MACPLAS INTERNATIONAL
Supplement of August-September 2017 - Published by Promaplast Srl - Centro Direzionale Milanofiori - Palazzo F/3 - 20090 Assago (Milano, Italia) - ISSN 0394-3453
THE MAGAZINE FOR THE PLASTICS AND RUBBER INDUSTRY
ITALIAN MACHINERY MANUFACTURERS - SUSTAINED GROWTH IN FOREIGN TRADE www.macplas.it DESIGNING FOR REUSE AND RECYCLING MAXIMISING THE PRODUCTIVITY OF PLASTICS PROCESSORS LONG-CHAIN POLYAMIDES FOR TECHNICAL APPLICATIONS www.ultrasystem.ch
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INNO VA TION
BIESSE.COM
TECHNOLOGY FOR CREATIVITY.
The new Materia range of machining centres, designed for the machining of thermoformed plastics and composites, offers a vast selection of technologies for the processing of materials considered complex because of their shape, size or the type of material used.
Materia CL
INSIDE 2017 19-21 OCTOBER PESARO, ITALY
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WATER AND OIL TEMPERATURE CONTROL UNITS - Wide range of heating powers, cooling capacity and pump performance - Operating temperature range from 30°C to 350°C - Modbus, Profibus,
DIGITAL MICROPROCESSOR CONTROL FOR SET AND ACTUAL TEMPERATURES AND SAFETY ALARMS - USER-FRIENDLY ELECTRONIC CONTROL WITH PID FUNCTION (PRECISION 0.5 °C) AND GRAPHIC SYMBOLS OF ALL FUNCTIONS
Digitale Mikroprozessorsteuerung zur Einstellung und Überwachung der Temperaturen und Alarme - Bedienerfreundliche Elektronische Regelung mit PID Algorithmus (Genauigkeit 0,5°C) und grafischer Anzeige aller Funktionen - Serielle Schnittstelle RS485 mit Modbus Protokoll
RS485 communication facility
Wasser und Thermalöl Temperiergeräte - Vielfältiges Angebot im Bezug auf Heizleistung, Kühlkapazität und Pumpencharakteristik - Betriebstemperaturen von 30°C bis 350°C - RS485, Modbus, Profibus,
EXECUTIONS AVAILABLE WITH - NO-SEAL VERTICAL PUMPS - CENTRIFUGAL PUMPS WITH SPECIAL SEAL - MAGNETIC PUMPS
Ausführungen verfügbar mit - Dichtungslosen Tauchpumpen - Kreiselpumpen mit Spezialdichtungen - Magnetgekoppelte Pumpen
Profinet Schnittstelle
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TECHNOLOGY OR DESIGN? ALL IN ONE SOLUTION.
FUTURA 40 THE NEW EXTRUSION LINE » Energy saving » Improved functional design » Easier man-machine interface » Process data control » Simplified maintenance » Remote assistance service » Higher safety standards
Barcelona / Spain 02 - 06 October 2017 Pav. 3 - Stand B290
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Friedrichshafen / Germany 17 - 21 October 2017 Pav. A6 - Stand 6111
www.friulfiliere.it
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CONTENTS
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13
10
MARKETING 10 13 16 18 18 20 20 21
23
23 26
28 28
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EDITOR’S LETTER BY ALESSANDRO GRASSI ITALIAN MACHINERY MANUFACTURERS - SUSTAINED GROWTH IN FOREIGN TRADE ITALIAN EXHIBITORS AT FAKUMA 2017 ITALY AMONGST THE FASTEST GROWING FLEXIBLE PACKAGING MARKETS PLASTIC WINDOWS CONTINUE TO REPLACE WOOD PRODUCTS HDPE - WESTERN EUROPE IS GROWING AGAIN AUTOMOTIVE WILL CONTINUE TO DOMINATE THE TPE MARKET THREE DIVISIONS FOR THE NEW DOWDUPONT HOLDING
PLASTICS AND ENVIRONMENT
26 27
30
30
DESIGNING FOR REUSE AND RECYCLING IMPORTANT GROWTH FOR THE ITALIAN BIOPLASTICS INDUSTRY THE CATERPILLAR THAT DIGESTS POLYETHYLENE RECOVERING PEF BOTTLES THE SAME WAY AS PET BOTTLES MORE THAN 45% OF THE MOST RELEVANT BIOPOLYMERS ARE PRODUCED IN ASIA LIMONENE IN PLACE OF BISPHENOL A
37 40 42 42 43 43 44 44 46 48 52 54 56 58 58 60 60 61 61 62 64 64
MACHINERY AND ANCILLARY EQUIPMENT 30 33
MAXIMISING THE PRODUCTIVITY OF PLASTICS PROCESSORS WHERE SMART BECOMES SMARTER AND SMARTER
65 65
NEVER SO FAST COEXTRUSION FOR MULTILAYER BOTTLES AUTOMATION AND SAFETY A MULTIPURPOSE BAG-MAKING MACHINE FOR STACKED BAGS HIGH-END PROCESSING TRANSFORMING IDEAS INTO CONCRETE DESIGN FIRSTHAND TWO IN ONE SINGLE-STATION MOULDING MACHINE FOR LARGE PARTS READY FOR NEW CHALLENGES ALL IS 4.0 COMBINING POWER AND VERSATILITY TO SIMPLIFY COMPLICATED PROCESSES “IMITATION IS THE SINCEREST FORM OF FLATTERY” A GREAT GOAL! THE ADVANTAGE OF BEING “SMALL” EFFICIENCY WITH LOW ENERGY CONSUMPTION TOWARDS INDUSTRY 4.0 INFRARED AND UV SOLUTIONS HOT RUNNER TECHNOLOGIES FOR COMPLEX CHALLENGES SUBSTANTIAL INVESTMENTS IN NEW PRODUCTION SITES A LIFE FOR SCREWS AND BARRELS SOLUTIONS FOR COMPOUNDERS AND MULTI-LAYER EXTRUSION LINES PROVIDE PROCESSORS WITH INNOVATION, FLEXIBILITY AND SERVICE A RECORD SUMMER ENHANCING THROUGHPUT AND PART QUALITY IN INJECTION MOULDING MACPLAS INTERNATIONAL AT FAKUMA 2017
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COVER STORY
MACPLAS INTERNATIONAL
Supplement of August-September 2017 - Published by Promaplast Srl - Centro Direzionale Milanofiori - Palazzo F/3 - 20090 Assago (Milano, Italia) - ISSN 0394-3453
THE MAGAZINE FOR THE PLASTICS AND RUBBER INDUSTRY
www.macplas.it
ITALIAN MACHINERY MANUFACTURERS - SUSTAINED GROWTH IN FOREIGN TRADE DESIGNING FOR REUSE AND RECYCLING MAXIMISING THE PRODUCTIVITY OF PLASTICS PROCESSORS LONG-CHAIN POLYAMIDES FOR TECHNICAL APPLICATIONS www.ultrasystem.ch
70
85
67
MATERIALS AND APPLICATIONS 67
TIME SAVING BY EMBRACING 3D PRINTING FOR SACRIFICIAL TOOLS 70 LONG-CHAIN POLYAMIDES FOR TECHNICAL APPLICATIONS 72 FROM DOSING VALVES TO LEAKAGE PROTECTION 76 AN UNQUESTIONABLE INNOVATION CONTENT 78 THE PURSUIT OF COLOURS 80 A NEW R&D CENTRE IN TARNÓW 80 THE ANTIMICROBIAL VALUE OF THE MARFRAN.MED AU FAMILY 81 COMPOUNDS AND MASTERBATCHES FOR ANY KIND OF INDUSTRIES 81 ANTI-CORROSION PROTECTANT FOR MOULDING APPLICATIONS 82 CLOSED-CELL-SEALING TECHNOLOGY FOR HIGH WATER RESISTANCE 82 SOLID SILICONE RUBBER FOR AUTOMOTIVE AND OVEN COMPONENTS 83 COLOURS THAT RESPECT THE PLANET 83 EFFICIENT COLOUR CHANGES
85
TRADE FAIRS AND CONFERENCES 85 PLAST 2018 - OVER 1,000 EXHIBITORS ALREADY REGISTERED
88 ONE OF THE FASTEST GROWING INDUSTRIES IN TURKEY 88 EXHIBITIONS & TRADE FAIRS 90 REGULATIONS, INNOVATIONS AND ENVIRONMENTAL IMPACT OF PVC
90 MEETINGS & CONGRESSES MACPLAS INTERNATIONAL AT FAKUMA 2017
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Purging compounds: a valuable resource Purging compounds help obtaining flawless products within a seamless production. In the beginning, cleaning procedures with purging agents of the first generations did not provide noteworthy benefits. Low cleaning power and lengthy purging processes made them seem like a burden to the eyes of most converters. Unfortunately, this vision remains imprinted even today. Market changes have altered production techniques and planning, and now purging compounds should be regarded as a valuable resource, rather than avoidable costs. Manufacturers are now focused on just-in-time production for reduced response times from suppliers to customers. Concretely, this implies smaller warehouse stocks and frequent changeovers in production. The main issues originating from these changes, among others, are black spots which appear when switching from one plastic resin to the other because of the difference in processing temperatures. Another frequent problem concerns colour stripes, when changing mainly from a dark colour to a bright one, or in colour changes with the latest neon colours. Ultimately, you could consider these as the underlying causes of the real problem: the long downtime required to safely eliminate these issues. In fact, timely response is essential under just-in-time manufacturing, and purging compounds will reduce both, the time spent on the actual changeover, as well as the time spent on getting rid of unforeseen appearance of defects thus decreasing drastically scrap production. Eventually, machine productivity will climb sharply. Shortened purging times do not just optimize production, they also come with reduced waste and energy consumption, which means a remarkable cost decrease as additional benefits to the manufacturer. It also provides a help towards a reduced carbon dioxide output for the environmentally conscious ones. Finally, a good purging agent will bring peace of mind to the quality management, who will see a strong decrease of production defects. It goes without saying that greater benefits are obtained with the best purging compounds. With continuous investments by Ultra System in research and development, Ultra Plast purging compounds are currently in their fifth generation. This generation, with Qualipurge technology, achieves one of the best results one can obtain in the branch so far. All Ultra Plast products are strictly without any toxic or abrasive components, and they do not generate smoke or bad smells. They are produced according to the world’s strictest legislation on food-contact and clean (white) room productions. www.ultrasystem.ch
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MACPLAS INTERNATIONAL
ADVERTISERS’ LIST 11 ARBURG
www.arburg.com
Supplement of MACPLAS August/September 2017
92 AMAPLAST
www.amaplast.org
22 BD PLAST
www.bdplast.com
Editor in chief Riccardo Ampollini
2 BIESSE
www.biesse.com
74 BINOVA
www.binovapm.it
Editorial staff Luca Mei, Girolamo Dagostino, Stefania Arioli
91 CHINAPLAS
www.chinaplasonline.com
66 COLOR TECH
www.colortechsrl.it
69 EPROTECH
www.eprotechsrl.com
Sales office Giuseppe Augello Editorial assistant Giampiero Zazzaro Editorial committee Alessandro Grassi, Andrea Franceschetti, Massimo Margaglione, Corrado Zanga Contributors to this issue Assobioplastiche, Ceresana, ECVM, EPBP, Freedonia Group, Angelo Grassi, Institute of Chemical Research of Catalonia, nova-Institut, Oreste Pasquarelli, PCI Wood Mackenzie, Smithers Rapra, Spanish National Research Council Published by Promaplast Srl Centro Direzionale Milanofiori - Palazzo F/3 20090 Assago (Milano, Italy) Tel.: +39 02 82283735 Fax: +39 02 57512490 e-mail: macplas@macplas.it www.macplas.it Registration at the Court of Milan n. 68, 13/02/1976 Registration at the National Press Office n. 4620, 24/05/1994 Managing director Mario Maggiani Administration Alessandro Cerizza Layout and prepress Nicoletta Albiero Printed by Prontostampa Postal delivery: IFS Italy
36 FILIPPINI & PAGANINI
www.saldoflex.it
29 FIMIC
www.fimic.it
57 FRANCESCHETTI ELASTOMERI
www.f-franceschetti.it
21 FRIGEL FIRENZE
www.frigel.com
3 FRIGOSYSTEM
5 FRIUL FILIERE
www.frigosystem.it www.friulfiliere.it
27 GAMMA MECCANICA
www.gamma-meccanica.it
9 GIURGOLA STAMPI
www.giurgolastampi.com
55 GRAFE
www.grafe.com
45 HELIOS ITALQUARTZ
www.heliosquartz.com
39 HRSFLOW
www.hrsflow.com
89 IPF
www.ipfjapan.jp
77 MAST
www.mastsrl.it
63 MOBERT
www.mobert.it
15 MORETTO
www.moretto.com
12 NEGRI BOSSI
www.negribossi.com
38 NORDSON
www.nordson.com
41 PLAS MEC
