mm), an in-line embossing unit and a high-speed die-cutting module up to 200 cycles per minute. At working speed, with the production line distributed
In the plastics extrusion sector for more than 25 years, the Italian company Profile Dies is specialized in the design and production of special equipment and complete systems for producing drip irrigation pipes, films, flat sheets, hollow profiles and sheets tailored to customers’ specific requirements. The company also manufactures extrusion lines for the production of furniture trim (made of PVC, PP or ABS) with thickness ranging from 0.4 to 3 mm, and PE/PP/PC/PMMA hollow sheets and profiles with thickness from 2 to 60 mm (up to 9 layers), as well as extrusion lines for the production of flat sheets with thickness from 0.2 to 15 mm. During the last years, Profile Dies has developed new automated extrusion lines for the production of drip irrigation pipes with flat drippers, which reach a maximum output speed of 250 m/min
Detail of the Saldoflex line for the production of polyethylene gloves
over 4 lanes, the plant guarantees a production capacity of 48,000 gloves per hour. “Our ambition is to be considered a reliable partner, with which to establish a long-term business relationship. Someone you can rely on. That he is technically prepared, able to provide advice and the best solution to the customer’s needs, able to face and manage emergencies and sudden needs”, concluded Marco Filippini, thus summarizing the philosophy that has always guided the operational choices of Saldoflex, founded in 1961 and soon became a reference partner for the plastics processing industry. “A common growth path with our customers: this is the path we have decided to undertake and which guides the choices of our company every day”. www.saldoflex.com
and can insert up to 2,000 drippers per minute with a mechanical or laser drilling machine, and extrusion lines for the production of round drip irrigation pipes with a production speed between 80 and 100 m/min and an inserting capacity up to 400 drippers per minute, to produce pipes with diameter from 16 up to 20 mm. Still with a view to solutions for the irrigation field, Profile Dies has recently presented to the market a new extrusion line for the production of drip-tape. This irrigation system is extremely cheap and suitable for both crops in open fields and gardens. It is easy to install and to remove after use, thanks to the low thickness of the pipe. The new line technical specifications are: maximum output speed up to 200 m/min, spacing (distance between holes) between 10 and 15 cm, minimum wall thickness of 5-6 mils. www.profiledies.com
MACPLAS INTERNATIONAL OCTOBER 2020
Electric machine
A sustainable blow moulding The Plastiblow PB30ES-750 electric blow-moulding machine, with high-efficiency mould, can be used for the production of 20-litre polyethylene stackable tanks with clear strips. Furthermore, this machine is equipped with two post-cooling stations and a parison wall distribution system (PWDS), ensuring optimal wall thickness distribution and extremely fast cycles. The fieldbus architecture with distributed intelligence, for the connection of the various electronic components, allows digital transmission of signals with maximum reliability and at maximum transmission speed, as well as precise synchronisation of electrically driven axes and accurate system di-
agnostics and supervision in real time. The machine has a module making it possible to recover the kinetic energy of the carriages in the deceleration phase and transform it into electricity which is fed back to the machine. The technical solutions (covered by several patents) used to obtain energy-saving servo-driven movements have always been a feature of Plastiblow machines, and they place this Milan-based manufacturer’s machines amongst the ones, in the blow-moulding sector, boasting the lowest energy consumption levels. The head design ensures excellent control of the parison in the extrusion phase and it has been optimised to allow
MACPLAS INTERNATIONAL OCTOBER 2020
rapid colour changes. The control panel is equipped with an integrated device for checking the quality
The fully electric blow-moulding machine PB30ES-750 by Plastiblow
of the flacons, allowing detection and rejection of defective products. www.plastiblow.it
57
ANCILLARIES AND COMPONENTS
IPM CONTINUES ITS R&D DESPITE THE PANDEMIC
END-OF-LINE AUTOMATION FOR POLYPROPYLENE PIPES OF LARGE DIAMETER A NEW PATENTED SYSTEM DEVELOPED BY IPM ALLOWS OVERCOMING DIFFICULTIES IN THE PRODUCTION OF PIPES WITH DIAMETER FROM 110 TO 230 MM, IMPROVING THE LINE PRODUCTIVITY AND THE FINAL PRODUCT QUALITY
O
perating in the field of auxiliary machin- its sleeves”, first of all by contributing with eries, today IPM exports its solutions considerable financial support to the local to 121 countries, with a production Covid-19 health facility, and, at the same of about 300 machines and plants per year time, implementing all anti-Covid-19 regulasuch as haul-offs, cutting units, socketing tions to ensure the safety of its employees, machines, automatic packaging plants, and continuing to study, design, manufacture and bending, threading and slotting machines, not develop new innovative systems for the plasto mention also special machines customized tics market. on customers’ request. The Italian company boasts countless patents and invests heavily and constantly in research and development. Unfortunately, the unexpected pandemic of this 2020 caused by the coronavirus has shaken many activities and production companies. Each of them has seen their forecasts, budgets, projects, and dreams collapsing, and the safeguarding of balances is not so obvious. In this moment of difficulties A BA 400 PP automatic socketing machine and “darkness”, IPM has “rolled up
58
A NEW PATENTED SOCKETING TECHNOLOGY In Northern and Central Europe, where the use of polypropylene is spreading more and more, especially in the field of sewer pipes, a bigger interest has been aroused around the automation of the end of line for large diameter polypropylene pipes. In this regard, however, some difficulties have been encountered, especially in the formation of the socket for such pipes with larger diameter ranging from 110-630 mm. For example, problems such as the possibility to obtain a better internal calibration of the sockets, the shrinkage of the sockets, the need to use reinforced rubber gaskets, the risk of gasket slipping during installation or transport of the pipes, the need to use sleeves, with consequent additional costs etc. To answer to all these aspects IPM MACPLAS INTERNATIONAL OCTOBER 2020
has studied and developed a new patented socketing technology for joining PP pipes, using a combination of the standard blowing system, with a mechanical system, to bypass all the above mentioned problems, ensuring results comparable to products obtained by injection. The new socketing machine is not only able to socket PP pipes of big size with stability, but it has been also designed to offer a very high production. By making hydraulic modifications, the idle times have been reduced to a minimum, and consequently machine cycle times have been speeded up. From the point of view of energy saving, in addition to the contact ovens of the machine, that are insulated to reduce heat dispersion, a short wave oven was added, that is able to guarantee high production and to reduce energy consumption, since it is able to switch on and work only when the pipes enter in it, without heat losses. The whole process optimization included also an automatic lubrication system that has been adopted to allow the required quantity of lubricant to be dosed with precision and repeatability. The automatic gasket inserter can work up to two pipes at the same time, and can be
MACPLAS INTERNATIONAL OCTOBER 2020
Packaging plant for pipes of large diameter up to 630 mm
equipped with a special patented device that performs the automatic checking of the seal of the gasket, consequently signalling eventual defective sockets and rejecting them. This device allows to implement the complete level of line automation, since all operations of manual insertion and/or seal control of the gaskets are avoided, thus guaranteeing the total autonomy of the line itself and the automatic feeding of the pipes produced that are brought to new automatic packaging systems: these are capable to place the pipes, for example, in wood-
en frames, cardboard boxes, iron boxes, polyethylene film, plastic saddles etc. in order to satisfy the demands of ever-growing customers, guaranteeing limited space, high performance, and maximum safety. In order to fit to the space available at the various processors’ sites, while always maintaining the high performances required, IPM technicians took advantage of Cartesian systems, anthropomorphic arms, suction pipe collection systems, and new safety systems to ensure maximum safety for each operator. www.ipm-italy.it
59
ANCILLARIES AND COMPONENTS
MAST DURING AND AFTER LOCKDOWN
RESILIENCE: THE KEYWORD FOR A COMPANY AND ITS PRODUCTS THE MACPLAS JOURNALISTS TALKED TO CARLO ARIOLI BY PHONE, AND HE TOLD US HOW HIS COMPANY, MAST, HAS HANDLED THE LOCKDOWN AND THE ENSUING ECONOMIC CRISIS. WITHOUT MAKING LIGHT OF THE DIFFICULTIES, BUT RATHER LOOKING TO THE FUTURE WITH OPTIMISM AND CONFIDENCE IN THE COMPANY’S RESOURCES AND ABILITIES
G
iving no indication of subsiding and actually showing an upturn in several countries, the coronavirus pandemic has affected and continues to affect the world’s economy and how companies operate globally, even though some experts believe that, at least in Italy, despite the multiple undeniable challenges, things are not going quite so badly as it seemed just a few weeks ago. This is an opinion that, though we need to treat with due caution, suggests a positive turn for our country, to be interpreted as the ability of its economic system to withstand and react to the impact of difficult moments. Credit for this is given to SMEs, which account for the largest share of Italy’s economy. One of these entreprises is Mast, based in Solbiate con Cagno, near Como, which specialises in the construction of screws and barrels MACPLAS INTERNATIONAL OCTOBER 2020
destined primarily for extrusion lines. As its owner, Carlo Arioli, tells us without making light of the difficult current times, the company has weathered the impact of the coronavirus crisis and forced it to tackle this initial stage living day by day. This is in part because in the first days of the lockdown, the industry was thrown off track by unpredictable and unexpected events. “On a daily basis, decrees and regulations were changed, just as they are still being constantly changed. Everything happened with no warning from one day to the next and, as a result, without the chance to put down a plan”, Arioli says. Based on Italy’s classification of business categories (Ateco codes), Mast was able to carry on working, but in the early days of lockdown it was forced to a stop, because the “rug was pulled out from under” the company, in the
Magic MP
BY LUCA MEI
Carlo Arioli, owner of Mast, photographed at the annual Amaplast general meeting, held last September
61
ANCILLARIES AND COMPONENTS Barrels for twin screw extruders
words of Carlo Arioli, because the same thing was happening to all its suppliers. And while one of the company’s strengths, stated without false modesty, lies in its ability to handle many stages of its production cycle in-house, the impact of the sudden halt reverberated throughout the pipeline, making raw and consumable materials scarce, and making it difficult to do some kinds of jobs, such as heat treatments. “The true lockdown came for us later on when, having used up the stocks that we had accumulated and had been carrying forward, the orders stopped coming. We were unable to pick things back up”, Arioli says, explaining that, “in fact, we began to reduce work hours in June and July, and in September we worked at a slower pace, too”.
LOOKING BEYOND THE PANDEMIC But, as we said, Mast is an Italian SME capable of doing (almost) everything in-house, whose beating heart is its metalworking department. So, with little smart working, which is not suited to its type of business except for the administrative and commercial side of things - both handled by no more than three people - work hours were reduced by up to 20% after the summer break and, in particular, a lot of work was done on field. Beginning with customer relations, which never stopped but which had to be reinvented, with a drive and desire to exploit its value in order to overcome reciprocal difficulties, as well as to seize opportunities given after the “restart” following healthcare guidelines to stop the spread of contagion. A disenchantment of sorts gave rise to resilience with the aim Machining of a screw with a diameter of 30 mm
62
of addressing and if possible overcoming the crisis. Clients become the true strength in this challenge, driving production and innovation at Mast and becoming the focus of the company’s efforts and rewards. The company, in fact, is a typical subcontractor, a kind of manufacturer easily found in many industrial areas around the world. In practice, Mast does not manufacture its own products, but it makes screws and barrels for major manufacturers of extrusion lines or for the users of extrusion plants and, therefore, it has to keep into account the final use of this equipment. “Innovation for us comes from client specifications. This means processing new materials, using new types of steel and new coatings for screws and barrels, developing new profiles for screws - and we must be ready to
do what is asked of us. As we know, plastic is in the line of fire for reasons associated with the environment and nature and, therefore, in particular, new biodegradable materials are being developed, which however pose numerous problems in the development stage in terms of corrosion and wear on screws and barrels. So, as far as we are concerned, we are moving towards the use of new types of steel, in particular sintered steels, to give screws and barrels similarly new characteristics and properties”, Carlo Arioli points out. “Research and development is focused more on screws than barrels. As far as co-rotating extruders are concerned, for example, screws are made in segments, in sectors, which are made from sintered steel”. On an equal footing with technological development, pandemic apart, Mast is moving forward with an investment plan to modernise its facilities. The works originally planned at the current site were soon set aside, because it would not have been possible to adapt premises built almost a century ago to the growing needs of the company and modern industrial operations. Currently, the project involves the construction of a new facility, which according to the company’s plans should be ready between the end of 2022 and early 2023, taking into account already lengthy bureaucracy procedures being made even more difficult by coronavirus. The intention is not only to expand the space available for offices and workshops, but also to improve the organisational side of things, to be achieved in part through the gradual replacement of machinery as per the investment plan. “We look forward in any case with optimism. Not recklessly, but, I repeat, with due optimism”, Carlo Arioli concludes. www.mastsrl.it MACPLAS INTERNATIONAL OCTOBER 2020
RUBBER OR THERMOPLASTIC? BOTH IN ONE SOLUTION
ThermoplasTic copolyesTer elasTomers
Via Leonardo Da Vinci, 5 - 27036 MORTARA (PV) - Italy Tel. +39 0384 295237 • Fax + 39 0384 295084 sipol@sipol.com • www.sipol.com
ANCILLARIES AND COMPONENTS
FIMIC LIKES CHALLENGES
TIMES CHANGE, RECYCLING CHANGES WITH AN EXPERIENCE OF MORE THAN 50 YEARS, NOW FIMIC DEVELOPS RECYCLING SYSTEMS TO RECOVER MATERIALS BEFORE CONSIDERED TOO COMPLICATED TO BE TREATED AND THEREFORE NEGLECTED. WITH IMPORTANT RESULTS IN TERM BOTH ECONOMIC AND ENVIRONMENTAL
A
leading player in the plastics recycling market for more than 50 years, Fimic is now widely known, and appreciated, for its self-cleaning filters for plastic waste recycling. Its flagship machine, the RAS scraping melt filter, has demonstrated to the industry how it is possible to manage complicated and heavily contaminated plastics to obtain excellent quality pellets. The company has been able to meet
64
the market needs, which have become increasingly demanding over the years. The need to be able to produce materials that could be reused in more sophisticated applications has grown exponentially over the past ten years. For this reason, Fimic has focused on continuous research and development, reaching filtrations up to 80 microns, through the use of the latest laser-drilling technologies that made it possible to perform a very large number of holes on metal sheets of different thicknesses, accurately choosing several parameters (type of material, distance between holes, treatments etc.). A WEEE scrap The company’s experience has
been based for years on the typical polymers intended for recycling, like LDPE and LLDPE from packaging, PP from crates, bins or big bags, HDPE from pipes or bottles etc. Fimic has over time managed these materials better and better and with proportionally lower operational costs. To date, the RAS filter can manage LDPE and LLDPE from post-consumer packaging (for example wrap films, including paper labels) to obtain a pellet quality that can be used to extrude new film up to 17-20 microns. Or it can process HDPE from bottles regrinds, which is filtered up to 100 microns even at high outputs (1500-1800 kg/h) to produce excellent-quality, heavy-duty HDPE pipes.