www.plasmec.it
75 PLAST 2018
www.plastonline.org
87 PLAST EURASIA
www.plasteurasia.com
59 PLASTIBLOW
www.plastiblow.it
84 PLASTIMAGEN
www.plastimagen.com.mx
19 PRESMA
www.presma.it
4 PROMIXON
www.promixon.com
51 RADICIGROUP
www.radicigroup.com
35 SALDOFLEX
www.saldoflex.it
32 SIPOL
www.sipol.com
47 STAR AUTOMATION EUROPE
www.star-europe.com
Cover, 93 ULTRA SYSTEM
www.ultrasystem.ch
www.vanettimaster.com
25 VANETTI
Back Cover ZAMBELLO www.zambello.it
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
INSTITUTIONAL SPONSORS AMAPLAST ITALIAN PLASTICS AND RUBBER PROCESSING MACHINERY AND MOULDS MANUFACTURERS’ ASSOCIATION ASSORIMAP ASSOCIATION OF ITALIAN PLASTICS RECYCLING AND RECLAIMING COMPANIES AIPE ITALIAN ASSOCIATION OF EXPANDED POLYSTYRENE IIP ITALIAN PLASTICS INSTITUTE
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UNIONPLAST ASSOCIATION OF ITALIAN PLASTICS PROCESSING COMPANIES SPE ITALIA SOCIETY OF PLASTICS ENGINEERS CIPAD COUNCIL OF INTERNATIONAL PLASTICS ASSOCIATIONS DIRECTORS UNIPLAST ITALIAN STANDARDISATION BODY FOR PLASTICS
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STAND A5-5117
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EDITOR’S LETTER
“
ASSOCOMAPLAST CHANGES ITS NAME AND BECOMES AMAPLAST In a logic of renewal and in order to further strengthen the image of our association and the machinery manufacturers it represents, I submitted a proposal, in agreement with the board and the executive committee, to change the name of the association from Assocomaplast to Amaplast, a shorter name, easier to pronounce, especially for non-native speakers. On June 7, to my great satisfaction, the member assembly unanimously approved the new name during its annual meeting. A shorter acronym was also adopted: AMP (Associazione Macchine Plastica), with a three-colour logo green, white, and red (the colours of the Italian flag) - as a reference to our national identity. I am fully aware that changing the association name is a challenging choice, but the objective is not a fresh start, forgetting about over fifty years of history ... quite the contrary. In a period when plastics are constantly in the spotlight and often criticized, the new name sends out a positive signal and aims at strengthening the idea of an organization and a group of companies committed to the development and spread of cutting-edge technology for the production of quality products, with a careful eye on environmental sustainability, reduction of raw material consumption (by adopting, for example, increasingly thinner packaging), and energy saving. The association was founded in 1960 with the aim of raising awareness and encouraging the use, across the world, of Italian plastics and rubber processing technology, now ranking quite high, in terms of production and exports, worldwide. Since the early 50s, the Italian manufacturers have offered a complete range of original, reliable machines. Today, Amaplast (a member of Confindustria) represents over 160 major Italian companies manufacturing plastics and rubber processing machinery, ancillary equipment and moulds.
Alessandro Grassi, president of Amaplast
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”
MACPLAS MACPLAS INTERNATIONAL INTERNATIONAL AT FAKUMA AT k 2017
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QuALITy KNOw-HOw
MACHINES TECHNOLOGIES
THE HOME OF INJECTION MOuLDING MARKET LEADERSHIP PASSION vISION
INNOvATION
r 17-21 O c to b e 3101 , B o oth 3 A ll a H , n fe a sh Frie drich y n a rm Ge
For as long as ARBURG has been involved with injection moulding, its aim has always been to be the home of the process. You won’t find another company in the world that is dedicated to the development and perfection of injection moulding with the same level of consistency and commitment. We always have one objective in mind: your success. www.arburg.it
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PLAST 2015
MARKETING
ITALIAN MANUFACTURERS OF MACHINERY AND ANCILLARY EQUIPMENT
SUSTAINED GROWTH IN FOREIGN TRADE THE END-OF-JUNE STATISTICS HIGHLIGHTING CONTINUING GROWTH IN EXPORTS ARE AN IMPORTANT SIGNAL FOR ITALIAN MANUFACTURERS OF PLASTICS AND RUBBER PROCESSING MACHINERY, EQUIPMENT, AND MOULDS
I
mports up by 9.1%, exports by 14.6%: these are the results of the first half of 2017 with respect to the same period in 2016 based on the analysis of Istat (Italian national institute of statistics) foreign trade data by the Amaplast Statistical Studies Center. The two trends point to further improvement in the positive balance of trade for the sector (by more than 1.1 billion euros), with an increase of seventeen percentage points compared to January-June 2016. While imports have slightly slowed down with respect to year-end 2016 and the first months of 2017, sales abroad confirm the robust double-digit growth that has characterized the entire first half of 2017. As regards exports - the main outlet for national production in the sector - Italian machinery manufacturers may consider themselves satisfied both as regards the range of products and in terms of the geography of sales.
MACPLAS INTERNATIONAL AT FAKUMA 2017
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ing machines, and machines for foamed materials, all machine types have recorded marked improvement in foreign demand, and particularly extrusion lines (+17% over the previous year), flexographic printers (+23%), thermoforming machines (+37%), and moulds (+18%), just to mention some of the principal customs codes.
PERFORMANCE BY MACHINE TYPE
PERFORMANCE BY GEOGRAPHY
With the exception of negative performance in plants for mono- and multi-filament, blow mould-
Europe As for outlets, Europe remains the principal destination market (see figure 1). Sales within the EU have increased by over twenty percentage points with respect to the first six months of 2016, and a similar upsurge is recorded across the rest of Europe generally. It is worth underscoring the positive performance in Russia, where the value of sales more than doubled from approximately 21 to nearly 50 million euros. Americas The Americas absorbed a fifth of Italian exports in the sector, with an increase on the order of ten percentage points, imputable mainly to growth “The new name Amaplast aims at strengthening the idea of an organization and a group of companies committed to the development and spread of cutting-edge technology, with a careful eye on environmental sustainability”, said Amaplast’s president, Alessandro Grassi
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MARKETING
AMAPLAST PRESIDENT’S COMMENTS “It should be noted”, points out the satisfied president of Amaplast Alessandro Grassi, “that the recovery in supplies to important historical markets such as Russia and Brazil, which were sputtering in the recent past due to their respective, well publicized economic and political problems, gives a quite significant boost in confidence for companies in our sector”. “The end-of-June statistics highlighting continuing growth in exports for the sector”, continues Grassi, “are an important signal for Italian manufacturers of plastics and rubber processing machinery, equipment, and moulds, who thus have a more tangible perception of recovery in their market and can look forward to a new record in production and exports at year end. Com-
Plast 2018 is a member of “The Innovation Alliance”, which unites five international exhibitions (Ipack-Ima, Meat-Tech, Plast, Print4All and Intralogistica Italia), all accessible with a single admission ticket
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Fig. 1 - Italian machinery exports by areas (shares and, below, Δ% 2017/2016) panies also note a parallel recovery in the domestic market, sustained in part by the stimulus measures implemented by the Italian government to support investment by manufacturers within an “Industry 4.0” approach. Italian manufacturers of plastics and rubber processing machinery are ready to contribute to the process by providing cutting-edge, competitive systems”. Confirming the above foreign trade statistics, the mid-year survey conducted at the end of July among Amaplast member companies, comparing the first half of 2017 with the same period in 2016, revealed a positive trend both in turnover (rising for 45% of the interviewees and stable for 51%) and current orders (improving for 51% of those surveyed and stable for 35%).
EVENTS IN THE PLASTICS INDUSTRY These months bring an intense calendar of major specialized trade fairs around the world, where Amaplast is playing an active role in promoting the made in Italy: • I ranplast (Tehran, September 24-27), where the association, together with ICE-Agenzia, coordinated the national collective of some thirty companies; • Equiplast (Barcelona, October 2-6); •P lastimagen (Mexico City, November 7-10), with some 40 exhibitors in the Italian pavilion; •P lastics & Rubber Indonesia (Jakarta, November 15-18); • Plast Eurasia (Istanbul, December 6-9). Naturally, the Italian presence at these exhibitions also offers the opportunity to intensify promotion of Plast 2018 (Milan, May 29 - June 1, 2018) among potential visitors. In the meantime, the organizational office of the fair has completed the stand assignment procedure, which is being reviewed by the more than one thousand currently registered exhibitors, who have reserved close to 90% of the available space. Plast 2018 is a member of “The Innovation Alliance”, which holds together five international fairs (Ipack-Ima, Meat-Tech, Plast, Print4All and Intralogistica Italia), all accessible with a single admission ticket, and will occupy the entire Rho-Pero fairgrounds. It will be the plastics
PLAST 2015
in Latin American markets, with Brazil in the lead (+73%). The Nafta countries, on the other hand, recorded more modest growth, due to a slowdown in sales to Mexico. Asia Sales to Asian countries remained rather stagnant, conditioned by a drop in exports to the Middle East in general, and specifically to Saudi Arabia and Iran. Sales to the Far East did not fare much better, dragged down by the -12% recorded for China, which was certainly not offset by the +1% to India (just looking at the two principal markets in the area). Africa While the aggregate sales to Africa are modest in value, Mediterranean countries and Sub-Saharan countries both recorded an increase approaching twenty percentage points.
industry’s most important event in Europe for 2018 and will also include three satellite fairs: Rubber 2018 (for the rubber segment), 3D Plast (3D printing and associated technologies), and Plast-Mat (innovative plastics).