TREATING PVC AND WEEE SCRAPS But times changed and plastic recycling can MACPLAS INTERNATIONAL OCTOBER 2020
no longer be limited to the regeneration of just a few materials, no matter how predominant they are. The society itself requires greater and greater efforts to prevent plastic from becoming a problem instead of a great resource. Confident of its previous experience, Fimic has therefore decided to turn its attention even to applications that were always considered more complicated and that were therefore neglected. In particular, two fields were heavily explored: PVC (soft and hard), considered a material that has to be carefully treated, given the possibility of the release of the dangerous vinyl chloride and in general for its corrosiveness over time and its tendency to degrade; plastics that come from the recovery of WEEE (Waste Electrical and Electronic Equipment), which can contain contaminants sometimes difficult to manage. In both cases, the company entered only after extensive internal research and tests were completed, before installing the machine for end users. In the PVC field, after about three years of testing, the machine was first installed at a large player in Germany. This company pro-
MACPLAS INTERNATIONAL OCTOBER 2020
Granules obtained after the recovering and the recycling of WEEE scraps
cesses soft PVC from garden hoses, with contamination mainly composed of fibres (PES or PA, from 0.5% up to 4%) in addition to other minor contaminants such as dust, wood, and aluminium. Previously, the company used slide plate filters, but was unable to process the material at less than 400 microns (40 mesh) and was forced to change the screens frequently. With the RAS filter, it can now work continuously for 4-6 days, before having to change the screen (an operation that takes less than 30 minutes from a single operator), as well as reducing the filtration fineness (and therefore
increasing the quality of the finished product) to 150 microns (100 mesh). As for the risk of corrosion, the filtering chamber has been completely treated against it, and it has been verified that the material always flows continuously inside the machine and therefore there is no risk of material degradation. As for plastics waste coming from WEEE, the first Fimic machines were installed in Scandinavia, at a company reprocessing ABS and PS regrinds, coming indeed from the recovery of electronic waste. The change for the customer was truly remarkable. From the need to constantly employ four operators for two lines, now only one is needed. The savings are therefore significant, in terms both of personnel and operational costs, as it switched from typically one screen change every 15 minutes (on a slide plate filter) to a Fimic laser screen for up to three months in a row, with no need to intervene. Plus, the production of the extruder has increased by 20%, despite reducing filtration fineness down to 150 microns. www.fimic.it
65
ANCILLARIES AND COMPONENTS
THREE GENERATIONS AT EUROVITI
MORE THAN A QUARTER OF A CENTURY IN THE SCREW MANUFACTURING A
ctive since 1992 on national and international markets, Euroviti was born by an initiative of Giuseppe Barrale, his brother Andrea Barrale (current president) and other partners from Brescia, Italy. Euroviti immediately established itself in the markets of Italian injection moulding machinery manufacturers and began looking for opportunities on international markets to increase visibility and business opportunities. It quickly established itself in Turkey and South America, where emerged that the market for PVC pipes and
A processing phase
MACPLAS INTERNATIONAL OCTOBER 2020
IN THE COURSE OF ALMOST THREE DECADES OF ACTIVITY, EUROVITI HAS PRODUCED HUNDREDS OF THOUSANDS OF SCREWS FOR DIFFERENT APPLICATIONS IN THE FIELD OF INJECTION MOULDING, EXTRUSION AND RECYCLING, TO NAME BUT A FEW
blown film could give very great results and highly satisfactory feedbacks, which in a few years affirmed Euroviti as one of the best after market players in those areas. With the Italian injection moulding machines manufacturers crisis, between 2005 and 2010, Euroviti began to search for new horizons and new market positions. It opened a commercial office in Annecy, France, in 2006, in order to be closer to its French customers, while in Italy it started looking for new customers amongst end-users, creating and counting relations with internationally renowned names linked to the PVC pipe and profile markets, blown film and cable, with great success. A collaboration later followed in Moscow with a very important partner who helped developing the Russian market. In 2011 the company bought SBI, a com-
petitor that in the early 2000s had customers inside and outside the national borders. At the same time the current technical director joined the company, also coming from SBI, capable of designing single screw, and injection and extrusion profiles for any polymer to be processed, thus improving performance, mixing, plasticizing and energy saving. Furthermore, by exploiting SBI’s commercial network, Euroviti faced the international market more widely, affirming itself especially in twin-screw spare parts, where Euroviti still has great relevance today. Latent in the injection moulding market, a new project started in 2018. The inclusion of two nationally and internationally recognized figures as injection sales directors, both for the Italian and the foreign market, plus a new pro-
67
ANCILLARIES AND COMPONENTS
duction manager. Today Euroviti faces the injection market with an implemented knowhow, and the knowledge gained in injection allows it to respond quickly to customer queries. Thanks to a large warehouse, a series of spare parts from the German, Austrian and Italian IMMs manufacturers can be delivered within 24 hours. The warehouse of bimetallic liners (or barrels), with hole diameters from 18 to 130 mm, allows for delivering a complete injection unit in three weeks. The new Italian injection sales director has 20 years of experience with international users and is a skilled connoisseur of injection moulding machines and plasticizing processes, the ideal figure to help customers in solving problems. Thanks to the work of the new export manager, new relationships are being established with new costumers and dealers across the Alps and beyond. A very important component is added to the team in solving injection moulding problems. Expert in the use and maintenance of IMMs, and project developer from the Kunststoff Institute Lüdenscheid, he has worked in Stork and Engel companies. The acquired skills during his 30 years’ experience allow for supporting Euroviti and solving plasticizing process problems. Giuseppe Barrale’s son and granddaughter, Dario and Elena, collected his inheritance. After joining the company at the end of the Nineties, the first began working on machine tools and then moved on to managing Euroviti technical office. With the help of a team of designers, he has the possibility to make checks and evaluations on costumer’s site, both in Italy and abroad, with the possibility of dimensional measurements on the samples, and then proceeding to mechanical construction. The investments in software made in recent years, give a greater guarantee of the finished product, precisely verifying the appropriate clearance and timing on the parallel and conical twin screw. His granddaughter was always at
Particular of a screw
68
the high efficiency in plasticizing, mixing and melting give them all the qualities to satisfy all requests. Finally, HPE are customized screws for extruders. These screws do not have a defined profile because are dedicated to multiple applications including pipes, profiles, and cables, film extrusion, recycling, rubber process, and more. Depending on the customization, their best performance consists in the increase of the output from 30 to 40%, in the better mixing, in the high efficiency in the dispersion of masters.
BIMETALLIC ALLOYS
The different sectors of twin screws
his side, learning his technicality and collecting his commercial legacy following the national and international markets mainly in the world of extrusion. More and more demanding, customers turn to Euroviti in search of technology and much more. Ad hoc solutions are designed daily, speed in responses, speed in solutions, choice of the steels to be used, alloys, armouring, coatings and special steels are the know-how that allows the company to provide long-lasting and effective solutions.
Euroviti uses four bimetallic liners (barrels): anti-abrasion EUV100, anti-corrosion EUV200, a mix of anti-abrasion and anti-corrosion EUV400 (the most used), and EUV1000W. EUV100 is an iron-based alloy containing percentages of Ni/B/C with hardness ranging from 58 to 65 HRC, used exclusively to counteract abrasion. EUV200 is an iron/chromium-based alloy containing percentages of Ni/Cr/B with hardness ranging from 48 to 56 HRC, mainly used to counteract corrosion. EUV400 is a nickel-based alloy containing percentages of Ni/Mo/C/B with hardness ranging from 64 to 69 HRC. It is the liner most used due to its effectiveness against both abrasion and corrosion. EUV1000W is an alloy with high percentages of tungsten carbide immersed in a nickel matrix, with hardness ranging from 58 to 66 HRC. It is the nonplus-ultra bimetallic liner that currently exists on the market, and the most suitable solution when extreme corrosion and extreme abrasion coexist.
DESIGN The three screw profiles - HPS (High Performance Screw), HPB (High Performance Barrier), and HPE (High Perfomance Extrusion) are elements of the Euroviti know-how, which allow it to give a very important added value. Linked to them are the types of steels and coatings that are effective in countering wear and corrosion. HPS are customized profiles dedicated to the IMMs. They consist in screws with variable pitch, which allow to reduce the feeding times, to obtain energy savings from 10 to 20% in comparison to standard screws, to reduce the breakage of long fibres and to obtain an excellent quality of the melt. For mixing or homogenization problems, a mixer can be added at the end of the screw. Also HPB are customized profiles dedicated to the IMMs. They are transfer screws, and have a laminating effect avoiding the presence of unmelted material. The increase in volume, the reduction in cycle time up to 40% compared to standard screws,
KNOW HOW Tens of years of history, hundreds of thousands of pieces produced, different categories of products destined for injection moulding, extrusion, regeneration, recycling, and others give the company a very broad knowledge of possible problems. To what described so far, the knowledge of the whole world of parallel, conical, and self-cleaning corotating twin screws has to be added. Giuseppe Barrale left a great commercial and technical legacy of these sectors. As for parallel screws, mostly used for pipes, compound, and regeneration, the company proposes different solutions to counteract the most filled materials. Helix armouring with iron, nickel, or molybdenum-based alloys according to the characteristics of the compounds to be processed. As for parallel, conical, and corotating screws, Euroviti can faithfully recreate components made by the largest European manufacturers. www.euroviti.com MACPLAS INTERNATIONAL OCTOBER 2020
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
EXE_VANETTI_ANN_MACPLAST_INTERNATIONAL_210X297+3mm_EN_A40_20.indd 1
21/07/20 11:22
ANCILLARIES AND COMPONENTS
A YOUNG COMPANY DESIGNING MACHINES FOR RECYCLING PLASTICS, BREAK POLYMER HAS DEVELOPED A SCREENCHANGER ABLE TO REGENERATE VERY CONTAMINATED MATERIALS, REDUCING THE OPERATOR WORK, SPEEDING THE PRODUCTION, AND IMPROVING PRODUCT QUALITY
RECYCLING SYSTEMS
TAKE A… BREAK! D
ynamic and young company specialized in the design of machines for the recycling of plastic materials, Break Polymer developed the Break automatic continuous self-cleaning filter for the removal of impurities from compounds, thus obtaining high quality products even from highly contaminated plastic materials. The Italian company Break Polymer was born with the goal of adding value to the plastic material to be processed and aims to become one of the worldwide benchmark for the decontamination of plastic materials. Its automatic filtering machines are built according to the highest standards of mechanical design, with filtration technology ensuring excellent quality standards and reliability. The innovative Break systems can be easily integrated into the existing process chain in order to deliver the highest quality. The company focus is
70
to reduce operating costs, optimize production processes and save energy for the entire production plant. Break Polymer researches and develops innovative technologies capable of satisfying the need of regenerated plastic material. All its R&D investments are strongly oriented towards the “cradle to cradle” sustainable approach, which stimulates to reuse materials after the end of the products life. With the development of Break, the automatic self-cleaning filter for recycling plastic materials at high filtration levels, it is now possible to produce high quality products even from highly contaminated plastic compounds. Break is suitable for production lines of recycled granules, masterbatch and compound granules, adhesives (hot melt), tubular or flat films, sheets for thermoforming, pipes and profiles, cable covering.
HOW IT WORKS AND HOW TO USE IT The Break automatic screenchanger eliminates impurities down to 80 microns and is able to operate up to a temperature of 300°C and a pressure of 240 bar without degradation of the treated material. It guarantees an uninterrupted material flow without significant pressure variations. The extruder pushes the contaminated plastic material into the screenchanger, where a metallic mesh screen or a perforated steel screen (punched or laser micro-perforated) takes care to filtrate the plastic material. Depending on the cleaning mode set, the impurities of the plastic compound blocked by the screen are discharged through the automatic opening of the valve, with minimum waste percentages. Unlike conventional screenchangers, which require the constant intervention and attention of an operator, Break screenchanger can work autoMACPLAS INTERNATIONAL OCTOBER 2020
matically and without interruptions. As for the working mode, it allows two types of cleaning in one machine. The automatic filter is designed to adapt to the most varied filtration requirements and to the impurities present in the plastic material. This approach leads to the creation of two different filtration systems. Scraping cleaning system The scraping process uses a thick steel breaker coupled with a second breaker, that has the goal of improving the passage and increase the flow of plastic material, especially for the finest filtrations setting, and a perforated interchangeable screen for a filtration from 100 to 2000 microns. A two-blade impeller acts on the screen, suitably spaced from the screen not to damage it during scraping cleaning. The impeller blade holder is hollow to collect impurities and is connected to a discharge valve for the expulsion of contaminated material. It is also possible to adjust the rotation speed of the impeller and the opening time of the discharge valve in order to optimize the filtration process. The scraping cleaning system can be set in two modes. The “pressure mode” is regulated by a sensor that detects the pressure of the material inside the filtration chamber. During the filtration process the pressure tends to increase due to the increase of impurities that accumulate on the filtering section. Once the pre-set pressure level is reached, the screen cleaning is automatically activated by removing the impurities through the discharge valve. The “continuous mode” involves a constant rotation of the impeller and therefore a continuous cleaning of the screen. This operation mode is recommended when the plastic material contains a high level of impurities. The discharge
A possible layout of a line with the Break system installed
is set at time intervals regulated by a timer, bypassed in case a pre-set internal warning pressure is reached. With scraping cleaning, the waste rates are very low and are close to 1% of the hourly production. Backflush cleaning system The backflush process is suitable for slightly contaminated materials or for a possible second filtration and is suitable for filtrations from 80 to 300 microns. The Break automatic screenchanger elements can be easily replaced to switch from scraping to backflush mode. In this case, three parts are used: a wire mesh screen instead of perforated steel screen; an additional protection breaker; a cleaner connected to the discharge valve that replaces the blade-holder impeller. The backflush system uses the pressure generated by the extruder to filter out the impurities. When the pre-set pressure value is reached, the cleaner starts to turn automatically and at the same time the discharge valve opens to eliminate the impurities that clog the wire mesh. With backflush cleaning, the percentage of waste can reach a maximum of 5% of the A detail of the hourly production. Break system with the graphic representation of the processed material flow
MACPLAS INTERNATIONAL OCTOBER 2020
Switching from scraping to backflush cleaning The average time to change from one cleaning system to another is about 15-20 minutes. This is because it is possible to access the heart of the machine simply by unscrewing with a wheel gun the nuts that secure the cover to the filtration chamber and
then replace the three accessories and switch to the other cleaning system, saving machine downtime and therefore hourly production. All the adjustments and operating parameters of the machine can be customized according to the customer’s needs and this allows a great versatility of use and to optimize the production process in the best way. Whatever the cleaning method used, the Break automatic self-cleaning screenchanger guarantees high purity of the treated plastic material and this is why it is suitable for recycling plastic contaminated by any material such as metals, wood and derivatives, rubber, glass, cellulose etc.
MAINTENANCE AND CUSTOMIZATION Routine maintenance of the Break automatic screenchanger has been considerably simplified compared to traditional self-cleaning screenchangers. In case you need to change the perforated steel screen or metallic mesh screen, the heart of the machine can be reached in just 10 minutes by simply unscrewing with a wheel gun the nuts that secure the cover to the filtration chamber. Then, just replacing the screen and mounting the spare impeller supplied with the system, the production can be restarted in about 20 minutes in total. The operation takes place according to the frequency of use and the quantity of contaminants present, but it is also possible to change the screens only once a week, greatly reducing machine downtime and thus increasing production. The control environment of the filter is made simple by a system architecture with sector control and can be customized with touchscreen displays, agreeing with the customer the graphic layout and the desired reading parameters. Break can be connected with the company communication network 4.0. The machine is also designed for assembly according to the customer’s needs, with dedicated inlet and outlet flanges. www.breakpolymer.com
71
ANCILLARIES AND COMPONENTS
NEWS New hot runner technology
Increasing quality in cascade injection moulding New and advanced developments around HRSflow’s hot runner systems are specially designed to increase product quality in cascade injection moulding. This includes the only recently launched HyFlow technology developed for applications with hydraulically actuated cylinders, in which the opening and closing speeds and the positioning of each individual pin can be precisely adjusted via the oil flow rate. Now also available in the market is the Hyper-GF series for processing abrasive thermoplastics. On the application side, HRSflow uses a current pilot project to show how Flexflow Evo (the recently presented advancement of the Flexflow technology for servo-electrically driven valve gate systems) can be used to achieve outstanding results when back-moulding sensitive films. HyFlow uses a controller with
HyFlow, the recently introduced development to control the needles’ opening and closing speeds in hydraulically actuated cylinders, is available as complete or - when applied to selected actuators only as hybrid version
72
One of most promising application trends for Flexflow Evo includes back-injection of films, here using the example of the HMI concept panel with backlight functions and integrated capacitive sensor
a user-friendly interface to set the lock position of each individual pin. The opening and closing speed for each nozzle can be set by a manual adjustment mechanism. This allows for controlling the melt flow rate in a way that cascade injection moulding results in a uniform mould filling process without sudden pressure drops and the associated surface defects. The positio-
ning of the pin also allows for optimal balancing of the pressure distribution in the cavity during the entire injection process. The new Hyper-GF series, available for HRSflow’s Ga and Aa nozzles, is designed to improve the long term performance of the hot runner system when processing highly abrasive materials such as glass fibre reinforced ma-
terials. It supports extended service lives even in injection moulding processes with very high productivity. Contributing factors include the use of special steels and an optimized flow channel design. The possibilities offered by the Flexflow Evo hot runner system for film insert moulding (FIM) are demonstrated in a joint project with the film manufacturer Kurz (Fürth, Germany). This pioneering technology enables, for example, the integration of capacitive films for sensors or touch control panels in combination with backlit decorative films. This provides a previously unknown design and functional flexibility, especially for automotive interior applications. In cooperation with Kurz, a film featuring functional capacitive elements for touch operation and decorative elements was back-injected with a crystal clear polycarbonate (PC) in a single step, enabling backlighting in the area of the operating elements. The servo driven valve gate technology produced results of a quality level that would not be achievable with conventional concepts. In particular, after back-injection with the Flexflow Evo technology, the thin functional and decorative elements do not show internal stress as in conventional cascade injection moulding, thanks to the evenly and low-pressure spreading melt flow front, whilst any damage to the film was reliably avoided. www.hrsflow.com
MACPLAS INTERNATIONAL OCTOBER 2020
ROAD TO
AUSTRALIA Euroviti expands its horizons reaching the Australian market with its core product: Twin Screws
INJECTION
MONO SCREW EXTRUSION
TWIN PARALLEL
CONICAL SET
SPECIAL APPLICATIONS
CO-ROTATING
Via per Ospitaletto, 159 25046 - Cazzago San Mar tino (BS) Italy info@euroviti.com T. +39 030 7750520 / F. +39 030 7751075
www.euroviti.com
ANCILLARIES AND COMPONENTS
NEWS Recently launched and bestsellers by Star Automation Europe
A Hall of Fame of greatest achievements The ZPX-1000 robot
Amongst the recently launched or bestsellers of the Star Automation Europe robot portfolio, the ZPX-1000 model is even faster than the ZXW-VI series and has been designed for those processors who do not simply settle for average results, but always aim at the highest performance levels. Its vertical axis is entirely carbon-made, allowing the machine to obtain outstanding results in terms of speed and cycle time, never achieved before. The not-to-be missed XW-1000VI model is then an unrivalled protagonist and a bestseller of the company range. The “servo-head” accessory, composed of two servomotors, ensuring maximum freedom inside and outside the mould, is also installed on the robot vertical arm. The ZXW-1600VI, the “big brother” of the above mentioned ZXW-VI series, is able to combine large dimensions with high speed. Both robots are controlled by the fully programmable Stec520 and they are handling EOATs entirely made with Eins components. The Stec-520 controller has been recently sided by the new Stec-620A controller as a flagship of the range. Thanks to its completely reviewed operative system, Stec-620A guarantees flawless integration into the command panel of the IMM (Injection Moulding Machine), thus making the operator work much easier. The range of Star Automation Europe also includes solution as the I-70IVSII pallet changer, to confirm that the company can play the role of exclusive partner for the total automation of extraction and palletizing operations on the IMM side. www.star-europe.com
74
The Perfect Vortex according to Mixaco
Bread and butter in PVC mixing When it comes to high-quality and will cause the mixer to start vibrating badhigh-performance mixing, there is more ly. If the tip speed is too high (>35-40 m/s), than just raw materials in a bowl with the material is pushed up and to the side tools. In PVC mixing that means more walls, while creating a huge vacuum in the than 10 batches/h with a superb efficien- centre. The material will have no top-down cy. When the desire is to obtain these out- movement and a high radial motion. This standing performances, Mixaco proposes is called “Donut-Mixing”, where the quality the perfect Mixing Vortex. In hot mix- of the blend decreases significantly. ers, the vortex is describing the flow The filling level of the heating mixer is an of the material as it moves inside the important parameter in creating the best mixing bowl. It is specified as a materi- vortex. In general, the heating mixer is al-free zone, which is formed by the speed designed to work with a certain amount and gravity achieved by the design of mix- of material inside. The useful and recoming tools and vessels. In a vortex, there mended volume in Mixaco is 85%. Based are different movements (combined vec- on this, the vessels, tools, and motors are tors). The bottom blade mainly creates a engineered. With a low filling level, the vertical upwards movement and pushing mixer cannot create much downforce. As the material to the sides, while the mid- a result, the blend is pushed upwards and dle tools only create a radial remains at the top of the vesforce. Due to the speed of the sel and the tools are moving blades, a centrifugal force is without touching much macreated (radial vector). The material. The mixing effect is terial gets pressed to the side very less. The vortex needs a walls of the bowl and a vacuum space to move (free volume), is created in the middle. Thereespecially when it heats up fore, the material is dragged to the PVC particles get bloated the shaft (horizontal vector) and and use more volume. If the pulled down (vertical vector), mixer is overfilled, the vortex which creates the vortex. This will not move efficiently and is enhanced by the special enthere is a danger of blowing gineered bowl design. In addithe filter or lid connections. A tion, turbulences created by more challenging way to afthe mixing tools improve friction fect the vortex is by changand blending performance. ing blade design or enhancThe Vortex can be affected by ing the blade configuration. many factors during the mixThere are a lot of different ing process and it is importblade designs on the marant to know the influences of Different movements ket. The truth of the matter is in a vortex each of these factors. Some of most of the current designs the most common and easiest practices are just revisions of the old designs. The are the following: tip speed; filling level; revised and newer blade designs achieve blades. An easy way to control the vor- a better vortex. If the blend used is very tex is the tip speed of the mixing tools. By light or has a big spread of different bulk changing the speed, the centrifugal force densities, it is helpful to change the blade is strongly affected. The perfect tip speed configuration. Light materials tend to keep depends on the raw materials, blade, at the top of the mixer and do not homogand vessel design. The best range of tip enize well in the whole blend. Moreover, speed is always mentioned by the suppli- this can occur with very fluidized blends. If er. If the tip speed of the blades is too low so, the blades can be lowered to achieve (<20 m/s), there is no vacuum created in more space for the materials to collapse the middle of the bowl and no horizontal in the centre of the bowl creating the best movement. Additionally, many times this vortex. www.mixaco.com MACPLAS INTERNATIONAL OCTOBER 2020
Baruffaldi-Primac renews its logos
Image aligned with the technological development Pandemic did not stopped Baruffaldi-Primac. On the contrary, the company has recently renewed its logos to update and evolve its image, aligning it to that of its latest generation machines that stand out for their high-tech level. Baruffaldi is an Italian company which has designed and manufactured machines for plastic profiles since 1953. The Baruffaldi “B” in the logo is a robust, compact and dynamic frame just like the Dosi Group, of which the company is part. The “B” conveys the concept of a solid group that works in synergy and is always up-to-date with the latest technologies. The new logo has an elegant and dynamic style just like the company, which has never stopped making a name for itself in the last 70 years, as an Italian excellence in high-technology solutions for the extrusion of plastic profiles. “Plastic” and “technology” are the keywords of the Baruffaldi brand and the new logo reinforces the identity of its machines. The Primac logo has been completely renewed both in its form and concept, but it always maintains the red colour that distinguishes it. “Machines for plastic pipes” and “by Baruffaldi” added to the new Primac logo immediately clarify the brand positioning. “The core is always the same, we only innovated our logos. We did not change our goal, we made it clearer, to immediately convey our mission”. This is how Alberto Dosi, the company CEO, proudly describes the change. In the course of 2020 Baruffaldi technical team designed and manufactured two new machines: the MM100, an automatic line for the production of surgical face masks and the TGG-HB-V, the vertical version of the patented hot blade guillotine. The MM100 is an automatic line that welds the three TNT layers specially folded and cut and the ear bands. At the end of the line the masks are automatically stacked by means of a palletizer. The first line sold supplies face masks to the Italian regional health facilities. With the TGG-HB-V Baruffaldi expanded the range of guillotines for profiles becoming the specialist of the swarfless cutting systems. This latest version of the hot blade guillotine is equipped with the exclusive vertical cutting system and blade heating system. Thanks to this technological upgrade the machine is extremely versatile. www.baruffaldi.eu
The recently renewed logos of Baruffaldi and Primac MACPLAS INTERNATIONAL OCTOBER 2020
75
ANCILLARIES AND COMPONENTS
An S20-S Sytrama robot
NEWS Sytrama wide range of products
The answer for growth, competitiveness and innovation Research and development on products and processes, joint to give the best response to customer needs, is the common thread that has distinguished Sytrama for 40 years. The company features a wide range of Cartesian robots for IMM from 40 to 6000 tons, produced in Italy with components from leading European companies, managed by a single control system for all the technologically advanced automatic solutions, and able to satisfy all safety regulations thanks to integrated PLCs and safe drives. In addition, in the control panels, an ethernet connection is available for remote connection through the Internet via VPN which, together with the presence of the UPC-UA protocol, position the product at the highest levels of the market; robots and automations are therefore managed by a control system that centralizes all information, allowing easier and more immediate supervision and diagnosis. In addition to Cartesian robots, the product range extends to anthro-
pomorphic robots of leading brands, also integrated with the Sytrama SCP2 control, offering a standard user interface for both 3 and 6-axis robots, regardless of the model. Also there is a wide range of turnkey solutions for automation dedicated to moulding factories: IML systems, insert loading, comoulding, sprue cutting, welding, flaming, marking, assembly and all that can be needed for a 4.0 Factory. These solutions, together with the flexibility particularly appreciated by international customers, have allowed the company to collaborate with the largest groups in the automotive sector and beyond, providing numerous automatic cells. As a demonstration of this, a recent and important success concerns the supply of a system to produce car bumpers, designed to work 24 hours per day, and able to perform the production change in a few minutes, without setup interventions by the operators. www.sytrama.com
Screen changers for extrusion lines
Turnkey package for continuous flow With an output rate up to 1,200 screen changers per year, BD Plast confirms itself as the favourite partner of extrusion line manufacturers in Italy, Europe, North America and Asia. BDOx3 BF is a triple-plate continuous flow back flushing screen changer. The result of an accurate study deriving from a number of machines already tested in several applications, it represents a technical solution which is quite different from those most commonly seen on the market. First of its kind, it provides an automatic system for extracting the filtering packs, completely controlled by PLC. This system considerably simplifies and speeds up the replacement operations of screen packs, offering a high level of automation
76
and ensuring a full efficiency advantage. The extremely effective back flushing system allows the reduction, up to two thirds, of the amount of purged polymer thus generating a significant reduction of waste. During the replacement of screen packs, the polymer discharge channels are inspectable and easily accessible in case of obstruction. Both during the back flushing phases and the replacement of the filtering media, 66% of the total filtering area remains in the working position, allowing high flow continuity and pressure homogeneity. The purged polymer is then collected in a cooling tank, connected to the protections by means of a magnetic sensor, so as to guarantee absolute safety during the ma-
BDOx3 BF triple-plate continuous flow back flushing screen changer