AFTER THE NAME CHANGE, THE NEW WEBSITE IS NOW ONLINE On June 7, during the annual assembly, Assocomaplast was renamed Amaplast. The new shorter name is easier to pronounce, especially for non-native speakers. Besides that, a new, even shorter acronym - AMP, which stands for Associazione Macchine Plastica - and a new three-colour logo (green, white, and red, which refer to the Italian flag and thus to the national identity of the association) have also been adopted. Information on the plastics industry, as well as the full list of the associated companies, divided by name and typology of product, are available on the new website, under the new name and with a new graphic layout: www.amaplast.org. The association office has also created a brief animated presentation to underscore the importance of the new name. Currently, Amaplast represents more than 160 manufacturers of plastics and rubber processing machinery, equipment and moulds. www.amaplast.org MACPLAS INTERNATIONAL AT FAKUMA 2017
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MARKETING
ITALIAN EXHIBITORS AT FAKUMA 2017 ABATE BASILIO & C. AIGLE MACCHINE ALEA AQUATECH ARCA AUSERPOLIMERI BAUER COMPRESSORI BBG BINOVA BMB BMZ MOULDS CAMPETELLA ROBOTIC CENTER CANNON CB STAMPI CELLOPLAST CF CIMBRIA CMC CMS COFIT INTERNATIONAL COIM COMEC ITALIA COSSA POLIMERI CS PLASTIC DEPA STAMPI DIAP DIOMA DOMO ENGINEERING PLASTICS ELIOS EPAFLEX POLYURETHANES EPROTECH ERIMAKI ESSETI PLAST GD EUROCHIMIND FB BALZANELLI FILTEC FIMIC
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HALL STAND A7 7106 A7 7205 Foyer Ost 33 A7 7201 A5 5117 Foyer Ost 22 Übergang Ost 10 A7 7009 A6 6207 A4 4105 A5 5117 A7 7208 Foyer Ost 38 A7 7008 A5 5116 Foyer Ost 18 B1 1308 A5 5303 A1 1428 Foyer West 24 B2 2121 A1 1403 B4 4314 Übergang Ost 06 Übergang Ost 06 Foyer Ost 19 A5 5117 B4 4216 A4 4012 B5 5417 A2 2115 Foyer Ost 37 A5 5116 B4 4407 A6 6304 A6 6421 A6 6414
FI-PLAST FORMAC FP SERVICES FRANCESCHETTI ELASTOMERI FRANPLAST FRATELLI VIRGINIO FRIGEL FRIUL FILIERE GALDABINI GAMMA MECCANICA GEFIT GEFRAN GIMATIC GIURGOLA STAMPI GREEN BOX GRUNIVERPAL HBI HELIOS ITALQUARTZ HEROFLON IHR IMG C/O HAITIAN INTL. IMI FABI INGLASS - HRSFLOW INPROS INTERCABLE ISPER ITI POLYMERS LATI INDUSTRIA TERMOPLASTICI LAWER DOSING SYSTEMS LORANDI SILOS LUCCHINI RS MACPLAS MB CONVEYORS MENZOLIT MEPOL MILLUTENSIL MIOZZO ML ENGRAVING
B4 4314 Foyer Ost 77 A1 1500 B5 5212 B1 1306 A7 7212 A5 5108 A6 6111 Foyer West 42 Foyer West 31 A3 3306 A3 3005 A7 7204 A5 5117 A7 7214 A7 7300 Foyer West 111 A4 4201 B5 5212 A2 2405 A1 1101-1103 B4 4108 A2 2217 A4 4129 A7 7503 A5 5121 A5 5115 B2 2205 Foyer West 94 B3 3207 A1 1328 Foyer West FP (Press Corner) B1 1106 B4 4503 A5 5115 A6 6104 Foyer West 100 A6 6212
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ITALIAN EXHIBITORS AT FAKUMA 2017
MORETTO NEGRI BOSSI NOVA FRIGO ENGINEERING NUOVA RET NUOVA SITT OFFICINA CANNAROZZI OMG Srl OMG SpA OMMP-MOULDS OREMPLAST OTS PENTA PIOVAN PLAMATIC PLASTIC METAL PLASTICWOOD.IT PLASTRADING POLIBLEND POLIPLASTIC POLIS PROGIND RADICI PLASTICS RB RIALTI RITMO RIVI c/o RÖMHELD RIVI RMP SAVOINI ROMAGNANI STAMPI ROSÀ PLAST SABO SALA MAURIZIO STAMPI SARA SCM GROUP SCS (SOCIETÀ COSTRUZIONE STAMPI) SERISTAMPA SIMATEC SIRMAX SOREDI c/o TEKUMA
MACPLAS INTERNATIONAL AT FAKUMA 2017
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B3 3208 Foyer West 03 Foyer Ost 10 A1 1511 A1 1222 A5 5117 Foyer Ost 53 B3 3004 A4 4113 Foyer West 65 A7 7003 A7 7201 A7 7201 B3 3207 A7 7212 Foyer Ost 36 Foyer Ost 15 A5 5116 Foyer Ost 57 B4 4305 A1 1402 A1 1106 A7 7009 A4 4210 A6 6012 A1 1223 A1 1402 A5 5117 A6 6216 Foyer West 134 Foyer West 41 A6 6505 A1 1428 B1 1102 B3 3008 Foyer West 03 B2 2207 B1 1216
SPA (STAMPAGGIO PLASTICA AFFINI) A2 2102 STAMPLANET Foyer West 76 STAMPLAST A5 5226 STAR AUTOMATION EUROPE A7 7115 STILO GRAFICA Foyer West 23 SYTRAMA - ROBOLINE Foyer West 03 TAFER B5 5314 TARO PLAST B5 5207 TAURUS SAGES A5 5006 TECHNICAL PLAST Übergang Ost 12 TECNICA DUEBI A3 3113 TECNOMAGNETE A1 1207 TECNO SYSTEM Übergang Ost 14 TECNOMATIC A7 7405 TECNOSTAMPI FRATELLI PELIZZARI B5 5201 TECNOVA A6 6207 TECNOVITI A6 6207 TEXER DESIGN A4 4125 THERMOPLAY A1 1211 TOSH A1 1124 TOYO EUROPE - RP INJECTION A6 6222 TRAFLEX A6 6005 TRIA B3 3118 TVMP Foyer West 142 UCISAP A5 5117 UNIFORM A5 5117 UNION OFFICINE MECCANICHE Foyer Ost 60 VALTORTA ESERCIZI INDUSTRIALI C/O BATTAGGION A6 6111 VAMP-TECH A4 4004 VEGA A4 4125 VERSALIS c/o TEKUMA B1 1216 VIBA Foyer West 63 VIGNATI A2 2113 VIRGINIO NASTRI Foyer West 03 ZAMBELLO RIDUTTORI 2 A6 6105 ZANOLA Foyer Ost 33 ZOPPAS INDUSTRIES HEATING A7 7317 ZRE A5 5310
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MARKETING
NEWS Packaging in Europe
Italy amongst the fastest growing flexible packaging markets One of the last reports published by PCI Wood Mackenzie reveals the fastest growing major flexible packaging markets in Europe in 2016 were Italy, Poland and Turkey, each growing by more than 3% during the year. This compares
with growth in European flexible packaging of 2.1% overall. According to the report, Europe’s 13.8 billion euro flexible packaging market remains one of the largest and most sophisticated in the world, accounting for around 18% of
From the United States
Plastic windows continue to replace wood products Demand for plastic windows in the United States is forecast to rise 5.5% per year to 6.5 billion dollars in 2021, outpacing wood and metal windows and accounting for half of total sales. Home and business owners will continue to specify vinyl windows for their energy efficiency, low cost, and low maintenance. Specialty plastic windows are projected to see above average gains, spurred by increased demand for skylights, roof windows, and customized shapes. Fibreglass and wood-plastic composite products are expected to gain share, although vinyl will continue to represent over 90% of sales. These and other trends are presented in “Windows Market in the US”, a new study from The Freedonia Group, a Cleveland-based industry research firm. Plastic windows saw much faster penetration of residential (versus commercial) markets through 2016, primarily displacing wood products. Through 2021, the residential market for plastic windows is projected to advance 5.7% per year to 5.8 billion dollars, outpacing 4.0% yearly gains in the commercial segment. According to analyst Carolyn Zulandt: “The residential market will continue to account for nearly 90% of plastic window sales, as builders of commercial structures rely more heavily on metal products for their superior durability and security”. However, vinyl and fibreglass windows have displaced many wood windows used in offices, retail structures, and such structures as hotels and educational facilities. www.freedoniagroup.com
Source: The Freedonia Group
US plastic window market outlook
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Flexible packaging for tobacco products was the only category to register a contraction in Europe, mainly because of anti-smoking legislation, growth of the illicit tobacco trade, and the rapidly growing popularity of e-cigarettes
the global total in 2016. Looking forward, the consulting company forecasts that flexible packaging demand will pick up slightly in Europe in 2017, subsequently growing by 2.2% per year to reach 15.5 billion euros in 2021. PCI Wood Mackenzie’s Paul Gaster, said: “For the third year in succession there have been few inflationary pressures with volume consumption growth in most European countries broadly tracking that of value. Poland, in particular, stands out as a major market where demand has continued to grow strongly, underpinned by robust domestic demand and a successful focus on packaged food exports, especially into Western Europe”. In Italy, demand grew by 3% underpinned by the growing importance of supermarket retailing and changing consumer buying habits. Growth in Turkey, while significantly lower than earlier in the decade, continues to be boosted by a growing national economy, urbanisation, and relatively rapid population growth, including the influx of more than 3 million refugees fleeing the civil war in Syria. There has been some significant M&A activity in flexible packaging over the past year - 26 converters with more than 100 million euros of flexible packaging sales now account for nearly 70% of the total market. The most significant development has been the rapid emergence of Spanish international paper group Saica as a leading player in flexible packaging, having acquired Centroplast (Italy), Americk Packaging (UK) and three Netherlands based businesses - Schut Flexible Packaging, Hellema Verpakkingen, and Lemapack Flexible Packaging. Mondi has also been very active, having concluded three significant bolt-on acquisitions, buying Uralplast (Russia), Kalenobel (Turkey) and Excelsior Technologies (UK). According to the report, end uses are growing faster than the market as a whole and include coffee, snack foods, fresh produce, ready meals and pet food. However, flexible packaging sales for sugar and chocolate confectionery, one of the largest categories, were broadly unchanged. www.woodmac.com MACPLAS INTERNATIONAL AT FAKUMA 2017
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MARKETING
NEWS Future of thermoplastic elastomers to 2022
Global Market for HDPE
Automotive will continue to dominate the TPE market
Western Europe is growing again
Scutaro
High-density polyethylene (HDPE) is the type of polyethylene offering the highest rigidity and least flexibility. The rigid and slightly hard plastic is highly suitable for a broad range of applications such as rigid containers and tubes, as well as a variety of everyday household goods such as flasks, clothes pins, or handles of dishwashing brushes. Furthermore, HDPE is processed into films. Ceresana has already published the fourth study on the world market for HDPE. The latest study expects, on average, a 2.7% growth of HDPE demand per year up to 2024. The Asia-Pacific region is by far the largest consumer of HDPE with a global market share of about 45%. This region will experience the most dynamic growth in the upcoming eight years, but not to the same extent as in the past. The development in Western Europe is reversed - while the HDPE market only registered marginal growth in the past, it will presumably increase at higher rates. The most important HDPE methods of processing are extrusion, blow moulding, and injection moulding. The extrusion of films plays the most important role - almost 11 million tons were processed in 2016. Ceresana forecasts growth rates of 3.3% per year in the upcoming eight years for the processing of pipes and profiles by extrusion. Milk bottles, water pipes or fireworks - HDPE is used for a wide range of products. In 2016, this polymer was mostly used in the production of rigid packaging. Almost 28% of global HDPE was processed into butter dishes, yogurt cups, trays, bottles, boxes and caps. Another significant application area is product manufacturing for the construction industry, with products such as tubes and cables. The demand for HDPE in this segment will presumably develop in an especially dynamic way. www.ceresana.com
Building & Construction represent a significant application segment for high-density polyethylene
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The global market for thermoplastic elastomers (TPEs) will grow strongly across the next five years according to the latest exclusive research from Smithers Rapra. Its latest in-depth study - “The Future of Thermoplastic Elastomers to 2022� - charts how this sector has expanded at a Compound Annual Growth Rate (CAGR) of 5.45% since 2012 to reach 4.24 million tons in 2017. Even though TPEs is an increasingly mature market, Smithers research shows this growth will continue at a rate of 5.58% across the next five years to hit 5.53 million tons in 2022. The success of thermoplastics depends on their acceptance and growth within a number of different industries. The automotive industry, being the most important consumer of TPEs, sets the pace here. This segment grew at an above average rate of 5.9% for 20122017 and reached 1.84 million tons - or 43.4% of the total market - in 2017. The prediction for 2022 is a consumption of 2.46 million tons, representing a market share of 44.4% and a CAGR of 6.0%. TPE demand in medical application is also forecast to witness above-average growth for the future, and to a lesser extent packaging. Appliances and housewares; building and construction; sports, leisure, toys; and wire and cable are showing less-than-average growth but are nevertheless growing above regional GDPs. Equally, the economic health and growth of any country and region has a real effect on the supply and demand of thermoplastic elastomers. If a given market is suffering, due to outside competition, this will have a knock-on effect on TPE consumption. Styrene-block-copolymer-based TPEs (TPS) have long dominated the global market for thermoplastic elastomers, but it will slowly lose market share to other olefinic-based products over the next five years. In 2022, it will still be the most important thermoplas-
tic elastomer, but this may not last for very long. The main weaknesses of TPS are its higher price and the fact that there appear to be very few technical refinements in the pipeline. The introduction of cross-linkable TPS is showing some promise, but this is still a long way from commercial introduction. Furthermore, the low barriers to market entry for TPS is ensuring that there will continue to be overcapacity for this material for 2017-2022, especially in Asia and in particular China. High-performance elastomers represent just over 3% of the total global elastomer market. They more than make up for this with their well above-average revenue and profitability. Challenges to entering the high-performance elastomers market include technological demands that involve significant R&D costs; complex production systems; difficult to produce monomers or precursors; and more. Nevertheless, there are producers that are willing to face these challenges, even with such very high entry barriers. The global market for high-performance elastomers is considered to have been 918,300 tons in 2012, and is forecast to be 1.22 million tons by the end of 2017, with a CAGR of 5.8%; and growing from there to 1.66 million tons, with an increased CAGR of 6.4%. www.smithersrapra.com MACPLAS INTERNATIONAL AT FAKUMA 2017
25/09/17 18:59
DowDuPont merger successfully completed
Three divisions for the new DowDuPont holding On September 1 DowDuPont announced the successful completion of the merger of equals between Dow Chemical and DuPont, effective August 31, 2017. The combined entity is operating as a holding company under the name DowDuPont with three divisions Agriculture, Materials Science and Specialty Products. Shares of DuPont and Dow ceased trading at the close of the New York Stock Exchange on August 31, 2017. Beginning September 1, DowDuPont started trading on the New York Stock Exchange under the stock ticker symbol “DWDP”. Pursuant to the merger agreement, Dow shareholders
received a fixed exchange ratio of 1.00 share of DowDuPont for each Dow share, and DuPont shareholders received a fixed exchange ratio of 1.282 shares of DowDuPont for each DuPont share. “Today marks a significant milestone in the histories of our two companies”, said Andrew Liveris, executive chairman of DowDuPont. “While our collective heritage and strength are impressive, the true value of this merger lies in the intended creation of three industry powerhouses that will define their markets and drive growth for the benefit of all stakeholders. Our teams have been
working for more than a year on integration planning, and - as of today - we will hit the ground running on executing those plans with an intention to complete the separations as quickly as possible”. “For shareholders, customers and employees, closing this transaction is a definitive step toward unlocking higher value and greater opportunities through a future built on sustainable growth and innovation”, said Edward Breen, chief executive officer of DowDuPont. “DowDuPont is a launching pad for three intended strong
Edward Breen (DuPont CEO, on the left) and Andrew Liveris (Dow CEO) are respectively chief executive officer and executive chairman of the new DowDuPont holding
companies that will be better positioned to reinvest in science and innovation, solve our customers’ ever-evolving challenges, and generate long-term returns for our shareholders”. Dow (stand 3207, hall A3) and DuPont (stand 4200, hall B4) are exhibiting in different pavilions at the Fakuma fair, in Friedrichshafen. www.dow-dupont.com
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MACPLAS INTERNATIONAL AT FAKUMA 2017
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PLASTICS AND ENVIRONMENT
Finecki/Fotolia/PlasticsEurope
PROPOSAL FOR RECOMMENDATIONS FROM WORKING GROUP 11 “PLASTICS RECYCLING”
DESIGNING FOR REUSE AND RECYCLING T
he linear model of economic growth followed in the past needs to evolve in order to meet, more rationally and effectively, the needs of today’s companies, operating in a globalised world. Looking to the future, it is crucial to abandon the linear, or “disposable”, model, since many natural resources are not infinite and it is essential to use them in a way that is both environmentally and economically sustainable. The transition to a “circular economy” is becoming indispensable. Waste has already been reduced and production technologies are constantly being improved in line with the “reuse” and “recycling” principles. The real start of this process (see figure 1) can be traced back to the publication of Directive 94/62/EC on packaging and packaging waste. That directive, taking into account the free movement of products within the European Community in order to create a single market, introduced the principle of the “shared responsibility” of all those involved in the life cycle of a product. It also set specific targets for the recovery and recycling of packaging waste, to be reached by June 30, 2001. The targets set for the first five years were: • recovery of between 50% and 65%, by weight, of packaging waste entering the European market; this amount would therefore be subtracted from the ordinary flow of waste sent for disposal; • recycling of between 25% and 45%, by weight, of all packaging materials; • recycling of a minimum of 15%, by weight, for each type of packaging material. Directive 94/62/EC was subsequently updated through the following versions: Directive 2004/12/EC (deadline for transposition into national legislation in the member states: August 18, 2005); Directive 2013/2 EU (deadline for
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SUSTAINABLE DEVELOPMENT OF THE EU ECONOMY DEPENDS VERY MUCH ON THE RESOURCES AVAILABLE. LOOKING TO THE FUTURE, WE NEED TO FIND WAYS OF USING THESE IN A BETTER, MORE DIVERSIFIED AND, ABOVE ALL, MORE SUSTAINABLE WAY BY ORESTE PASQUARELLI
transposition of amended annexes: September 30, 2013). With regard to plastic materials, Directive 2004/12/EC had set a recycling target of 22.5% in weight, to be reached by 2008. At present, Europe does not use, and therefore disperses in the environment, about 600 million tons per year of waste that could potentially be recycled or reused. It is estimated that only 40% of waste generated by EU households is recycled. Therefore, with a view to achieving
more efficient use of resources, it is crucial that waste be regarded as new raw materials. This would indeed be a decisive point in the creation of a more circular economy. Therefore, the new common objectives proposed by the EU for the coming years are: • to recycle 65% of urban waste by 2030; • to recycle 75% of packaging waste by 2030; • to cut, by 10%, all waste dumping in landfills, again by 2030.