terial purging phases. The machine is combined with a PLC control system, equipped with a touch screen that permits the most extensive adjustment of the functions of the cleaning cycles as well as remote control via LAN. BDOx-6 is a double-plate continuous flow changer with optimized flow channels. The sixth generation of continuous flow screen changers has been subjected to a careful ergonomic and functional study, which has led to a significant reduction of the angle between the flow channels - from 100° to 40° inclination. The polymer stream is therefore much more linear and favourable in terms of flow. The overall dimensions have been reduced (by 20%), as well as the num-
ber of components, in order to obtain a simpler but at the same time more performing product. The level of safety has been significantly increased by adopting coded and certified “performance level E” magnetic sensors, interconnecting the position control sensors of the screen changer plates with the hydraulic control unit in a crossed and redundant way. BDLG is a manual changer with gear and ratchet drive. An accurate study made it possible to create units of medium-large filtering area on more compact and rigid machine housings. The reduction of the mass led to a 20% reduction of energy consumption, emphasizing the company’s sensitivity towards an eco-compatible approach. www.bdplast.com
MACPLAS INTERNATIONAL OCTOBER 2020
ANCILLARIES AND COMPONENTS
NEWS Zambello Riduttori “on the job” since 1957
The best means of reducing engine speed A gearbox is the most classic transmission element, and it essentially consists of gears positioned between the machine to be driven and the engine that supplies the power to the machine itself. The main purpose of mechanical gearboxes is that of limiting the rapidity of power transmission, so that the final speed of the machine and the motor torque are actually compatible with each other, obviously with reference to the application involved. The mechanical gearbox still today remains the best means of reducing engine speed, whatever type it may be, and for increasing the operational torque maintaining the same power levels - always with a good degree of approximation. Today Zambello Riduttori is one of the point of reference amongst the manufacturers of gearboxes for the leading rubber and plastics processing machinery manufacturers. At present, the company manufactures 5,000 gearboxes a year, with no less than 350 different types of casing, always giving top priority to technology, in the sense that it does not manufacture gearboxes to customer’s design. However innovation is essential. For example, in the face of a very specific request on the part of users of twin-screw extruders, for torque and high performance levels with the same centre distance, thanks to R&D department the company is able to satisfy these demands by providing impeccable high quality solutions specifically dedicated to these customers. It is precisely the contribution of the R&D department that has made it possible for In the photo from the left: Alessandro Zambello, marketing manager, and Elio Zambello, R&D and internal production systems director, Zambello Riduttori
78
Examples of Zambello gear boxes for twin-screw and single-screw extruders
the company to cover such a wide range of applications; in fact the company, whilst always remaining in the sphere of plastics and rubber, can offer a fully extensive range of products, from gearboxes for single-screw extruders to gearboxes for co-rotating twin-screw extruders, as well as counter-rotating twin-screw extruders, in both parallel and conical layout, not to men-
tion gearboxes and gearmotors for injection moulding machines (both electric and hydraulic), as well as special gearboxes. In strategic terms, the concept of “make or buy” refers to the choice that a company makes between undertaking operations in-house (make), or deciding to outsource (buy) a component, product or service that is necessary for produc-
tion. The choice is often based on a comparison of the total costs involved in the two cases, bearing in mind also both the actual availability of the components on the market and therefore the risk of any critical situations - as well as the actual resources available for this purpose inside the company. The “make” option offers the clear advantage of being able to assure direct control of operations, on the procurement and on the quality of the product/ service offered. The “buy” option has instead the advantage of involving fewer overhead costs, and therefore a lesser degree of fixed assets, thereby allowing for greater flexibility in terms of production capacity. In terms of manufacturing processes, Zambello decided that only two types of production processes are entrusted to external specialists: the casting of the iron casings and the heat treatments of the steel used. www.zambello.it
MACPLAS INTERNATIONAL OCTOBER 2020
The prince of filtration
Reliability, savings and quality First unveiled at K 2016 by CM Evolution tration, completely automatic functioning, Plast, Principe EVO, an innovative automatic linearity and stability. Principe Evo ensures a continuous flow screen system, has proved significant cost reduction by using a continthat plastics filtration “issues” are “manage- uous-flow automatic belt conveyor system. able”. It has demonstrated that recyclers have The system linearity and the excellent filtering a new source of “productivity”. surface management allow contained presIncreasing of system productivity, twenty-four sure and weighted variations to avoid melt alhours of consistent productivity, productivity teration. independent of the material contamination Another important feature consists in the level can now be obtained with the larger ver- ease of use, which requires just one simple sion CM-EVO 300 installed for the first time in operation - changing the tape roll. The oper2019, which processes 3,500 kg/h of HDPE- ation does not require welding or other debased material filtered to 90 microns, through vices, nor any special equipment. It is carried an area of 2,000 square centimetres of effec- out during the normal production cycle. The tive filtration. duration (in days) of the 100-m roll depends Today three CM-EVO 300 versions are avail- on the degree of material contamination. This able and they process different types of plas- patented device does not require any ordinary tic materials up to 4,000 kg/h. Principe Evo or extraordinary maintenance. system has many features working simulta- After-sales technical assistance is hugely imneously, including flow, tape portant13:52 for CM Evolution Plast. “Testing, in1-Mezza continuous pag. 2020-GB.pdf 1 fil04/09/20
An example of the Principe EVO system
stallation and after-sales service define our way of being. Even though the Principe Evo machinery is designed for long-term trouble-free operation, we have a bond with the customer who chose this device. This bond exists from the installation, and it is a relationship that never stops. Considering the performance of our systems, we tend only to see our customers to say “hello”, or when they want to purchase new models. Whatever the customer needs, we will be there and have the spare parts and components required for any quick maintenance. CM Evolution Plast provides help by using a powerful remote assistance tool from Rescaldina (Milan), which allows us to operate on the systems installed at customers’ premises at any time with effective support from our qualified personnel”, the management of CM Evolution stated. www.cmevolutionplast.com
C
M
Y
CM
MY
CY
CMY
K
MACPLAS INTERNATIONAL OCTOBER 2020
79
INSTRUMENTATION AND CONTROL
TECHNOLOGIES FOR PLASTIC FILM PRODUCTION
TOP-QUALITY CORONA TREATMENT
Corona treatment system for BOPP film (width: 10.5 m)
THE KEY TO ME.RO’S SUCCESS IS THE CARE AND ATTENTION THEY PUT INTO RESEARCH AND INNOVATION. THE ROLE OF THE AFTER-SALES SERVICES IS ALSO CRUCIAL IN PROVIDING SUPPORT TO THE CUSTOMERS
C
orona treatment increases the surface tension of the film, thus improving the adhesion of ink, coatings and adhesives. The role of this so-called “accessory” is, therefore, essential because it must ensure a level of reliability that will not compromise the operation of the production line in any way. With a wide and varied offer, Me.Ro is amongst the leading companies worldwide in the field of corona treatment systems. The Tuscany-based company, owned by the Mennucci family, has successfully built up an excellent reputation in this specific field over the years, specialising in the production of corona treatment systems for a wide variety of applications and supplying top-quality machinery manufacturers like the German company Brückner. Robustness, strength, reliability and full integration with the existing processing devices are the stand-out features of the corona treatment systems that Me.Ro offers to the market,
80
together with a large number of possibilities for customisation based on specific application and user requirements. The wide range of generator power and types of discharge station allow the development of a corona treatment that is perfectly in line with the specific application, so the processor has the guarantee of being able to rely on the best and most reliable solution available. This is coupled with a constant focus on innovation, resulting in the continuous evolution of the product. Me.Ro does not offer a “static” catalogue with a set number of models, but constantly integrates its offer with the new products and technological innovations that appear on the market. A range that is always up-to-date, following all the market evolutions in real time.
APPLICATIONS One of the sectors on which Me.Ro has focused in particular, and one in which it has
been operating since the 1980s, is that of biaxially oriented film lines for polypropylene, polyethylene, polyester and polyamide. The company is the official supplier of corona treatment devices to Brückner, a leading manufacturer of machinery for biaxially oriented film, with whom it has established a partnership of more than thirty years. In the case of “historic customers”, system upgrading or specific requests from the technical departments, Me.Ro also works directly with user companies, deploying its expertise to identify and provide the most suitable solution. The BOPP core business is complemented by the converting sector with applications on printing and lamination machines, extrusion coating and coating machines. The converting sector, which was secondary for the company until about twenty years ago, has grown significantly over recent years, in response to the demand for increasingly high quality. The MACPLAS INTERNATIONAL OCTOBER 2020
cast film sector (especially for polypropylene) is another historic sector for Me.Ro, and one that is still growing. In that field, the company can boast an expertise recognised by leading European manufacturers. Last but not least, blown film applications represent a sector which has produced very encouraging results thanks to the increased widespread use of these applications. In addition to corona treatment devices, the company also offers vacuum plasma and atmospheric plasma treatment systems. The latter is, in fact, a variation of the corona treatment which achieves better results on certain kinds of films, guaranteeing a longer duration of the surface tension and, thus, better adhesion of inks, glues etc. The vacuum plasma treatment systems, on the other hand, operate in high vacuum conditions and the surface treatment takes place between the unwinder and metallisation phase. This treatment makes it possible to achieve better adhesion on metal or on other aluminium/silicon oxide coatings, resulting in better barrier properties. The metal is, thus, spread out more evenly, avoiding the formation of imperfections responsible for the passage of oxygen and water vapour through the metallised surface. Recently, there has been a trend, especially in the food packaging sector, to create a transparent coating as an alternative to aluminium one (the coating par excellence to create a barrier), using aluminium or silicon oxides specifically to obtain transparent barriers. Another application in the packaging sector, even if not specifically used for films, involves the use of induction cap sealing machines, mainly employed in the bottling sector but also in the beverage, food, motor oil, pharmaceutical, cosmetic and agro-industrial sectors. Me.Ro 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, for example, in packaging for milk, fruit juice and sauces, as well as engine oil and fertiliser.
INNOVATION AND CUSTOMISATION Talking about business strategy, Me.Ro has opted for an approach focused 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’s efforts have always focused on ensuring the quality, reliability and robustness of the generators and discharge stations. “Companies, working with 10.5-metre-wide systems producing 50,000 tons of film per MACPLAS INTERNATIONAL OCTOBER 2020
year, cannot afford to stop the process due to a malfunction or break in the corona treatment”, explains Armando Mennucci, managing director of Me.Ro. “We need to be able to ensure total reliability and robustness both on a mechanical and electronic level. Our discharge stations are built on the criteria of overall strength. If the film breaks on systems producing 650 m/min, an impressive film backlog will impact the discharge station, that would very likely damage the entire device if the electrode and station structure were not designed with certain characteristics, resulting in problems of treatment uniformity. Our job, therefore, is to ensure the very best in terms of robustness and reliability and the manufacturing choices resulting from the BOPP sector are transferred to other applications as well”. Another of the company’s strengths 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 possible to offer a tailor-made solution for the specific application. “Offering such a vast choice is certainly a challenge, but it is a key factor that sets us apart from the competition”, continues Mennucci. “There is, in fact, a large number of variables involved, such as the type of film, speed, film width, to name but a few. We are able to offer the treatment that best meets the specific characteristics of the application in question.
Corona treatment system for metallised films on fast slitting machines (speed: 1000 m/min)
Until some time ago, this placed us in a higher price range compared to some of our competitors, but recently we have been able to significantly reduce the price difference, adopting a more “combative” sales and marketing strategy whilst keeping the quality unchanged. Indeed, we have no intention of creating low cost lines, which would backfire on us. On the contrary, we continue to use all the new technologies on the market to offer increasingly reliable and higher-performance machines”. The company has always focused on electronic management, too. Me.Ro was the first company to integrate the recipe-based 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 to be particularly useful in converting processes. Another advantage is the company’s flexibility in adapting the configuration of its devices to existing machinery layout; a capability that is highly appreciated by manufacturers.
SERVICE
Air-cooled electronic generator for induction cap sealing systems
Service plays an increasingly strategic role in the business. That is why Me.Ro offers its customers the support of a team of ten technicians who are ready for deployment to the customer site, when necessary, to solve their problems. In 2005, the company also opened an office in China to support the Asian market more efficiently, where the number of installations and systems is rising. It is that market, together with South America, that drives exports, as well as Europe, of course, which continues to represent an important slice of the company business. Currently, 95% of the company’s installations cover foreign markets. In 2019, Me.Ro recorded a turnover of 17 million euros and in 2020, despite the difficult situation, the turnover appears to be more or less in line with the previous year. www.mero.it
81
INSTRUMENTATION AND CONTROL
NEWS Customized solutions since 1940
80 years of experience in IR and UV lamps for industrial applications The IR lamps and units made by Helios Quartz are particularly appreciated in the plastics and elastomers sector. The production range meets all the most common plastic and rubber forming and processing needs from the sealing of plastic components to lamination, from the shrinking of heat shrink materials to the stretching/lengthening of plastic film. The product portfolio
includes: quartz IR lamps (in single or two-row tubes) either in short, medium or medium-fast wave; IR units; tubes, sheets and discs of quartz glass; quartz glass articles according to drawings; UV lamps and equipment for the curing of glues, inks, varnishes and resins that react to UV light; UV ray kits and systems; Inve 2000 systems for ageing tests.
Testing machine in the Helios Quartz centre close to Milan, Italy
Furthermore, thanks to a thorough knowledge of production processing, Helios Quartz is able to design and develop tailored modules to meet specific customer needs. Its IR units in particular are fully wired and ready to be connected on line, and fitted with a high temperature heat sensor and ventilation system in order to perfectly accommodate the IR lamps. The company is also able to supply units ready to be assembled both on new and existing production lines. It can provide units of up to 6.5 m in length, complete with control systems to meet specific customer requirements. Furthermore, Helios Quartz has set up a test centre at its factory in Cambiago (near Milan, Italy) complete with instruments capable of testing the reaction of various kinds
SEA Hypersort in an Indian recycling plant
An innovative solution for the plastics recycling industry Plastics recycling means taking care of the environment, to create a sustainable lifestyle for us and for the future generations. In line with this vision, Placity Recycling decided to establish their company in India, with the main goal to make the plastics recycling process more efficient. The family-owned company collects mixed materials to allow the recycling process of the individual polymers, such as HDPE, PET, PVC, PP, PE etc. Malay Patel, who is a young and future-oriented entrepreneur, visited the Cimbria SEA factory in Imola, Italy, with different sets of samples, that were processed by SEA Hypersort, having advanced NIR hyperspectral cameras. The Cimbria SEA laboratory in Italy
82
performed successful test results, conforming to the industry purity standards, ensuring the finalization of the order. As a result, Cimbria has recently installed the SEA Hypersort electronic sorter, which The SEA Hypersort electronic sorter has been developed by Cimbria to separate impurities and unwanted polymers by means of infrared hyperspectral sensors
of materials (film and samples) when exposed to infrared radiation. Using the results of the testing undertaken with the various wavelengths, the company technicians are then able to go on to develop the best solution for each application and product. A longstanding group established in 1940, Helios Quartz boasts two factory sites, the historic one in Italy (Helios Italquartz) and the recent factory premises in Switzerland (Helios Quartz Group). A solid distribution network covers all four corners of the globe (Europe, the United States, South America and Asia). The group, which has obtained the TĂ&#x153;V certificate, is extremely flexible and dynamic, with a highly international leaning. www.heliosquartz.com
is extensively used by Placity Recycling to separate impurities and other polymers from the main product. This electronic sorter is equipped with infrared hyperspectral cameras to separate unwanted polymers and materials that have the same colour and transparency, when there are no visible differences in the material to sort. PET, PVC, PE, PP, PS etc. can be separated according to their chemical nature, to match with the purity standard required by the market. The hyperspectral NIR sensors recognize elements based on their specific spectral properties of reflected light, representing the state-of-the-art solution in the polymer sorting process. As a global leader in electronic sorting technology, Cimbria is proud to contribute to reducing the need for disposal of valuable plastic materials. This will be a benefit not only for Placity Recycling, but also for the city of Rajkot, in the State of Gujarat, and indeed for the whole planet. www.cimbria.com
MACPLAS INTERNATIONAL OCTOBER 2020
C
M
Y
CM
MY
CY
CMY
K
iStock
MATERIALS AND APPLICATIONS
GREEN AND DIGITAL
NEW TRENDS FOR THE PACKAGING OF THE FUTURE CONSUMERS TODAY WANT ENVIRONMENTALLY FRIENDLY PACKAGING FOR EVERY PRODUCTS IN DAILY USE, BUT ALSO TECHNOLOGICAL SOLUTIONS. THE NEW EU PLASTICS STRATEGY IS PLACING EVEN MORE STRINGENT DEMANDS ON MANUFACTURERS AND RETAIL SECTOR IN THIS REGARD. THE CHALLENGES THIS CREATES FOR PACKAGING INDUSTRY ARE OFTEN COMPLEX
A
t the point of sale, the first impression is generally the packaging, because it’s the first thing that the customer notices. In this context, design is especially important. Nina Saller, designer and founder of Munich-based XbeyondS, said that younger target groups in particular, like Generation Y and Z, are very discerning about packaging. Their value systems are very different from those of the older generations. The consumer behaviour of Generation Y, also known as “Millennials” (i.e. those born between 1980 and the late 1990s), and the subsequent Generation Z (born 1995 to 2010) is characterised by enjoyment, individuality but also a social conscience. Saller explained that packaging manufacturers are responding to these preferences, requirements and beliefs with packaging that is manufactured using few MACPLAS INTERNATIONAL OCTOBER 2020
resources, gives the consumer added value, looks classy and can be re-used, composted or recycled. “The packaging of the future has to serve both consumers and the environment and must take the entire cycle into account”, adds Cornelia Fehlner, exhibition director for FachPack (Nuremberg, September 28-30, 2021).
INSPIRING, SMART AND SUSTAINABLE PACKAGING IN DEMAND With regard to packaging trends, Nina Saller identified three main categories that can be described using the umbrella terms “identify-inspire”, “enrich-smart” and “preserve-sustainable”. These include packaging as an “identity-defining accessory”, that generates elements of surprise, offers added value and serves as a
communication medium. For example, packaging elements can be printed with special ecologically sound inks that are only visible under UV light. These inks can be used for brand protection and for advertising messages. Packaging in the category “preserve-sustainable” is characterised by the following properties: consists of sustainable resources or waste material, easy to process, doesn’t look “green” and is biodegradable. The University of Ghent, for example, developed a sustainable packaging from coriander oil and chitosan (a biopolymer derived from the shells of crustaceans) to extend the shelf life of food products and cosmetics. The material has natural protection against fungi and bacteria, is as strong as aluminium but weighs only half as much, and is completely compostable.
85
MATERIALS AND APPLICATIONS Downgauging (thickness reduction) in food packaging films allows plastics processors to do more with fewer resources
Packaging performs an essential service where foodstuffs are concerned. It protects the contents against harmful influences and ensures a longer shelf life, in addition to food safety. Thanks to the latest packaging materials, these requirements can now be fulfilled with much less material than a few years ago, and sometimes improving the protective function. According to the Gesellschaft für Verpackungsmarktforschung (Society for Packaging Market Research, gvm), plastic packaging consumption has decreased by 35% compared to the state of the art in 1991. And in that same period, according to IK (Industrievereinigung Kunststoffverpackungen, the German Plastic Packaging Industry Association), packaging has become 25% lighter. Increases in material efficiency in plastic packaging since 1991 resulted in a saving of around 2.6 million tons of CO2 in 2013, gvm reports. This was made possible by reducing wall and film thicknesses, improved material properties, and optimised shaping and processing techniques. Despite increased demands on packaging such as re-sealing and divisibility into smaller units, it was still possible to save materials. The same applies to drink cans made of tinplate, for example, which are now 60% thinner than in 1974.
DOWNGAUGING TURNS LESS INTO MORE
www.packagingaward.de
Thinner film solutions have reduced the use of resources for flexible packaging of the kind specifically used for foodstuffs. “Downgauging” is the umbrella expression for measures in this area. Briefly, it means turning less into more. Maximising efficiency without compromising on quality. In practice, downgauging refers to the process of replacing a traditional thicker film with a thinner film that offers better performance. The advances made in packaging design now make it possible, for example, to pack fresh
More than 90% of the PCR (post-consumer recycling) material is used as granulate to produce “Pöppelmann Blue” packaging. This is safely sorted after use and returned to the recycling stream through the yellow plastics bin to be processed into new granulate for further use
86
iStock - Meilun
FOOD PACKAGING GETS LIGHTER AND MORE SUSTAINABLE
products like meat and fish in skin packaging that uses much less material. The products are placed on a tray that is then sealed with a skin film. Just by switching its ready-packaged poultry range to this type of packaging, the German discount retailer Netto aims to reduce its plastic waste by up to 13 tons per year. Managers of that company report that, compared to traditional plastic trays of the same size, the very thin, airtight skin film should achieve a saving in packaging material of up to 60%.
GREEN AS A DESIGN PRINCIPLE Other adjustments in addition to using thinner materials can be used to cut down material consumption. For example, manufacturers can adjust the size of packaging to save unnecessary space. Practical refilling solutions are also available in the case of foodstuffs that are bought in for stock. Refill packaging is subject to fewer functional requirements, or larger formats can be used. Appropriate designs for sponsor packaging can boost customer loyalty at the same time. Traditional examples in this area are salt and spices. If the ability to cut down on materials reaches its limits, consideration should be given to replacing particular materials with others (like biopolymers or regenerated materials) with a lower impact on resources, if this can be done without compromising on their protective function. These measures come under the heading of eco-design, and include a comprehensive analysis of the environmental impacts of packaging. The all-encompassing approach represented by eco-design goes beyond primary packaging to include secondary packaging, product logistics and also recycling. Especially in the context of
the new European legislation on circular economy, eco-design has progressed in the meantime from a niche to a mainstream topic in development departments. Even before, designers were aware that even minor reductions in materials can add up to big savings across large sales volumes. In this connection it is not only the material that plays a key role. More can also be achieved by drawing on technical innovations. When cutting out top films, for example, a tighter pattern - if the film properties will allow it - can help to reduce film consumption.
THE IMPACT OF DIGITISATION As a carrier of digital technologies, packaging offers promising options for improving logistics and production processes. The German Association for the Promotion of Innovative Logistics Solutions (VVL) tests and researches innovative packaging solutions and approaches for logistics planning, with a wide range of options for making packaging intelligent using digital solutions. One such approach, for example, is the IntelliData Project, which is intended to discourage consumers from throwing away edible foodstuffs so indiscriminately in the future. The objective of this project led by the German company QuoData is to develop an App that will be able to determine this accurately in the future. “However, it will not be done using smell or taste like in the past but by means of a sensor label in or on the milk packaging”, says Christian Bläul, IT Manager at QuoData. To do this the label determines certain variables that together can accurately determine whether the milk is still drinkable. In collaboration with the project’s partners, who represent the entire supply chain including MACPLAS INTERNATIONAL OCTOBER 2020
the consumer, a prediction algorithm and sensor label are now being tested that do not impede the logistics and provide reliable use-by dates. Bläul stressed that this system could also be adapted to other foodstuffs.
German designer Anne Bansen developed a clever alternative to the conventional best-before date with her Tast(e) Food packaging. As soon as biochemical changes occur in the protected atmosphere, the packaging “communicates” with the consumer via a sealing foil that changes its structure and indicates when the contents are inedible
RFID chips on or in the packaging of a product, which share data and communicate with the environment, are what make this an intelligent packaging solution, explained Matthias Grzib, project manager IDH (Institute for Distribution and Trade Logistics) at VVL. In this context, the properties of smart products, Packaging 4.0 and intelligent packaging overlap - but they are not necessarily identical. A smart product is therefore a vital component of Industry 4.0. It needs to be able to communicate and interact with other stakeholders in the production chain. Alongside its previous functions like product protection, marketing and handling, it performs other tasks, e.g. communicability, interconnectivity and the control of processes. If supplied with dynamic information on an RFID chip, intelligent packaging can turn a “normal” product into a smart product that was previously not suitable for the demands of Industry 4.0. For example, the packaging can then communicate from the warehouse with the manufacturer via appropriate readers and indicate which products that it can be used for. According to Matthias Grzib, the benefits of intelligent packaging lies in the customer and product-specific choices it provides, in the optimum product protection, in lower costs and self-organisation within the supply chain.
REUSABLE TRANSPORT PACKAGING WITH ADDITIONAL BENEFITS
Witte Group
According to Thomas Walther, managing director of Walther Faltsysteme, the dynamics of the smart factory still needed to be put into practice. However, for companies that are already incor-
Printed on packaging, NFC interfaces are able to put two different devices into communication using short-range wireless connectivity MACPLAS INTERNATIONAL OCTOBER 2020
www.packagingaward.de
HOW INTELLIGENT DOES PACKAGING NEED TO BE?
porating these principles into their processes, Walther is already offering returnable containers with various smart functions. For example, RFID data carriers can be attached to a reusable container from the outside, or integrated into the material of the container or pallets. In this context, the transport packaging always has to be suited to the relevant supply chain: it must be identifiable, controllable and ideally, also be able to communicate in future. Despite these wide-ranging requirements, the packaging manufacturer has to be capable of offering a durable and economic product that can provide and receive this kind of information. The great advantage is that information technology is becoming increasingly less expensive and therefore it is now much more feasible to implement the technology than it was some years ago. Thomas Walther also talked about its use in intelligent design, where simulations provide security throughout the complex development process - from the 3D CAD drawing to 3D printing pre-production and serial production.
3D PRINTING OF PACKAGING While rapid prototyping of packaging is already being realised with 3D printing, the further development of this application, i.e. printing the packaging in serial production, has not yet been economically viable. The progressive individualisation of packaging could change this in the future, stressed Jörg Loges from VVL association. Already, 3D printing can be worthwhile for product protection purposes, i.e. for the custom manufacture of special transport containers or packaging for valuable goods. Batch sizes are getting smaller and the packaging has to follow suit, explained Loges, pointing to customised serial production in this context. At the moment, 3D printing is experiencing widespread use, as the technology is becoming more and more mature
and cheaper. It is not possible to predict at the moment whether the technology will also be suitable for serial manufacturing. Nevertheless, 3D printing structures can produce a weight reduction and stability that was not previously possible. Today packaging is already playing a major role in ensuring an exchange of information in production, logistics and commerce. The growing demand for individualised, safe and inexpensive products is continuing to drive the development of intelligent add-on functions. As a result, manufacturers increasingly have the opportunity to set their products apart from the competition through their packaging and to significantly improve their logistics processes.
HYBRID ELECTRONICS FOR SMART PACKAGING Thin, flexible and in some cases transparent electronic components open up revolutionary application opportunities for labels and packaging components. With its core competencies in the areas of functional printing and finishing, Witte Group presented solutions for products such as printed circuitry and functional surfaces, energy storage systems and printed solar cells, smart labels, and also fully printed electronic components. Witte SmartPack functions range from lighting with printed resistive, capacitive and inductive sensor elements to printed NFC (Near-Field Communication) interfaces, able to put two different devices into communication using short-range wireless connectivity. Printed elements in packaging serve as NFC sensors to record temperature to monitor the cold chain, for example, or measure pressure and humidity. Optical and digital security features can also be integrated. As an electronic anti-tampering device, they meet security requirements in the pharmaceutical industry. www.fachpack.de
87
MATERIALS AND APPLICATIONS
ADVANCED MATERIALS
FIRST-OF-ITS-KIND POLYPROPYLENE TO EXPAND 3D PRINTING APPLICATIONS NEW HP 3D HIGH REUSABILITY POLYPROPYLENE IS NOW AVAILABLE ON THE MARKET THANKS TO THE EXPANDED ALLIANCE BETWEEN BASF AND HP. TO EXPAND MARKET OPPORTUNITIES FOR 3D PRINTING, HP IS ALSO COLLABORATING WITH EXTOL, GKN, HENKEL, OECHSLER, PROTOTAL AND FAST RADIUS. IN PARTICULAR, THE NEW INDUSTRIAL PARTNERSHIP WITH OECHSLER DRIVES PERSONALIZATION AND REDUCTION OF COMPLEXITY FOR AUTOMOTIVE AND OTHER INDUSTRIES
O
n last June 3, during a special virtu- been qualified for HP’s production-grade 3D al press briefing, Ramon Pastor, in- printing systems, and is ideal for customers terim president of 3D Printing and in the automotive, consumer, industrial, and Digital Manufacturing at HP, made a set of medical sectors seeking an optimal balance announcements demonstrating the con- between performance and cost2. Furthertinued 3D printing and digital manufactur- more, HP unveiled a new partnership with ing momentum and industry leadership. Oechsler, the global design and manFirst of all, helping expand the overufacturing player, to develop all market and unlock new appliapplications for both the new cations for customers, HP is PP and HP’s broader materidelivering a first-of-its-kind als portfolio. polypropylene (PP) material for additive manufacturing. The new HP 3D High Reusability PP, available thanks to the Automotive partnership with Basf, components manufactured is a versatile, durable, by Oechsler using the new and chemically resis- HP 3D High Reusability tant1 material that has PP enabled by Basf
88
“The response to the Covid-19 crisis is a watershed moment for the industry. HP and its partners have 3D printed more than 2.3 million parts to bridge supply chain gaps, enable local production, and help healthcare professionals on the front lines”, said Ramon Pastor. “As we navigate this new landscape, we continue to execute on our strategy and push innovative new 3D printing materials, solutions, and partnerships forward to help our customers re-open manufacturing and deliver disruptive innovation for the world’s industries”.