Fig. 1 - The European Commission’s legislative package promoting the circular economy
Waste Framework Directive
WEEE
Packaging and Packaging Waste Directive
ELV (End-of-Life Vehicles)
Landfill Directive
Legislative procedure is ongoing
BATTERIES
Legislative Source: Bosmans, EU Commission, November 2016
23 25/09/17 18:59
PLASTICS AND ENVIRONMENT
THE ROLE OF CEN This organisation was created with the purpose of drafting regulations to be transposed and shared by all the participating countries. CEN currently has more than 30 member states, including both EU and non-EU countries. Every country wishing to take part in these unification efforts must be represented by their own official standardisation body. For example, the Italian national unification body, UNI, participates on Italy’s behalf. The member countries have a different voting “weight” for the ratification of documents, and this is proportional to their population. For example, Italy, France, the United Kingdom, Germany and Turkey each have a “weight” of 29, while the “weight” of Iceland and Malta, which are at the bottom of the ranking, is 3. The standards drawn up must be accepted by at least 50% of the members whose combined “weight” must be greater than 70%. Although the final approved documents do not contain fixed rules, they are important in promoting standardisation of production procedures and products within the individual countries, and this serves to facilitate the exchange of technical knowledge and correct practices (best practice). In the field of packaging waste recovery and packaging recycling, several CEN standards in support of Directive 94/62/EC have been officially approved, and therefore supplement the relevant legal provisions. On February 19, 2005, a text entitled “Commis-
sion communication in the framework of the implementation of the European Parliament and Council Directive 94/62/EC of December 20, 1994, on packaging and packaging waste” was published in the Official Journal of the European Union (OJ). It included the following headings and references to harmonised standards under the Packaging Directive: • EN 13427:2004 - Requirements for the use of European standards in the field of packaging and packaging waste; • EN 13428:2004 - Requirements specific to manufacturing and composition - Prevention by source reduction; • EN 13429:2004 - Reuse. Packaging used several times for transporting/storing materials; • EN 13430:2004 - Requirements for packaging recoverable by material recycling (this means mechanical recycling to produce new reusable material); • EN 13431:2004 - Requirements for packaging recoverable in the form of energy recovery, including specification of minimum inferior calorific value; the value decided was 5 MJ/kg, which causes packaging waste to burn without the addition of further fuels; EN 13432:2000 - Requirements for packaging recoverable through composting and biodegradation - Test scheme and evaluation criteria for the final acceptance of packaging. In April 2016, a meeting was organised between the European Commission’s “Environment” DG and the CEN Technical Committee CEN/TC 261
Fig. 2 – Considerations on the life cycle of plastic materials Life cycle of products that contain, amongst others, plastics:
Converters, tr y u s tu r il nd ufac ic a an e m ics m h C a st pl
ers
Further pro semifinis cessing of h suppliers ed goods, , major b rands
Plastics production
Mechanical recycling
Raw material feedstock CO2
processors
OEMs: packaging, B&C, auto Product etc. manufacturing
Energy
Renewable feedstock Fossil feedstock
Chemical recycling
Energy recovery
Reuse, repair
Post-use phase Landfilling, illegal dumping, littering Fonte: PlasticsEurope
24 023_024_Paquarelli.indd 24
Use phase Materials for vehicle weight reduction
Efficient packaging
Insulation for B&C
on “Packaging”, in order to evaluate the state of the art on the following topics relating to the evolution of environmental issues and the development of a circular economy (“Closing the loop”). The following topics were discussed: • Directive 2015/720 amending Directive 94/62/ EC on measures to be taken to reduce the consumption of plastic carrier bags; • the initiation of cooperation between the EU Commission, the Parliament and the Regional Committees in order to activate a joint plan promoting development of the circular economy; • the development of a proposal for an EU directive to update Directive 94/62/EC on packaging waste. The topic of recycling plastic materials was addressed by a special working group (WG 11 “Plastic recycling”) within the CEN/TC 241 “Plastics”. In March 2017 this working group drafted an interesting document in which it suggested a series of measures and activities aimed at improving recovery and recycling, and thus at speeding up the transition from a linear to a circular economy. These suggestions were: • to evaluate a closed loop process for the post-consumer recycling of PVC window fittings; • to expand the area of competence of the working group, from “plastic recycling” to “plastics & environmental aspects”; • to have TC 249 develop activities and collaborations in order to define a “strategy for plastics within the development of the circular economy”. In addition, in order to provide a complete overview of the scope for achieving a circular economy in the plastics sector, a report by Ingo Sartorius (PlasticsEurope) was attached. In this report, Sartorius also indicates, for each of the below-listed phases in the life cycle of plastic materials (deriving from non-renewable sources or from renewable sources), ways in which the production cycle might be improved (see figure 2): 1. Production of plastic materials - specific chemicals industry 2. Production of semi-finished and manufactured goods - specialised processing industries 3. Final use of plastic materials - Sectors: lightweight packaging, automotive (weight reduction), building (thermal insulation), agriculture 4. Post-use - Reuse, mechanical recycling, chemical recycling, energy recovery. Reducing landfills. These are familiar operations, but they need to be improved and stepped up given that, with an eye to the future, they will be the only means of transitioning from a “linear” to a “circular” economy. www.macplas.it MACPLAS INTERNATIONAL AT FAKUMA 2017
25/09/17 18:59
Vanetti S.p.A. masterbatches are the company’s forte. Created for colouring all types of thermoplastic resins, today our masterbatches offer a truly extensive range of shades and chromatic effects. Their unique feature is the high pigment concentration combined with our selection of only the highest quality raw materials. Our products are specially developed to provide the solution to any colouring requirement.
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27/09/17 14:31
PLASTICS AND ENVIRONMENT
NEWS High potential, hindered only by a lack of respect for the law on plastic bags
Important growth for the Italian bioplastics industry Double digit growth for the Italian bioplastic industry, confirming that the circular economy represents a counter-trend factor in the enduring economic crisis and that it is destined to also experience a great thrust forward in agreements for a progressive decarbonization of the economy, by 195 countries
from around the world, at COP 21 in Paris. These are the main results revealed by a recent study of the sector sponsored by Assobioplastiche and conducted by Plastic Consult. With 2,000 employees, (+5.5%), 54,500 tons of manufactured items (+25%) and revenues of 475 million euro (+10%), in 2015
the Italian bioplastics industry welcomed 31 new operators on the primary processing market and, conversely, losed 20 operators from the secondary processing market (becoming primary processing companies). Today approximately 210 (+5%) companies operate in this sector, divided into producers
Chance discovery by an Italian biologist
The caterpillar that digests polyethylene The name Galleria Mellonella probably does not mean much to many people. But the definition “larva of the greater wax moth”, perhaps, is beginning to shed light on what it is all about. The caterpillar in question (and now it is clear what we are talking about) has a unique ability, discovered accidentally by an Italian biologist. It digests polyethylene. The biologist and beekeeper Federica Bertocchini, from the Spanish National Research Council (CSIC), put some larvae of the moth in question on a plastic bag, she then realised that the bag was full of holes and that the larva had perhaps made the holes. Together with Paolo Bombelli and Christopher Howe, from the Department of Biochemistry at the University of Cambridge, she set up an experiment to see if her reasoning was correct. Approximately one hundred larvae were placed on a plastic bag and, half an hour later, the first holes appeared. After 12 hours, the bag had lost 92 milligrams. According to the researchers, this is a degradable level judged to be significant and extremely rapid compared to, for example, certain bacteria, which take a day to degrade approximately 0.13 mg of PET. It is made possible because these larvae feed on bee wax, a rich complex of various molecules that contain a bond similar to the one that sustains the strong molecular structure of polyethylene. The degradation of plastic, the precise metabolism of which will be the subject of an upcoming study, does not occur only as a consequence of a mechanical action - chewing by the caterpillar - but also as a result of an actual chemical process. Further chemical analysis will therefore reveal the enzyme or bacteria present in the larva’s digestive system responsible for the process. If it is a case of a single enzyme, it would be possible to reproduce on a large scale using biotechnology. The discovery, therefore, could represent the first step in developing a new and effective method to free waters and land of the The Italian biologist Federica Bertocchini (Spanish National Research Council) discovered that the larva abundant plastic bag. of the greater wax moth was able to digest polyethylene www.csic.es
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According to Marco Versari, president of Assobioplastiche: “Data shows unequivocally the powerful growth of the Italian bioplastic industry”
of chemical substances and commodity intermediates (4), granule producers (16), primary processing operators (128), secondary processing operators (60). In regard to application sectors, 73% of the 54,500 tons of polymers processed were destined for the production of disposable shopping bags, 17% of bags to collect organic waste and the remaining 18% divided between manufacturing for agriculture, catering, food packaging and personal care. In particular, the 10% growth (from 65% in 2013 to 73% in 2015) of the market share of disposable compostable shoppers clearly reflects a lack of application of the administrative sanctions - introduced on August 21, 2014 - which, according to the intentions of the legislators, should impact those who do not comply with the Italian Law no. 28/2012 on the production and sale of shopping bags. The Plastic Consult study has revealed another very concerning trend, namely a marked slowdown and massive return to polyethylene in the first months of 2016, confirming dwindling compliance with the law. “Today we are ready to compete on global markets, but, as long as our investments and sacrifices keep going to waste, we need the country to follow us, and to beat illegal production”, the president of Assobioplastiche, Marco Versari, said. www.assobioplastiche.org
MACPLAS INTERNATIONAL AT FAKUMA 2017
25/09/17 20:13
Synvina receives interim approval from EPBP
Recovering PEF bottles the same way as PET bottles The European PET Bottle Platform (EPBP) has given interim approval for the recyclability of polyethylenefuranoate (PEF) produced by Synvina - a joint venture of Avantium and Basf, located in Amsterdam - in the European bottle recycling market. Following EPBP’s assessment PEF bottles are expected to be disposable through existing recovery systems the same way as polyethylene terephthalate (PET), the conventional material for plastic bottles. The interim approval applies to a PEF market penetration of up to 2%. This corresponds to the amount of PEF that could be produced from Synvina’s intended 50,000 tons reference plant for furandicarboxylic acid (FDCA). FDCA made from renewable resources is the main building block for PEF. A final statement based on PEF quality, packaging designs and regional launch markets will be
issued before market introduction of the novel material. “EPBP confirms that consumers are expected to be able to return or dispose PEF bottles the way they are used to do with PET bottles. This is a major milestone for our innovative material based on renewables”, said Patrick Schiffers, CEO of Synvina. “The recyclability has become one of the most important aspects for the packaging industry to meet the standards of the circular economy. EPBP’s interim approval confirms that with PEF we are able to offer solutions for our customers to meet these standards”. PEF quantities in the European packaging market are expected to exceed the 2% market share on a medium term. Therefore, Synvina works jointly with recyclers and brand owners to develop a dedicated recycling stream for PEF based bottles to separate the valu-
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Thanks to its recyclability, PEF offers a significant advantage to the packaging industry in comparison to alternative bio-based plastics or barrier materials
able PEF from conventional plastics. PEF recycling in other markets like the US and Japan will be reviewed near-time. Polyethylenefuranoate is a biobased plastic with improved barrier properties for gases like carbon dioxide and oxygen, which leads to a longer shelf life of packaged products. Moreover, it also offers a higher mechanical strength, thus thinner PEF packaging can be pro-
duced and fewer resources are required. PEF is suitable as the main component or as a barrier layer in cups and trays, flexible packaging as well as bottles for carbonated and non-carbonated soft drinks, water, dairy products, still and sports drinks, alcoholic beverages as well as personal and home care products. www.synvina.com www.epbp.org
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PLASTICS AND ENVIRONMENT
NEWS Bio-based building blocks on the rise
More than 45% of the most relevant biopolymers are produced in Asia Fig. 1 - Share of Asian bio-based polymer production capacities on global production by polymer in 2016
PBS(X)
APC APC cyclic cyclic
PA
PET
PTT
PBAT
Starch Blends
PHA
PLA
PE
Fonte: nova-Institute
Recent nova-Institute’s trend report “Asian markets for bio-based chemical building blocks and polymers” shows latest data and development in China, Japan, Malaysia, South Korea, Taiwan and Thailand. A global capacity of 2.4 million tons bio-based polymers was established in 2016, from which more than 45% of the most important bio-based polymers are produced in Asia (without considering cellulose acetate and thermosets). The worldwide capacity is expected to reach 3.6 million tons in 2021, nearly 52% of this volume will be installed in Asia. This equals an increase of installed capacities of 71% in the next five years. The Asian region has a 100% share in production capacities of PBS(X) and cyclic aliphatic polycarbonate (APC) since several years, as it is shown by figure 1. For bio-based building blocks, the report sees an increase of the implementation of biorefineries and bio-hubs in South-East Asian countries to strengthen their competitiveness. Stronger emphasis on cooperation and partnership along the value chain and with R&D providers becomes a key factor to success. Potential investors and customers in Asia are eager for a change in governmental policies and incentives. At the moment, government measures are mostly targeted at enhancing the export capabilities of countries and generating technology transfers. Countries such as Thailand have reacted to the demands of the market and introduced “roadmaps” to support the introduction of bio-based plastics or/and biotechnology. Main increase of future production capacities (and shares) is expected for PLA and polyamides (PA). PHAs are another biopolymer group in focus of Asia, capacity volumes and underlying trends are another focus of the nova trend report. The drop-in bio-based polymer PET, which is only partly bio-based at present, holds the major share of the total Asian production capacity. In 2021, PET is expected to contribute with 59% to the total capacity of biopolymers in Asia, which are in focus of this trend report. “Biodegradable,
compostable” polymers (such as PLA, PBS, PBAT, PHAs) are expected to be contributing about 25% to the Asian production of bio-based polymers in 2021. However, that means that about 75% of the total bio-based production in Asia will be focusing on durable polymers. Additionally, biorefinery concepts are emerging in Asia. It will allow producers to diversify economic risks by broadening existing marketing possibilities into additional complementary market segments including the biobased plastics industry. Current new developments in South-East Asia are even targeting the establishment of large scale bio-hubs, bio-clusters or bio-based polymer parks like in Thailand or Malaysia. The future focus in Asia will be most likely more on bio-based building blocks such as organic acids, diols or bio-based monomers such as biobased ethylene, rather than only on bio-based polymers, by integrating the available agriculture resources into the process. www.bio-based.eu - www.nova-institute.eu
From Spain
Limonene in place of bisphenol A
Limonene is a hydrocarbon contained in citrus fruit peel
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A team of researchers from the Institute of Chemical Research of Catalonia (Spain) has developed a polycarbonate in which the traditional bisphenol monomer A (BPA) has been replaced with limonene, a hydrocarbon contained in citrus fruit peel. In the research, pub-
lished in the review ACS Catalysis, the researchers explained that they have developed a method to produce the polycarbonate based on two substances widely available in nature: carbon dioxide and limonene, commonly used in the production of cosmetics and toothpaste. It is limonene that may pose a solution to the presumed toxicity of bisphenol A. In June this year, in fact, the com-
mittee of EU Member States for chemical substances expressed its unanimous opinion in underscoring the possibility that bisphenol A has a harmful effect on the endocrine and hormonal system; a decision that may soon lead to further restrictive measures on its use. BPA has been banned in Europe since 2011 for the production of baby bottles. www.iciq.org
MACPLAS INTERNATIONAL AT FAKUMA 2017
25/09/17 20:13
imitation is the sincerest form of flattery
(Charles Caleb Colton)
VIDEO QR
THE ORIGINAL FIMIC
ITALIAN MELT DILTER
ITALIAN MELT FILTER
17th 21th October 2017 Friedrichshafen Germany
the originals and patented by:
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the melt filter specialist www.fimic.it - - 029_Fimic_ADV.indd 29
25/09/17 19:08
PROCESSING MACHINERY
MACHINERY MAINTENANCE
MAXIMISING THE PRODUCTIVITY OF PLASTICS PROCESSORS A
dvancements in hydraulic oil technology now means plastics manufacturers can select fluids which can help produce high quality components and provide outstanding levels of protection, as well as other benefits such as increased energy efficiency and decreased cycle times. ExxonMobil, for example, has developed an award-winning hydraulic oil Mobil DTE 10 Excel, which has been proven to help plastic injection moulding operators to increase productivity, reduce unscheduled downtime and improve the energy and cycle efficiency of their machinery.