BREAKTHROUGH NEW PP UNLOCKS OPPORTUNITIES AND IMPROVES SUSTAINABILITY Polypropylene is a versatile material ideal for a wide range of automotive, consumer, industrial, and medical applications. The MACPLAS INTERNATIONAL OCTOBER 2020
new HP 3D High Reusability PP enabled by Basf provides customers with a genuine new additive manufacturing material offering the same properties as commonly used PPs in injection moulding, which has proven to have nearly unlimited use. With its excellent chemical resistance, low moisture absorption, and long-term durability, PP is ideal for piping, fluid systems, and containers. For example, automakers will be able to use the same PP for prototyping and production of final parts found in vehicles’ interior, exterior, and underthe-hood. Developed in partnership with Basf for HP’s Jet Fusion 5200 3D Series, the new PP delivers high productivity and minimizes waste for industrial-level manufacturing. In addition to breakthrough economics and performance, the new PP helps reduce waste3 by enabling up to 100% reusability of surplus powder4. Therefore, HP is jointly developing entirely new PP applications with partners, parts providers, and customers. They include: Extol, specializing in plastics engineering and innovation with industry leading plastic assembly technology, custom automation, and engineering services; GKN Powder Metallurgy/ Forecast 3D, a provider of advanced industrial 3D printing, short-run manufacturing, and high-volume production; Henkel, a leader of high-impact adhesives and engineering solutions; Oechsler, an additive manufacturing parts provider; and Prototal, one of Europe’s most experienced parts manufacturers.
4.0 ALLIANCES FOR AN EXPANDING INDUSTRY To help customers accelerate their journey to large-scale digital manufacturing, HP announced new and expanded 3D profession-
HP launched a variety of new professional services for design optimization, mass customization and large-scale production using 3D printing
al service offerings and industrial alliances, including: • HP 3D Professional Services; the company is unveiling a variety of new professional service capabilities including design optimization for breakthrough applications, manufacturing process streamlining to enable mass customization and scale production, and applications identification and discovery services. • Basf and HP are advancing their strategic alliance to jointly develop new applications with market leading customers in the automotive, consumer, industrial and medical industries. With the new PP and the recent introduction of the innovative Ultrasint TPU01 thermoplastic polyurethane, the two companies are working together to accelerate the design and mass production of 3D printed parts, enabling customers to go to market faster, more cost-effectively, and more sustainably than ever before. • A new strategic alliance with Oechsler, a leading global engineering solution provider and one of the largest parts producers in the additive manufacturing industry. The alliance will span the product lifecycle from application design to production of final parts. Oechsler is using its fleet of HP’s Jet Fusion 5200 3D series printers and an extensive materials portfolio to help leading automakers, global consumer electronics companies, home and commercial appliances, and innovative medical device providers produce a variety of new applications. • Fast Radius, a leading manufacturing technology company, has qualified as a new member of the HP Digital Manufacturing Network, a global community of HP production partners to help design, produce, and deliver both plastic and metal parts at scale leveraging HP 3D printing solutions. Members of that community possess high levels of advanced additive manufacturing expertise, robust quality management and endto-end manufacturing processes, and a proven capability for volume job production.
INCREASING MASS PRODUCTION IN THE GOLF WORLD A foremost innovator in the golf world, Cobra is committed to revolutionary advancements in technology, engineering first-ofits-kind clubs and equipment designed to elevate the game. In particular, Cobra, HP, and Parmatech are working together on a strategic multi-year product roadmap, that leverages the design and manufacturing benefits of HP’s additive technologies to de-
MACPLAS INTERNATIONAL OCTOBER 2020
Jet Fusion 5200 3D printers at the HP Excellence Centre in Barcelona
liver golf equipment that raises performance and golfer satisfaction to new levels. This is the reason why Cobra Golf has selected HP Metal Jet technology for its entry into 3D printing for product innovation and mainly for mass-production of metal parts. “Cobra Golf strives to deliver high-performance products that help golfers of all levels play their best and enjoy the game”, said Jose Miraflor, vice president of marketing at Cobra Golf. “To do that, it’s critical to use the most effective manufacturing processes to design, develop, and achieve optimal results. To continue innovating and transforming the way equipment is manufactured, we decided to work with HP and Parmatech to take advantage of the benefits of Metal Jet 3D printers. We saw immediate benefits including design freedom, rapid design iteration and high quality parts that meet our economic demands”. www.hp.com - www.basf.com Based on internal HP testing on May 2020, to evaluate mechanical property retention, dimensional stability, and weight change after 7- and 30-day immersion with acids, bases, organic solvents, and aqueous solutions. 2 Compared to other materials in the HP 3D materials portfolio as of May, 2020. 3 Easier to process than standard HP 3D High Reusability PA 12, providing proper fusing along with good spreadability and compatibility due to its small particle size. 4 Based on internal HP testing, May 2020. HP Jet Fusion 3D printing solutions using HP 3D High Reusability PP provide up to 100% powder reusability ratio, producing functional parts batch after batch. 1
89
Greensan
MATERIALS AND APPLICATIONS
BIO-BASED AND COMPOSTABLE COMPOUNDS
GREEN TECHNOLOGIES TO MAKE SOMETHING GOOD FOR THE EARTH FROM SINGLE USE TABLEWARE TO COMPOSTABLE MONOLAYER BARRIER FOOD PACKAGING STRUCTURE
F
ounded at the end of 2017 from the experience of its managing director Francesco Mastrandrea, Greensan mainly provides compostable bio-based polymers and compounds with a very high rate of environmental sustainability. In addition, this Italian company provides specialized advice, the result of twenty years of experience in the sector, made available to the many processors of conventional plastics that look with increasing interest to bioplastics, and therefore need strong skills in the process of transition to green solutions, as imposed by today’s market demand. The support, in addition to the purely technical aspects, also includes strategic, structural and organizational aspects. Consolidated relationships with the most advanced Asian and American producers of raw materials and collaborations with the best chemical engineering universities allow a constant update on cutting-edge technologies and the latest developments in research. The ultimate goal is to take the customers’ busi-
90
ness to a higher step, helping them to find the ideal solutions based on their needs, analysing every detail, thanks to a very well-prepared staff. The application sectors are not limited to traditional packaging, food or logistics, but range from medical solutions, automotive, fashion and much more.
“The company was founded three years ago to represent several Asian and American polymer manufacturers in Europe”, explained Francesco Mastrandrea, executive managing director. “My passion for bioplastics was transmitted to me by my father, Gaetano Mastrandrea, pioneer of bioplastics in Europe, who taught me the moral values of life. I remember as if it was yesterday when I started working in his company, without receiving any treatment of privilege at all, but respecting the hierarchical roles of the company”.
BIO-BASED PRODUCTS AND SPECIAL APPLICATIONS
Every week, in Canada and the United States, 500 tons of exhausted coffee are collected from McCafé shops. They are used to manufacture a compound to produce new capsules and pods for coffee. A very good example of circular economy
Today Greensan distributes polyesters of China’s Tunhe Chemical, then PBAT and PBS, throughout Europe, and bio-based compostable compounds of several American and Canadian manufacturers produced in the facilities of Southern Italy and China. One of the latest products, created thanks to the agreement with Competitive Green Technologies (manufacturer of 110,000 tons in North America, and soon also in our conMACPLAS INTERNATIONAL OCTOBER 2020
Francesco Mastrandrea, executive managing director of Greensan (on the right), and his father Gaetano Mastrandrea
tinent with the installation of a production unit in South Europe), is a compostable bio-based compound produced by biomass (coffee, cocoa, rice), with very high barrier properties to the values OTR and WVTR that allow to have a shelf life from 2 to 5 years. Greensan will soon launch a new range of compostable monolayer packaging with barrier properties that will allow a shelf life of 5 years. This is also possible for the constant research the company does with the best European and American universities by investing in the development of innovative products and anticipate what will come using new innovative materials, such as PHA. To date Greensan serves different sectors (medical, food, horeca, fashion etc.), producing compounds for different applications: injection and compression moulding, thermoforming, blow moulding, extrusion… and blown films with surprising performances. “For a particular blown film grade, for example, we have developed a product that has the absolute lowest specific weight. This allows for a gain in terms of production compared to the other compounds present on the market today”, underlined Mastrandrea. “Another compound concerns its use in injection and thermoforming processes. Here too, thanks to our know-how in the sector, we have been able to provide ultra-light and highly performing compounds”. “The latest compounds that we have introduced into the Greensan house are those with high barrier properties to oxygen and water vapour, developed together with the University of Guelph and the Canadian government. The latter are Greensan’s excellence and flagship because they reflect the concept of circular economy and, I can boast to say, that they are unique in the world for their properties”, added the managing director. Compounds produced with so-called “Competitive Green Technologies” (CGT) are compounds considered innovative as they are produced with the use of biomass processing waste, therefore useful for the circular economy process. “Every week, in Canada and the United States, 500 tons of exhausted coffee are collected from the individual McCafé, which are used to manufacture a grade of injection and thermoforming compound with which capsules and pods are produced to package new coffee. McDonald’s will use them in the individual points, so this is an important example of circular economy”, continued Mastrandrea. “Another similar grade uses the production waste of cocoa beans and coffee beans in order to give surprising and excellent barrier properties to oxygen and water vapour with values that do not exceed unity. The innoMACPLAS INTERNATIONAL OCTOBER 2020
vation and the patent is precisely in producing a compound that can be used as a monolayer. Therefore, there is no need, in the case of flexible films, to have a three or five-layer structure as sponsored by other biopolymer manufacturers”.
BIO CARBON VS. TRADITIONAL CARBON BLACK Another important product that Greensan is presenting in Europe is Bioblakr (registered trademark), a masterbatch with bio carbon which replaces the traditional carbon black. It can be manufactured starting from different polymer bases: PP, PE or bioPE, PS, PBAT, PBS, PLA. The company produces Bioblakr by compounding the bio carbon obtained from a “patented” process of roasting and incineration at a controlled temperature and extraction, using vegetable waste as raw material (coffee husks, rice husks, miscanthus wood). This masterbatch has the advantage of having a low electrostatic charge, which favours the manufacturing process. It is certified by the USDA as a 99% new carbon C14 standard bio-based material. An important aspect of this product is its advantage in terms of effectiveness of agricultural crops. In fact, the Sodium Adsorption Ratio (SAR) is a quality parameter for irrigation used in the sodium-affected standard. A SAR below 3 is beneficial for the soil in order to maintain calcium (Ca) and magnesium (Mg) levels. A SAR value greater than 9 is an indication of danger for soil infiltration and permeability, which leads to a reduction in crop yield. Packaging obtained with Bioblakr masterbatches
“If we compare the traditional carbon black masterbatch with Bioblakr, we see a value of 43.5 in the first while we have a SAR value of 0.519 in Bioblakr”, explained Francesco Mastrandrea. “Let’s make the same consideration with antimony, a potentially carcinogenic substance. Carbon black has a value of 14.2 mg/g, while Bioblakr has a value of less than 0.8 mg/g. Another amazing advantage of Bioblakr is to act as a “lightweighting agent”. In fact, we did a case study in North America with the car manufacturer Ford and Competitive Green Technologies where we demonstrated that some components of the Ford Lincoln and Ford Fiesta moulded with Bioblakr were 22% lighter than the same parts moulded with polypropylene and traditional carbon black. We have a vision that goes beyond what consumers demand today. In 2021 we will inaugurate a 40,000 tons production plant in Italy, which we will start together with Competitive Green Technologies”.