DESPITE REPRESENTING ONLY A SMALL PERCENTAGE OF THE TOTAL MAINTENANCE SPEND, THE LATEST HYDRAULIC OILS HAVE THE POTENTIAL TO THE INJECT ADDITIONAL PRODUCTIVITY AND PERFORMANCE INTO PLASTIC MANUFACTURING OPERATIONS BY MOHAMED MOURAD*
dard hydraulic oils by up to three times whilst maintaining outstanding hydraulic system cleanliness and component protection. In addition to excellent protection, Mobil DTE 10 Excel can help provide quantifiable increas-
es in hydraulic efficiency compared to standard hydraulic oils. This can translate to reduced power consumption and cycle times, resulting in monetary savings. This is achieved through the oil performing at its optimum vol-
To help reduce unscheduled downtime, contamination control is a key requirement of a hydraulic oil. Contamination may be generated in the system or may ingress from the outside, so a hydraulic oil needs to demonstrate excellent oxidation resistance and filterability to avoid lubrication and component failures, and frequent oil changes. Other performance requirements of a hydraulic oil include preventing any pump damage or failures at equipment start-up and while operating at extremely high temperatures. Laboratory and in-service field demonstrations, conducted on a wide range of modern hydraulic systems, proved that Mobil DTE 10 Excel has exceptional oil life, outlasting stan-
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Following a successful test phase involving two injection machines, the German company Häfner & Krullmann decided to convert additional machines to Mobil DTE 10 Excel
www.lz.de
NEXT GENERATION HYDRAULIC OILS
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Reducing non-productive time and improving operating costs
Five tips to help plastics manufacturers umetric and mechanical efficiency level - a result attained when the two efficiencies, which are inversely proportional to each other, are in balance. To ensure this level is maintained throughout the day and to avoid late-day sluggishness (“PM fade”), the high viscosity index of Mobil DTE 10 Excel ensures the performance of the oil is not impacted by the equipment heating up during the day while in operation. In controlled laboratory efficiency testing, Mobil DTE 10 Excel was measured to provide up to a 6% improvement in hydraulic pump efficiency compared to a standard hydraulic fluid, when operating in typical hydraulic applications.** The ability of the oil to reduce cycle times delivers additional benefits. For example, in plastic injection moulding equipment, a 0.5 second reduction in cycle time can realise up to an 11% increase in productivity.
On the occasion of last Mecspe trade fair (Parma, Italy, March 23-25, 2017), ExxonMobil shared five tips to help plastics manufacturers optimize the performance of their machines. 1. Conduct oil condition monitoring As part of routine maintenance, the “health” of the lubricant and the equipment itself should be regularly checked. By trending oil analysis data it is possible to proactively address undesirable conditions before they result in equipment downtime. ExxonMobil offers Mobil Serv Lubricant Analysis (MSLA), a proprietary oil analysis programme, which sends maintenance professionals expert oil analysis assessments to identify potential issues, lists possible causes and recommends corrective actions.
PERFORMANCE IN THE FIELD Häfner & Krullmann, a company based in Leopoldshöhe, Germany, specialises in processing plastics and currently has more than 50 injection moulding machines, varying in size from 50 to 2,000 tons. The company is one of Europe’s largest manufacturers of plastic spools, ranging from special spools for the silver stripes used in hundred euro notes to spools produced under clean room conditions for medical applications. Aware of the importance of hydraulic oils in maximising the productivity of its equipment for a number of years, the company was keen to see what performance benefits could be realised through the introduction of Mobil DTE 10 Excel. Following a successful test phase involving two machines, the company decided to convert additional machines to Mobil DTE 10 Excel. Since then, five of the company’s installations have been filled with the product and for the other machines it has been used for topping up. Following this introduction, Häfner & Krullmann expect to extend oil drain intervals from 40,000 to around 50,000-60,000 operating hours and make an energy saving of 2-3%. The company also expects to double filter life, which in itself will deliver significant cost savings.
MAXIMISING PRODUCTIVITY In order to maximise the productivity of machinery and reduce costs, operators should incorporate an oil and equipment condition monitoring programme alongside the use of a high quality hydraulic oil. As part of routine maintenance, the “health” of the hydraulic oil and the hydraulic system itself should be regularly checked. Typically, it is advised that MACPLAS INTERNATIONAL AT FAKUMA 2017
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2. Choose high-performance versus conventional mineral oils While lubricants may represent a small percentage of operating costs, simply upgrading to a higher performing lubricant can have a significant impact on longterm maintenance costs. Advancements in lubricant technology, especially when it comes to fully-synthetic based products, have seen significant breakthroughs, including extending equipment life as well as oil drain intervals. 3. Streamline your lubricant inventory Maintaining equipment with advanced high-capacity lubricants can reduce the number of products which must be purchased, stored and applied to machinery. This means fewer purchase orders and simplified maintenance. The Mobil SHC
maintenance professionals perform quarterly oil analyses and annual system inspections. The oil analysis should include a measurement of fluid viscosity, water content, particle count and dissolved metals to determine how well the system is operating. Examining changes in the oil analysis data over time, also known as “trending”, is necessary to assess the condition of the hydraulic fluid. By trending oil analysis data it is possible to proactively address undesirable conditions before they become problems. For equipment maintenance professionals who want an effective oil analysis programme, there is ExxonMobil’s proprietary online Mobil
600 Series of circulating and gear oils, for example, are recommended for use in 1,800 applications by more than 500 major equipment builders. 4. Store and handle lubricants correctly Specialist lubricants for the plastics industry are formulated to satisfy very specific kinds of service. If not handled and stored properly, they can deteriorate or become contaminated and provide inadequate lubrication or become waste. Storage should be away from heaters, cold areas, moisture, dust and areas of varying temperature cycles. 5. Select the most appropriate lubricants ExxonMobil’s Looble selector tool helps determine the most appropriate lubricant and viscosity grade for use from a range of criteria, including application and equipment type and manufacturer. The right choice of lubricant can help to optimise performance.
ExxonMobil cooperates with plastics processors to optimise their machinery performance
Serv Lubricant Analysis (MSLA) programme. By combining the use of high quality oils and an effective oil and equipment analysis programme, plastic companies can look to achieve a competitive advantage in their operation, maximising productivity and reducing the energy consumption of hydraulic machinery. www.mobilindustrial.com www.exxonmobil.com * Industrial Marketing Advisor, Europe, Africa & Middle East at ExxonMobil ** Energy efficiency of Mobil DTE 10 Excel relates solely to the fluid performance when compared to ExxonMobil’s standard hydraulic fluids (Mobil DTE 20 series) in standard hydraulic applications, under controlled conditions. Results may vary depending on operating conditions.
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SPECIALISTS IN COPOLYMERS
TECHNIPOL® COPE - resins and hot melt adhesives TECHNIPOL® PA COPA - resins and hot melt adhesives SIPOLPRENE® TPC-ET thermoplastic elastomers (ether-ester)
SIPOL S.p.A. Via Leonardo Da Vinci, 5 - 27036 MORTARA (PV) - Italy Tel. +39 0384 295237 - Fax +39 0384 295084 sipol@sipol.com - www.sipol.com
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PROCESSING MACHINERY
ARBURG AT FAKUMA 2017
WHERE SMART BECOMES SMARTER AND SMARTER THE LOSSBURG-BASED COMPANY IS PRESENTING “SMART” MACHINES, PROCESSES AND TURNKEY SOLUTIONS FOR EFFICIENT PLASTICS PROCESSING. AT FAKUMA 2017, A HYBRID ALLROUNDER 920 H IS PRESENTED FOR THE FIRST TIME WITH A NEW DESIGN AND A NEW GESTICA CONTROL SYSTEM. FURTHER HIGHLIGHTS ARE A PRACTICAL INDUSTRY 4.0 APPLICATION, THE INJECTION MOULDING OF READY-TO-USE LSR/LSR WATCHES, NEWLY QUALIFIED MATERIALS FOR INDUSTRIAL ADDITIVE MANUFACTURING AS WELL AS HIGH-SPEED PACKAGING APPLICATION
“A
s a cofounder of Fakuma, we are proud to have been part of the event from the outset and to be the largest exhibitor at the 25th edition of this successful trade fair in 2017. With ten machines at our own stand and eight more at partner stands, our focus this year is, again, on “smart” and practical solutions for efficient plastic parts manufacturing. We also offer everything an injection moulding machine needs in the context of Industry 4.0, from the “smart machine” and the Arburg ALS host computer system to “smart services”. The absolute highlights are the ground-breaking large machines. After the success of the Allrounder 1120 H, we are now also presenting the Allrounder 920 H with a new design and a new Gestica control system”, explains Michael Hehl, managing partner and spokesperson for the Arburg’s management team.
NEW LARGE MACHINES, NEW CONTROL SYSTEM, NEW DESIGN At K 2016, Arburg celebrated a world preMACPLAS INTERNATIONAL AT FAKUMA 2017
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miere with the hybrid Allrounder 1120 H and expanded its range of clamping forces by 30 percent to 6,500 kN. In the meantime, the new large machine has been successfully used by pilot customers and can be ordered by customers worldwide from Fakuma 2017 onwards. The next step in the direction of the future-oriented new Arburg design and new Gestica control system is the hybrid Allrounder 920 H with a clamping force of 5,000 kN. In addition to its aesthetic appeal, modern colour scheme and shape, the well-conceived design provides for enhanced functionality and significantly improved ergonomics. The innovative Gestica control system has a high-resolution full-HD screen and uses industrial multi-touch technology to reproduce to the “look and feel” of smart mobile devices. While the Allrounder 920 H produces a technical part at Fakuma 2017 (hall A3, stand 3100), the Allrounder 1120 H forms a part of an innovative turnkey solution, producing the familiar folding step stool in the Arburg design in a
cycle time of 60 seconds. The eight individual parts are handled by a Multilift V 40 linear robotic system and assembled ready for use by means of a six-axis robot and assembly station.
The Gestica control system panel of the Allrounder 1120H
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PROCESSING MACHINERY
PRACTICAL EXAMPLE FOR THE INDUSTRY 4.0 RUBBER TENSION BELTS Rising costs, efficiency and scheduling pressures, greater diversity with smaller production orders and increasing automation are all factors leading to increasingly complex processes that should nevertheless remain easy to control and economically efficient. This topic, which is gaining increasing attention under the headings of “Industry 4.0”, “Digital Transformation” and “Smart Factory”, calls for host computer systems like the ALS and the integration of IT solutions in the production process. Arburg will use the example of elastic tension belts to show how customer wishes, expressed online, can be integrated into the ongoing injection moulding process. In industrial practice, such flexible production in single-unit batches is ideal, for example, for cable assemblies for the automotive industry. In the application presented at the trade fair, visitors are able to choose between rubber bands of different lengths and in different colours, as well as end pieces in hook/hook, hook/eyelet or eyelet/eyelet combinations, and have their order recorded directly at a terminal. A vertical Allrounder 375 V with a 4-cavity mould (two cavities each for the eyelet and hook) flexibly produces the desired variant from shot-to-shot. The two corresponding cavities and hot-runner nozzles are controlled by means of slides. The inserts are handled by a six-axis robot.
LSR/LSR WATCHES PRODUCED WITHIN THE INJECTION MOULDING CYCLE LSR/LSR wristwatches require complex manufacturing processes and set the standard for what can currently be achieved in the processing of liquid silicone. The centrepiece of the turnkey system is an electric two-component AllMoulding of watches made of LSR
Arburg’s new hybrid Allrounder 1120 H with a clamping force of 6,500 kN, new design and new Gestica control system can be ordered from the Fakuma 2017 onwards
rounder 570 A. Two two-tone wrist straps made from the LSR materials Silopren 2670 (70 Shore A) and 2620 (20 Shore A) are produced fully automatically in a cycle time of 75 seconds. The 2+2-cavity mould is from Rico, the dosing system from Reinhardt-Technik and the temperature control system from Regloplas. A Multilift V 15 linear robotic system copes with the demanding task of handling the flexible parts. The assembly of the watch mechanisms to complete the ready-to-use wristwatch takes place automatically within the injection moulding cycle.
FOUR IML TUBS LESS THAN TWO SECONDS A packaging version of the Allrounder 570 H specially designed for thin-walled parts demonstrates a high-speed application for the packaging industry. The production cell produces four IML tubs from PP in a cycle time of less than two seconds. The mould and the automation system for inserting the IML labels and removing and stacking the 3.55-gram decorated finished parts are from Brink.
TECHNICAL INJECTION MOULDING FOR THE AUTOMOTIVE INDUSTRY Based on the example of ring gears for transmissions, an Allrounder 370 E Golden Electric is used at Fakuma 2017 to demonstrate that the powerful electric entry-level machines meet the requirements for precise and energy-efficient production of complex moulded parts. Four 8.5-gram injection moulded parts, made from mineral-filled PA6, are produced in a cycle time of around 20 seconds. A linear Multilift Select robotic system performs the handling tasks. A hydraulic two-component Allrounder
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470 S with a 1+1-cavity mould produces covers for car interiors. This exhibit is also automated with a Multilift H linear robotic system. Arburg is thus exhibiting a total of six out of eight injection moulding machines at Fakuma 2017 in automated set-ups and/or as turnkey systems.
NEW FEATURES IN INDUSTRIAL ADDITIVE MANUFACTURING With two Freeformer exhibits, Arburg is showcasing innovations in the industrial additive manufacturing of functional parts and small-volume batches using qualified standard granulates. These include the processing of PP and the specially developed water-soluble armat 12 support material. At Fakuma 2017, screw cap prototypes for the packaging industry are produced from this semi-crystalline material. As the Freeformer and Arburg Plastic Freeforming (APF) offer the advantage of an open system, users retain independence. They can therefore also qualify original materials, as used in injection moulding for example, and optimise process parameters specifically for their particular application.
REMOTE MAINTENANCE VIA SECURE DATA CONNECTION Exhibits in the service area include the new remote maintenance tool from Arburg that enables fast, efficient and reliable online support, demonstrated on a hybrid Allrounder 370 H. The Allrounder injection moulding machine is equipped with a service router and integrated firewall for this “smart service”. Malfunctions can be efficiently analysed and dealt with while process sequences can be optimised through the online support. www.arburg.com MACPLAS INTERNATIONAL AT FAKUMA 2017
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PROCESSING MACHINERY
PIPES EXTRUSION AT FRIUL FILIERE
NEVER SO FAST A SHARED PASSION FOR RESEARCH AND DEVELOPMENT COMBINED WITH A STRONG FOCUS ON CUSTOMER SERVICE HAVE ALWAYS INSPIRED ALL ACTIVITIES AT FRIUL FILIERE (HALL A6, STAND 6111) AND ALLOWED THE COMPANY TO DEVELOP A TECHNOLOGY, A COMPLETE SYSTEM BASED ON DEEP PROCESS KNOW-HOW, FOR THE PRODUCTION OF PA PIPES AT VERY HIGH SPEED
E
stablished almost 40 years ago as a manufacturer of dies for the extrusion of plastic material, Friul Filiere now sells complete, turnkey systems all over the world to anyone looking for high-quality performance when manufacturing pipes and profiles, from technological extrusion lines, fully customised and guaranteed 100% made in Italy. Customers have access to decades of experience and flexibility and appreciate the “yes, we can” approach which reflects the deeply held belief in R&D. The company holds several European and international patents and customers look to it for projects characterised by the use of complex materials or the section of the product they require.
EVERY SYSTEM IS A PROTOTYPE From the conception to the delivery of the system, complete with machines and dies, all cusMACPLAS INTERNATIONAL AT FAKUMA 2017
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tom built. “Taking care of the customer and the project, for which we act as the sole partner, remains our main concern. Our passion for research is what leads us and determines the ambitious goals which we set for ourselves. This means we are motivated partners when undertaking projects for manufacturing special profiles and pipes which require a specific study and a made-to-measure technological solution. Starting from the customer’s idea, after a preliminary feasibility study, we take care of the combination of materials and process know-how to obtain the best possible performance in terms of production capacity and quality”, stresses Valdi Artico, chairman and CEO of Friul Filiere. Luna Artico, the sales manager, adds more details to the profile of a Friul Filiere customer: “We design systems and dies for profiles and pipes used in a wide variety of industries. This year alone, we have worked for companies in tele-
communications, industrial plants, irrigation, garden machinery, conveyor belts, lighting, and window systems, in addition to the building and furnishing industry”.
Tubeasy extrusion head
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PROCESSING MACHINERY
At the Fakuma 2017 exhibition, Friul Filiere shows an R63 twin-screw extruder, one of its main traditional machines, well-known and appreciated as featuring high production capacity together with low electric absorption, besides being strong, reliable and well-finished. But there’s more news. First of all, a surprising achievement: the highest speed ever reached by Friul Filiere in the extrusion of pipes made of PA6 and PA11 with 6-12-mm diameter. The company has recently built a complete plant that delivers high production speeds, putting to good use the experience gained in the pipe sector after its patented Tubeasy system proved a hit at its launch at K 2016. Tests on the plant have confirmed expectations by producing a 4x6 mm pipe at a speed of 102 metres per minute, which is more than double the current standard speed. Ideal for compressed air, automotive and industrial installations in particular, this plant comes complete with technology and processes developed by the in-house research and engineering team of Friul Filiere. Equipped with dedicated screw designed by Friul Filiere, the single-screw Omega extruder with 60 and 36 mm diameters combines energy saving and high output rates (160 kg/h) thanks to specific technology that reduces absorption.
HEAD AND CALIBRATION SYSTEM The extrusion head and the calibration system are particularly interesting. The head features the Tubeasy patented system that rapidly centres the material flow in the start-up phase by simply adjusting just two screws. It appears almost incredible given the fact that traditional ad-
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justment systems are difficult and slow to manage because of the numerous screws placed around the head, used to move the flow. Tubeasy, instead, reduces start-up scrap by 60% and controls the material in order to improve not only the production performance of the whole plant, but also the quality and physical-mechanical properties of the end product. The cooling system, also a special feature, makes an important contribution to the positive outcome of the process. Traditionally, the calibration of PA pipes takes normally place in tanks with a vacuum pump system that inevitably moves water in the tanks, affecting the pipe quality as a result. Friul Filiere has therefore developed a vacuum calibration system where the water does not move. This solution requires the application of special technology, designed by the Italian company for the management of complex and “extreme” materials like PA and PU. This technology can control flows that are otherwise difficult to calibrate and create smooth surfaces and sections that meet the minimum dimensional tolerances.
AUXILIARY MACHINERY The extrusion line had to be equipped with different auxiliary machinery: - a drying and automatic material loading system; - a masterbatch metering unit on the extruder; - an electronic marker; - a laser control system placed before the haul-off to monitor the diameter and thickness of the pipe; - a special haul-off allowing high extrusion
Samples of PA pipes
speeds over 100 m/minute; - a semi-automatic double-reel winder at the end of the line.