AN EXPANDING STRUCTURE In addition to the actual offices in Bari and Genoa, the organizational, production and logistics structure of Greensan is expanding. In fact, in the first quarter of 2021 the company will be operating in the Asian market thanks to its new logistic, production and commercial structure based in Shenzhen. The Italian company can count on an annual production capacity of 35,000 tons and intend to reach a total production capacity of 75,000 tons in Europe and of 35,000 tons in Asia by the end of next year. Its strategy focuses on several joint ventures with companies producing polymers and finished products, to be very lean and smart. In addition, Greensan has several other shortterm objectives. “Today the commercial network is made up of eight agents in Italy and four in Northern Europe, but we want to insert others by the end of the year, throughout the Old Continent, for a total of 40-45, and expand the commercial network also in Southeast Asia, a market that is becoming highly important”, emphasized and concluded Mastrandrea. “Thanks to a joint venture with Shenzhen Yanfa Technology, in January 2021 we will inaugurate the headquarters in Shenzhen, China, where there will be a compound production plant, a 5000 m2 warehouse and an organized sales network. We aspire to have a production capacity exceeding 100,000 tons/year by the end of 2025 and cover the five continents. We are a company open to collaborations and the development of new projects and ideas, because only in this way do I believe that it is possible to grow and make something good for the Earth!” www.greensan.it
91
MATERIALS AND APPLICATIONS
NEWS Compounds and masterbatches
The reference point for high quality and immediate delivery
Interior of the Plastore raw materials warehouse
Extension of the raw materials (granules) warehouse
“Taking now quality, reliability and consultancy for granted, the only requirement that basically differentiates one supplier from another is the price. And ours are the lowest prices on the Italian market”. It is the clear and direct opening of Monica Mingoia, owner and key woman of Plastore, a company that has just moved to the new headquarters in Villamarzana, in the province of Rovigo, Italy. “This year will be remembered as crucial in defining new ways of working and new business practices. We need to rewrite our best practices and take the opportunity to change... always for the better. This is why we have strengthened our commercial spaces: to offer more choice, more rapidity and the competence gained over years of activity at the service of our customers”. The austere and busy frown of Mr
92
Plastore, protagonist of the company’s communication since Fakuma 2018, hides a young, discreet and secluded entrepreneur, but not without the determination and skills necessary to navigate the turbulent and difficult waters of plastics industry in the recent years. Born in 2014 and grown at an exponential rate, when it was not obvious, Plastore managed to activate a network of producers, brokers, dealers and customers themselves, capable of constantly feeding the offer of plastic granules with highly competitive prices and capable of benefit many moulders in their daily needs. “In particular in injection moulding, we are strong thanks to an offer that includes all the main polymers (ABS, PA6, PA66, PBT, PC, POM, thermoplastic elastomers, masterbatches, commodities and
many others) of the best brands, but also Plastore-branded. We are talking about engineering polymers made by the most important Italian compounders, but sold at more competitive prices”. Monica continues with some enthusiasm. “During seasonal production peaks or in the physiological ones of certain types of polymers, the Plastore warehouse can become the reference point always ready for immediate deliveries, after the order. It’s not trivial!” But in addition to the plastic warehouse of Villamarzana, with more than 5000 square metres of covered surface and over 30,000 of uncovered space, there is also the “online warehouse” on the company’s website, where all the items in the portfolio are available, complete with technical data sheet and, from today, also assisted
by a live chat active from 8.30 to 12.30 and from 14.00 to 18.00, to speak directly with… Mr Plastore! “We don’t do mere e-commerce; our sales are neither impersonal nor occasional. Our goal is always to build trusting and lasting relationships with customers. For this we use the network to intercept new contacts, but then the consultancy and supply are developed through an in-depth knowledge of the dynamics of the market in which our customers move and of their specific needs. Offering the right material at the lowest price, with continuity and punctuality, is our best practice. Basically, Plastore consulting is a strategic lever for developing the processor business through careful daily problem solving”, Monica suggests. “Acquiring plastic materials at a lower price means having already gained in the purchasing office, even before producing added value at the factory!”, concludes the young businesswoman, getting back to work. www.plastore.it
The meeting and training room
MACPLAS INTERNATIONAL OCTOBER 2020
Polymers from renewable resources and chemical recycling
The sustainable evolution Nowadays the Italian company Sipol produces more than 100 different grades of co-polyesters and more than 30 of co-polyamides with particular attention to the use of raw materials obtained from no food-grade renewable resources and the development of “eco-friendly” polymers. All the co-polyamides currently produced (Technipol PA) contain more than 70% of renewable raw materials, obtained from the processing of vegetable oils. Even amongst co-polyesters, the company has historically produced grades that can be classified as bio-based polymers. For instance, Technipol 70 contains more than 60% of raw materials obtained from renewable resources (castor oil). This grade is totally biodegradable and characterized by a low melting point, which makes it easily applicable as an adhesive in the footwear industry and in the textile sector, and usable as a base polymer for biodegradable compounds. Furthermore, Technipol 061/E is an aromatic/aliphatic co-polyester, characterized by a medium crystallinity degree and low mel-
ting point. Due to its formulation, it can be used in biodegradable and compostable compounds. It shows good compatibility with other biodegradable polymers such as polylactic acid and starch. Lastly, Technipol IP 720 is a biodegradable and bio-based co-polyester based on PBS, characterized by a high hardness and high melting temperature, which make it the ideal substrate also for cosmetic applications such as scrubs, thus avoiding the problem of biodegradable microplastic pollution in the marine ecosystem. Alongside these historic products, Sipol has recently started the production of a bio-based thermoplastic co-polymer for use in automotive filters. Bio-based and post-consumer combination The plastic recycling industry is constantly growing, leading to significant benefits both in economic and environmental terms. In this context, PET undoubtedly represents one of the most discussed polymers due to its wide diffusion in the world of disposable packaging. In addition to being re-used as a polymer, the reversible nature of the
Technipol 232, 50% of renewable resources content + post-consumer PET flakes
MACPLAS INTERNATIONAL OCTOBER 2020
Technipol polyester adhesives for engine air filters
Sipol’s laboratories dedicated to R&D and characterization
polycondensation reaction (used for the polymerization of PET), allows this polymer to be chemically recycled, bringing it back to its main constituents (PTA and MEG). Taking advantage of this principle, Sipol’s R&D department has launched an innovative development process to increase the sustainability of its engineering plastics. Technipol 232 was born as an evolution of the existing Technipol 32, which is widely used for bonding, sealing and for the flexible reinforcement of both engine air and engine oil filters in the automotive industry. Thanks to one of its monomeric components of natural origin, Technipol 32 has a renewable
resource content of 29%. The new developed co-polymer, Technipol 232, was born by replacing part of those non-bio-based monomers with those obtained from the chemical recycling of post-consumer PET from bottles at a rate of 21%. The process developed for its production kept the original properties and performances of Technipol 32 unchanged and, at the same time, allowed the increase of its environmental sustainability, with some benefits also in terms of cost reduction. Technipol 232 is currently under approval at some main European Tier 1 automotive filter manufacturers. www.sipol.com
93
MATERIALS AND APPLICATIONS
NEWS Henkel and Covestro to combine their strengths to promote e-mobility
ADHESIVE SOLUTIONS FOR EFFICIENT LI-ION CELL ASSEMBLY With a strong consumer push to reduce electric vehicle prices, large-scale and cost-efficient lithium-ion battery cell assembly is a prerequisite for every automotive OEM. In their most recent collaboration, Henkel and Covestro developed a solution enabling the efficient fixation of cylindrical Li-ion battery cells inside a plastic cell holder. The solution is based on a UV-curing Loctite AA 3963 adhesive from Henkel and a UV-transparent polycarbonate blend from Covestro. They were developed for compatibility with high-volume automated dispensing techniques and offer flexible and fast cure mechanisms. The acrylic adhesive was formulated for use with the cell holder, which is constructed of a special flame-retardant plastic. It provides strong adhesion to the substrate material and offers production adaptability through long open times and short cure cycles. “High-volume manufacturing operations with short cycle times and process flexibility are essential”, explains Frank Kerstan, head of e-mobility Europe at Henkel. “The Loctite OEM-approved adhesive designed to secure cylindrical Li-ion cells into a carrier is a one-part, cure-on-demand formulation. After high-speed dispensing, the material’s long open time inherently builds adaptability into the process by allowing for any unexpected production interruption. Once all cells are placed into the adhesive and secured in the holder, curing is activated with UV light and takes place in less than five seconds”. This is a major advantage over conventional manufacturing where curing times can range from several minutes to hours, thus requiring additional storage capacity for parts. The cell holders are manufactured from Covestro’s PC+ABS Bayblend FR3040 EV. With a thickness of only one millimetre, the plastic already meets category V-0 of the Underwriters Laboratories’ UL94 flammability rating, but shows good permeability for UV radiation in the wavelength range above 380 nanometres. “The material allows us to construct dimensionally stable parts that are necessary for automated mass assembly”, says Steven Daelemans, market development manager e-mobility in the Polycarbonates segment at Covestro. “Together with the fast-curing capability of the Loctite adhesives, this material combination delivers an innovative approach to large-scale cylindrical Li-ion battery module production”. www.covestro.com - www.henkel.com Battery modules with cylindrical cells are constructed with Covestro’s Bayblend material and efficiently assembled with Henkel’s Loctite adhesive
94
More circular economy for Lanxess
Recycled glass fibres in the new ECO family of polyamides Specialty chemicals company Lanxess is increasingly making use of recycled raw materials in the production of its thermoplastic compounds and composites. “We want to help make the switch from a throw-away society to a circular economy. Our goal is to make more and more of our plastic products sustainable”, explains Günter Margraf, global product manager at the company’s High Performance Materials (HPM) business unit. Durethan ECOBKV30H2.0, ECOB- Lanxess also uses waste KV35H2.0 and ECOBKV60XF are glass at its glass fibre production facility in Antwerp the most recent examples of products made in line with this strategy. Recycled fibres manufactured from waste glass make up 30%, 35% and 60% by weight respectively of these three new polyamide 6 compounds. Ecocycle, an independent inspection company, has examined the amount of recycled material in each compound and the long-term use of the glass waste stream using the mass balance method and awarded an ecoloop certificate in accordance with ISO 14021:2016. The glass comes from waste left over from glass fibre production (post-industrial recycling). The mass balance approach is derived from an initiative launched by the non-profit Ellen MacArthur Foundation and is employed by a lot of companies around the world. HPM’s primary target for the three new compounds is the automotive industry. As Margraf explains, “For instance, Durethan ECOBKV60XF offers exceptional strength and rigidity, which make it suitable for manufacturing structural components such as front ends, pedal bearing brackets and A-, B- and C-pillars, as well as lightweight battery trays for electric vehicles”. The Lanxess business unit is going to be gradually increasing the number of ECO product types certified in accordance with the mass balance method. For example, it is planning to launch a new polyamide 6 with a glass fibre content of 30% and a reduced carbon footprint. The caprolactam required to produce this more environmentally friendly PA6 is based on a selection of petrochemical raw materials which support this concern. HPM is not currently using waste glass fibres from end-of-life components, but does view them as a particularly sustainable raw material for use in manufacturing new glass fibres. After all, they do offer similar benefits as the domestic collection and recycling of glass containers, which have been practiced successfully for quite some time. Waste glass melts at lower temperatures than the raw materials used in manufacturing glass fibres. It therefore makes it possible to save energy and thus lower CO2 emissions. “Using waste glass cuts down on the use of resources as well, because it saves glass raw materials”, says Margraf. “It also means there’s no need to dispose of the waste glass”. www.lanxess.com MACPLAS INTERNATIONAL OCTOBER 2020
Masterbatches
Green research and innovation
additives for engineering polymers, with the aim of obtaining innovative effects, new colour shades and performance that will allow the users of these products to differentiate in their own market. The current range includes: • Masterbatches: suitable for extrusion, injection moulding, filming and blow moulding processes, they come in a wide range of colour shades and high-performance raw materials complying with the regulations in force in the different industry sectors. • Additives: an ever-evolving range designed for meeting increasingly sophisticated needs, providing technical added value to the new products launched on the market. • Biomasterbatches (registered trademark): the TÜV certificate ensures that these products are eligible for biopolymer applications. These biopolymer-based masterbatches are easy to use and deliver top performance even when added in low quantities.
Plastics bottles are more transparent thanks to Vanetti masterbatches
• MasterbatchRecy (registered trademark): a brand new range of masterbatches obtained from post-consumer polymers, developed to comply with the new European rules on the reuse of plastics with total respect for the environment. Three ISO certifications (9001:2015, 14001:2015, 45001:2018), together with the new energy certification, have been obtained thanks to tireless commitment in the research of ecologically sustainable products, using high-tech, energy-saving laboratory instruments and production processes. The company’s aim, unchanged since 1971, is to deliver high quality products to customers, to guarantee them the safe use and development of high-quality end products and, above all, to create safe products that respect the environment at all stages of production through to the finished product. www.vanettimaster.com
promaplast srl
The Italian company Vanetti announced that it has set up a new in-house laboratory (its third laboratory) devoted entirely to green and ecologically sustainable research, allowing fully eco-friendly production processes to be offered throughout all stages of manufacturing. This laboratory provides further confirmation of the company’s philosophy which, thanks to its continual evolution, confirms its commitment to respecting the environment in every field when carrying out its activities. The company is therefore able to provide its customers with cutting-edge, reliable products that comply with environmental regulations for finished products. The TÜV certificates have made it possible to enlarge the range of Vanetti’s Biomasterbatches (registered trademark), which has been available for many years. The company also developed a new line of masterbatches and
A third laboratory entirely devoted to “green” research has enabled Vanetti to develop fully eco-friendly production processes
www.amaplast.org
ADV Amaplast 172x125 mm IT-ING.indd 2
MACPLAS INTERNATIONAL OCTOBER 2020
24/09/20 12:54
95
MATERIALS AND APPLICATIONS
NEWS Thermoplastic elastomers
Identity under the mask World has definitely changed since the arrival of Covid-19. Our living and working habits did the same along with our reference points and priorities. There have been different reactions against the pandemic. From a professional point of view, we have seen and experienced several changes: numbers, mood, attitude. All of us have suffered and took part at the changes. Italian company Francesco Franceschetti Elastomeri (FFE) has lived the lockdown and the following restart with the awareness of its geographical location between Bergamo and Brescia, the two Italian cities which have been worst hit. During this hard and complicated period even just to tell, the company has showed all the values and motivations that have always distinguished it and now they stood out in a stunning way. The first thing to be proud of is the helpfulness of the whole internal team towards different working ways: in the office, in the production department or in smart working. Since the first days of the pandemic, the whole company showed commendable contribution to the organisation and implementation of the new habits, respecting the norms and the safety of every single employee.
During the lockdown FFE has faced the pandemic and the fall of the demand by continuing to produce and by seizing new opportunities like the unexpected and suddenly growing request of disposable protection masks together with the sterilisable and reusable ones. Its Marfran and Marfran.Med TPEs (thermoplastic elastomers) are ideal for this application, both for the realisation of the facial sealing and for the entire support structure of the mask. The first representative example of this wave of requests was the solidarity venture of the wellknown Italian company Negri Bossi, that manufactures injection moulding machines for plastics. In their plant in Cologno Monzese (Milan), they used two lines to produce protection masks. Together with Francesco Franceschetti Elastomeri, Negri Bossi was at the head of a consortium of
Additives for biaxially-oriented polyethylene
Optimum quality for specific BOPE film structures Mono-material packaging is preferred to multi-material packaging to meet recycling targets set by the European Union for plastic packaging and boost the quality of mechanically-recycled material. Because the polypropylene (PP) recycling stream does not exist at scale in many countries and the polyethylene (PE) recycling stream is prevalent, the development of biaxially-oriented polyethylene (BOPE) film applications is emerging. BOPE film production also benefits from idle ca-
96
pacity on existing biaxially-oriented polypropylene (BOPP) film manufacturing equipment, requiring only an adjustment in processing conditions with no major machinery changes.
New Ampacet BIAX4CE portfolio for BOPE film applications supports the circular economy
companies which helped to manufacture in less than five weeks reusable and sterilisable masks with interchangeable filter made with medical thermoplastic elastomer Marfran.Med 50A M, offered as a social contribution. FFE’s employees are proud to have been chosen and significantly contributed to this initiative, which recognizes the technical and qualitative value of the materials and services provided, and shows the values of solidarity and sense of belonging that distinguish them. More recently FFE has been contacted from different companies, some of them just because of the need arose from the emergency situation like iMask, a young Sicilian start-up that designed an innovative reusable mask with interchangeable filter made with Marfran.Med compounds. www.f-franceschetti.it “A future full of challenges awaits us, but thanks to our experience as a company and as individuals we are aware of our strength, resilience and values that support and identify ourselves under every mask… better if made with our Marfran and Marfran.Med TPEs”, told Francesco Franceschetti, general manager of FFE
In laminated packaging structures, BOPE film allows substitution of some non-polyethylene substrates such as BOPP, BOPA, BOPET and CPP in the manufacture of mono-material PE packaging, leading to an improvement in the quality of the mechanically recycled PE stream, while requiring compromises on some packaging functionalities such as lower stiffness, gloss and gas barrier characteristics. BOPE structures present advantages over BOPP, including greater seal strength, improved packaging seal integrity and better puncture resistance. BOPE also has proven superior to PE blown films in downgauging, higher output and yield, better optics and tighter gauge control.
With decades of experience in masterbatches for BOPP film and PE blown film applications, Ampacet has recently introduced BIAX4CE masterbatch portfolio specifically designed for biaxially oriented polyethylene film. This portfolio includes additives as well as white masterbatches formulated to meet optimum quality and processing requirements for specific BOPE film structures. The Ampacet BIAX4CE additive range includes antiblock, antistatic, migrating and non-migrating slip, as well as high performance antifog masterbatches. BIAX4CE portfolio and other Ampacet sustainable solutions will be exhibited at PRSE, booth E25 (Amsterdam, October 27-28, 2020). www.ampacet.com
MACPLAS INTERNATIONAL OCTOBER 2020
IGN als S E D eri at &m
tec smar hno t log y
ty
ili b a n
tai s u S
ADV A4_2021 (no Alliance).indd 1
25/06/20 12:48
TRADE FAIRS AND CONFERENCES
The most important European plastics and rubber exhibition of next year
Plast 2021, the organization restarts
EXHIBITIONS & TRADE FAIRS 2020 November 3-6 - Ecomondo (Rimini, Italy) November 8-11 - Packexpo (Chicago, United States) November 9-12 - Adipec Expo & Conference (Abu Dhabi, United Arab Emirates) November 10-12 - Composites for Europe (Stuttgart, Germany) November 14-17 - Iranplast (Teheran, Iran) November 18-20 - Central Asia Plast World (Almaty, Kazakhstan) November 18-21 - Plastprintpack Iraq (Erbil, Iraq) November 23-24 - Europe Rubber & Latex (Budapest, Hungary) November 23-25 - Ecomondo Brasil (São Paulo, Brazil) November 24-26 - Plastics & Rubber Vietnam
After the suspension of all non-essential activities due to the Covid-19 pandemic, organization restarts for Plast 2021, the international exhibition for the plastics and rubber industries, taking place in Milan from May 4 to 7 of next year. Roughly 450 direct exhibitors (excluding the represented companies) have already confirmed their participation in the fair, reserving an area of 35,000 square metres. One fifth of subscribers are foreigners, in addition to Italian branches of foreign manufacturers. The effects of the pandemic greatly conditioned worldwide fairs, causing the cancellation of all events in spring and summer 2020 and moving the ones planned for this autumn to 2021. This was the case for various international plastics and rubber trade fairs and also for important events regarding the packaging and converting sector, such as Interpack and Drupa, originally planned for May and June 2020 but postponed to spring 2021. Such changes led to the decision to confirm the next edition of Plast between May 4 and 7, 2021, and to reschedule the other four fairs of The Innovation Alliance (Ipack-Ima, Meat-Tech, Print4All, and Intralogistica Italia), also due to the congestion at the Rho-Pero exhibition district. The Innovation Alliance project, favouring synergies amongst complementary sectors, is still a definite go. Although the five exhibitions are scheduled for different times, the organizers have already begun to plan unifying initiatives to assist operators in the planning phase. Here are some of the key figures for the past edition of Plast (Milan, May 29 - June 1, 2018): total fair area: 55,000 sqm net; exhibition sectors represented: 75% machinery, 20% materials and products, 5% services; total exhibitors: 1,510 (1,049 direct and 461 via representatives) from 55 countries (57% Italian, 43% foreign); visitors: 63,000 (27.5% from outside of Italy) representing 117 countries. The upcoming edition of Plast will once again feature the three satellite exhibitions, each dedicated to a sub-sector of excellence and its associated start-ups: Rubber (dedicated to the world of elastomers, in collaboration with Assogomma), 3D Plast (focusing on additive manufacturing and related technologies), and Plast-Mat (exploring innovative materials). www.plastonline.org
98
(Ho Chi Minh City, Vietnam) November 30 - December 2 - LuxePack Monaco (Principality of Monaco) December 2-4 - Plastics Expo Tokyo (Tokyo, Japan) December 2-5 - Plast Eurasia and Rubber (Istanbul, Turkey) December 7-11 - Wire & Tube (Düsseldorf, Germany) December 18-21 - Myanmar PlasPrintPack (Yangon, Myanmar)
2021 January 11-14 - Plastimagen (Mexico City, Mexico) January 25-28 - Saudi Plastics & Petrochem (Jeddah, Saudi Arabia) January 26-29 - Interplastica (Moscow, Russia) February 10-12 - A&T (Turin, Italy) February 25 - March 3 - Interpack (Düsseldorf, Germany) March 9-11 - JEC World (Paris, France) March 16-20 - Koplas (Seoul, South Korea) March 30 - April 1st - PlastPrintPack Nigeria (Lagos, Nigeria) April 13-15 - Utech Europe (Maastricht, The Netherlands) April 13-16 - Chinaplas (Shenzhen, China) May 4-7 - Plast (Milan, Italy) May 17-21 - NPE (Orlando, United States) May 31 - June 2 - Egyps (Cairo, Egypt) June 2-5 - Plastexpo (Casablanca, Morocco) June 2-5 - The Indonesian International Plastics, Processing, Packaging and Printing Exhibitions (Jakarta, Indonesia) June 15-18 - FIP (Lyon, France)
NOTE: The trade show calendar could be subjected to change due to the health emergency caused by Covid-19. Therefore, we invite you to visit www.macplas.it to take note of all possible postponements. MACPLAS INTERNATIONAL OCTOBER 2020
COURSES & CONFERENCES Austria November 30 - December 3, 2020 - Vienna: European Bioplastics Conference (converted to webinar) - European Bioplastics (www.european-bioplastics.org)
Germany November 3-4 - Amburgo: Chemical Recycling Europe - AMI (www.ami.international/events) November 9-10 - Cologne (converted in webinar): Plastic Free World - European Bioplastics (https://plasticfree-world.com) November 17-18 - Berlin: Plastic: Design for Sustainability Europe - AMI (www.ami.international/events) November 30 - December 2 - Düsseldorf: Fire Resistance in Plastics Europe - AMI (www.ami.international/events) December 8-9 - Francoforte: Thermoplastic/Silicone Elastomers World Summit - Smithers Rapra (www.elastomer-forum.com)
Spain November 2-5 - Barcelona (converted in webinar): Sustainability in Packaging Europe Smithers Rapra (www.smithers.com/events)
The Netherlands November 25-26 - Rotterdam: Biobased Coatings Europe - ACI (www.wplgroup.com/ aci/event/biobased-coatings-europe) December 7-9 - Amsterdam: Digital Print for Packaging Europe & E-Pack Europe - Smithers Rapra (www.smithers.com/events)
United States November 10-12 - Charlotte (North Carolina): Carbon Black World - Smithers Rapra (www.carbonblackworld.com) November 30 - December 2 - New Orleans (Louisiana): Stretch & Shrink Film North America - AMI (www.ami.international/events) December 1-2 - Cary (North Carolina) converted to webinar: Elementary Nonwovens Training Course - Inda (www.inda.org)
Webinars
Is Cyclic Gas Injection EOR the Future for Unconventional Resources? SPE (www.spe.org) November 16-20 - Webinar: Global Bioeconomy Summit - Biocom & European Bioplastics (https://gbs2020.net) November 24-26 - Webinar: SPE Virtual Workshop: Asia Pacific Digital Week - Digital and Data Driven Oilfields - SPE (www.spe.org/events/en/2020/
workshop/21wm14/asia-pacific-digital-week) December 1-3 - Webinar: P&P (Plastics & Paper in Contact with Foodstuffs) - Smithers Rapra (www.smithers.com/events)
NOTE: The event calendar could be subjected to change due to the health emergency. Therefore, we invite you to visit www.macplas.it to take note of all possible postponements.
Chinaplas moves to Shenzhen for April 2021 debut
Embracing post-pandemic opportunities The 34th edition of Chinaplas has been rescheduled to April 13-16, 2021, for the first time at a new venue - Shenzhen World Exhibition & Convention Center. Therefore, in the future the trade fair will alternate between Shenzhen (odd years) and Shanghai (even years), continuing to empower upstream and downstream plastics and rubber companies to uncover greater opportunities in the new phase of China’s economic development. During a recent virtual press conference, Stanley Chu (chairman of the organizer Adsale), Ada Leung (general manager) and Norris Chu (project director) announced the latest updates about the trade show, shared word of emerging developments from a new starting point, and discussed post-pandemic opportunities. Over the years, China’s plastics and rubber industries have laid a solid foundation and built strong resilience and continuity into the economy. Combined with continually emerging new trends and opportunities, all signs currently point to a positive outlook. In the first quarter, as a result of the coronavirus pandemic, business shutdowns, the Chinese New Year off-season and other factors, China’s plastic products output dropped 22.9% from the same period of 2019. Production resumed in April in an orderly way, and industries’ supply chains gradually returned to normal operations. In April, the year-on-year decline in the total output of plastic products narrowed, achieving a recovery of 8.6% from the previous month. In the battle against the pandemic, plastics played a key role in the production and
supply of vital healthcare materials, personal protective equipment, medical supplies, and medical facility construction. Furthermore, the post-pandemic era is seeing the acceleration of next-generation 5G wireless technology, artificial intelligence (AI), autonomous vehicles, high-end medical products, antibacterial and antimicrobial surfaces for use in everything from cars to appliances, and more. For its part, Chinaplas is accelerating the integration of online and offline show experiences and so it decided to launch “Chinaplas+” (online + offline services). For online experiences, Adsale has successfully held nine webinars on hot topics during the pandemic, building a cloud communication bridge for industry players. For offline experiences, the organizer will host new technical seminars and publish materials such as “Feature: Resuming Production” prior to the show, whereas international forums on industry trends, Tech Talk, thematic events on hot topics will be organized during the show to create a seamless integration between online and offline activities and transform a four-day exhibition to a 365day, non-stop communication platform. www.chinaplasonline.com
Next edition of Chinaplas will be held for the first time at the Exhibition Center in Shenzhen
November 2-19 - Webinar: SPE Virtual Forum: MACPLAS INTERNATIONAL OCTOBER 2020
99
EDITORIAL CONTRIBUTORS
THE FOLLOWING COMPANIES ARE MENTIONED IN THIS ISSUE:
MUCH MORE THAN A magazine MACPLAS SPLITS INTO THREE: MAGAZINE NEWSLETTER WEBSITE. MUCH GREATER VISIBILITY.À MANY MORE CONTACTS. MANY MORE BUSINESS OPPORTUNITIES.
ON THE MARKET FOR MORE THAN
YEARS
Publisher Promaplast Srl Centro Direzionale Milanof ori Palazzo F/3 - 20057 Assago (MI) phone (+39) 02 82283775 - fax (+39) 02 57512490 macplas@macplas.it - www.macplas.it For advertising: lerner-media@t-online.de
100
COMPANY/ASSOCIATION/INSTITUTE PAGE ACIMAC 13 AMAPLAST 10; 13 AMI 17 AMPACET 96 ARBURG 30 AUTHENTIC PRODUCTION 44 BANDERA 50 BARUFFALDI 75 BASF 88 BD PLAST 76 BFM 54 BIESSE 41 BMB 48 BREAK POLYMER 70 CHINAPLAS 99 CIMBRIA SEA 82 CM EVOLUTION PLAST 79 CMS 37 COVESTRO 94 CROSA 41 EUPC 25 EUROPEAN BIOPLASTICS 19 EUROVITI 67 EXTOL 88 FACHPACK 85 FAST RADIUS 88 FIMIC 64 FRANCESCO FRANCESCHETTI ELASTOMERI 96 GAMMA MECCANICA 46 GKN 88 GREENSAN 90 GVM 86 HAITIAN INTERNATIONAL 27 HELIOS ITALQUARTZ 82 HENKEL 88; 94 HP 88 HRSFLOW 72 ICIS 16 IK 86 IMG 27 INGLASS 72 IPM 58 LABORPLAST 24 LANXESS 94 MAST 61 ME.RO 80 MIXACO 74 MOBERT 52 NOVA-INSTITUTE 19 OECHSLER 88 PLACITY RECYCLING 82 PLAST 2021 98 PLASTIBLOW 57 PLASTORE 92 PRESMA 52 PROFILE DIES 56 PROTOTAL 88 ROBOLINE SYTRAMA 76 SALDOFLEX 56 SARA 53 SIPOL 93 STAR AUTOMATION EUROPE 74 STRATVIEW RESEARCH 16 TECNOMATIC 44 UCIMA 13 VANETTI 95 VINYLPLUS 24 ZAMBELLO 78 MACPLAS INTERNATIONAL OCTOBER 2020
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.
www.bmb-spa.com