ONE TECHNOLOGY, MULTIPLE PRODUCT POSSIBILITIES This plant delivers the opportunity for production performance levels that have never been reached before, as well as high-quality finished products. In this case, the products are PA pipes for applications especially in the automotive, air compressed and industrial installation sectors. However, the same technology can be applied to extrusion plants for the production of polyolefin (PP, HDPE) pipes for telecommunications or cosmetics, for example, or plasticised PVC pipes, particularly for the medical sector, or PMMA or PC pipes. www.friulfiliere.it
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hrsflow.com 17-21 OCTOBER 2017 VISIT OUR STAND: HALL A2 BOOTH A2-2217
Surface quality improvement Warpage reduction and dimensional stability High process repeatability and reliability
SERVO DRIVEN HOT RUNNER FOR ACCURATE, EASY AND FLEXIBLE FLOW CONTROL
DRIVING PERFECTION DRIVE TO Passion for expertise
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HRSflow Italy: Via Piave,4 - San Polo di Piave, Treviso, 31020 Italy - Ph. +39 0422 750 111 - info@hrsflow.com - www.hrsflow.com
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PROCESSING MACHINERY
NEWS Blow moulding
Coextrusion for multilayer bottles The Italian company Plastiblow provides advanced technology for the production of multilayer containers through blow moulding machines with single or double blowing unit and, depending on the production requirements, horizontal or vertical extruders and coextrusion heads up to 12 outlets and up to 7 layers. The heads design must be optimised in order to obtain more constant thickness and consistent speed for each layer. The layers thickness can vary by changing the extruders output. The coextrusion head is realized using numerically controlled machine tools capable of guaranteeing reduced and constant tolerances, thus allowing a thorough monitoring of each layer both in terms of thickness and uniformity in the annular coextrusion process. From a functional point of view, three types of coextrusion heads can be essentially identified: 1) double layer coextrusion heads for the realization of a decorative external layer; 2) three-layer coextrusion heads for the realization of an intermediate layer of recycled material; 3) coextrusion heads from 3 to 7 layers, including a barrier layer. Depending on the final application, it is possible to identify specific multilayer structures that meet the characteristics required for certain containers both in terms of aesthetics and correct preservation of content. The bottles used for cosmetics must have a bright surface, must be resistant to scratches and should be easily printable (screen printing process). Double layer coextrusion is normally used in these cases. The layers thickness results from the optimisation of two opposite requirements. On the one hand, the intention is reducing the use of masterbatch, which often
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implies high costs; on the other, it is necessary to ensure a good and uniform coating to obtain the same aesthetic result achieved when adopting single layer extrusion. The concentration of masterbatch necessary to ensure good coating increases with the decreasing of outer layer thickness and with the increasing of colour contrast between outer and mid layer. The outer layer is typically 20% of the total thickness. Another example of double layer structure is that of soft-touch bottles featured by a velvety touch feeling. This characteristic is obtained by using PP-based materials and the velvety touch feeling changes depending on the outer layer thickness, which in this case may be below 10% of total thickness. For the cosmetic sector, Plastiblow has recently supplied a double-unit electrically operated blow moulding machine with a 10-parison decorative coextrusion head with 110-mm centre distance. For chemicals containers PA is used as a barrier to improve re-
sistance to aggressive substances or impermeability to solvents. Three-layer structures are normally used. In case of usage of scraps, the structure consists of 4 layers: inner barrier layer/adhesive layer/ recycled material/outer masterbatched virgin material. For such applications, Plastiblow has realized several 4-layer coextrusion blow moulding machines. For food products a barrier is required against gases, air or water vapour and to reduce the loss of aromatic compounds. The bottles realized by using coextrusion technology ensure suitable content shelf-life, that is, the preservation of organoleptic and sensory characteristics during a specific period of time. Coextruded bottles used for such applications have a 5-layer structure, and if a recycled material layer is included the structure is made up of 6 layers. The typical layer sequence is: inner HDPE/adhesive/barrier/adhesive/recycled/ outer HDPE. The most widely used barrier material is EVOH and layer thickness depends on the type of
product. If the only requirement is a UV barrier layer, as in the case of long-life milk bottles, 3-layer structures are used, consisting of white/ black/white HDPE, normally in a percentage of 30-40-30 or 40-4020. The black layer provides an effective protection against sunlight, which would deteriorate the organoleptic characteristics of milk and its derivatives. Among the most interesting experiences in the field of electrical blow moulding, Plastiblow has realized a machine with long-stroke double unit for the production of 6-layer sauce bottles with 125-mm centre distance 8-cavity moulds. Layers composition, from the outer layer to the inner one, is as follows: PP/recycled/adhesive/EVOH/adhesive/ PP. Layers thickness vary from the 30 microns of the adhesive layer to the half millimetre of the recycled material layer. The blow moulding machine is equipped with three horizontal extruders (for outer, inner and recycled layers) and three vertical extruders (for adhesive and barrier layers). Given the dimensions of the extruders and head, special attention was paid to the supporting structure and the bobbing movement of the head. www.plastiblow.it
For the cosmetic sector, Plastiblow has recently supplied a double-unit electrically operated blow moulding machine with a 10-parison decorative coextrusion head with 110mm centre distance
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We cover the worldwide market.
MARS
will be the next?
PVC DRY BLEND, POWDER COATINGS, MASTERBATCH AND PIGMENTS, THERMOPLASTIC RUBBERS, WOOD PLASTIC COMPOSITES
PLAS MEC S.R.L. Mixing Technologies Via Europa, 79 - 21015 Lonate Pozzolo (VA) - ITALY - Tel. +39.0331.301648 - comm@plasmec.it
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196 7
YEARS OF
EXPERIENCE
2017
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PROCESSING MACHINERY NEWS Gamma Meccanica for Industry 4.0
AUTOMATION AND SAFETY Since its foundation, Gamma Meccanica (stand 31, Foyer West, at Fakuma 2017) has always been committed to providing its customers with continuous improvement in the performance of lines for the regeneration of plastic materials, with particular attention to the development of new tools to control product quality in real time and to make equipment more interconnected. In the era of Industry 4.0, promoting the digitization of production processes, GM lines are characterized by a high level of automation, maximum quality of the recycled product (granules), and improved energy savings. For several years Gamma Meccanica has installed devices for the remote connection of its machines on all its lines. Through this connection, it is possible to monitor the line while running and, if necessary, modify and optimize the software (both PLC and HMI). By connecting to the customer database it is possible to download data either to the Gamma Meccanica lines (for example, to set the necessary recipes for the production change) or to the database itself. The customer can store all operating parameters as well as machine alarms in real time. By using these data, it is possible to reset alarms and, for example, with graphs, to analyze the change of the values that the client considers as most important. Gamma Meccanica also offers a range of utilities that, thanks to the interconnection with the line, are able to offer a retrofit on existing lines which are running. An example is the inline weighing machine that can give the customer a whole series of data about production capacity. Another important characteristic is the very high security standards of GM lines, complying with the latest regulations. On the control panel there is a PLC exclusively dedicated to the management of safety devices and control circuits. Industry 4.0 for Gamma Meccanica is a well-known process, but thanks to constant customer feedback, the company continues to develop new, more reliable and powerful tools. www.gamma-meccanica.it
GM90 Compac to recycle special materials such as film, fibres, fabrics
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Modula SS Combi by Saldoflex
A multipurpose bag-making machine for stacked bags Production of T-shirt bags, bottom-sealed bags, bloc notes bags with handle, stacking either with or without pins, possibility to process standard polyethylene film (low density or high density) and also 100% biodegradable and compostable film. These are the key features of the automatic, servo-driven bag-making machine Modula SS Combi, the most versatile multipurpose machine within Saldoflex range for producing stacked bags. The latest unit being manufactured, destined to a leading Italian packaging company, can run on up to 5 tracks with a total sealing width of 1,350 mm starting from a 2,000 mm width jumbo roll. Its main specifications are as follows: great flexibility, offering the possibility of producing T-shirt bags, bottom-sealed bags and bloc notes bags with only one machine and thanks to the short set-up time; stacking either with or without pins, and possibility of hot-blocking of the bags piles; speed, up to 200 cycles/minute (without pins) or 250 cycles/minute (with pins), 160 m/minute; quick and easy shifting from single-seal to double seal by a simple selector; shaftless unwinder with AC servomotor for breaking, hydraulic-powered lifting and centring of the jumbo roll, multiple dancing roller system with quick drawing-in of the film; automatic edge-guide, electronically controlled slit-seal knives with automatic inserting and detaching from the web, motorized gusseting station suitable for obtaining gussets up to 200 mm depth each side; photocell to process also printed film; compensation system for forward-backward alignment of the printed webs to the sealing bar; electronic polarizer for processing even extremely low-thickness HDPE film; 20 punches (4 each track) with 6-mm diameter for air venting; brushless servomotors for film feeding, sealing bar movement, flying bar drive, stacking chariot; modular sealing bar, cross cut by means of cold serrated
General view of a complete Saldoflex line
blade, single and double seal with possibility to shift from one to the other directly from the operator panel and without stopping the machine; flying bar in carbon-fibre driven by brushless servomotor; “flip-flop� device to prevent the bottom-sealed bags to stick to one another while they are still hot; die-cutting system for T-shirt handle and banana handle; stacking chariot with independent pneumatic clamps to guarantee the highest reliability even when handling high-thickness bags; stacking belt for the piles, complete with folding unit; closed-circuit cooling system with water chiller for the sealing bar and the hydraulic oil. The range of bag-making machines manufactured by Saldoflex (which can be equipped with inline flexoprinting units made in its flexo division, Filippini & Paganini) includes the following models: Rollflex AU for fruit and vegetable bags on cored rolls - up to 6 tracks; Rollshopper for fruit and vegetable T-shirt bags on cored/coreless rolls - on 2 tracks; Rollflex for garbage bags on coreless rolls - up to 3 tracks; Rollflex Draw Tape for drawstring and anti-drop garbage bags on coreless rolls - on 1 or 2 tracks; Modula S, SS and SS Combi for T-shirt bags, bottom-sealed bags or bloc-notes bags - up to 7 tracks, stacking with pins and also without pins; Modula SV for bloc-notes bags or bottom-sealed bags - up to 7 tracks, stacking with pins and possibility of hot-blocking of the piles. www.saldoflex.com MACPLAS INTERNATIONAL AT FAKUMA 2017
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Fatra invests in Negri Bossi for producing Ikea articles
High-end processing Five Vector injection moulding machines have recently been delivered by Negri Bossi (stand 03, Foyer West, at Fakuma 2017) to the Napajedla and Chropyně production plants (Czech Republic) belonging to Fatra, ranking among the world’s major companies producing plastic parts, with more than 75% of its production headed for international markets, and which in 2016 recorded a turnover of almost 142 million euros. The Czech company Fatra manufactures high quality components and specialises in offering customer-tailored parts not only producing them, but also with targeted consulting services provided in 50 countries of the world. Materials processed include PVC-P, PVC-U, LDPE, LL-
DPE, HDPE, EVA, PP, PET, and ABS. The company provides a wide range of services to its customers including their research laboratories, testing facilities, preparation of samples, advice on materials and technical consultation. The manufacturing is supported by established quality management and ecology systems such as ČSN ISO 9001 and ČSN ISO 14001. In addition, Fatra has renewed its “Responsible Care” and “Safe Company” certificates over several years. The company is an integral part of the worldwide plastic processing industry, working together with international companies such as Ikea: Fatra’s success as a first-class supplier is based on its focus on customer’s needs, production accuracy, delivery
Fatra ranks amongst the world’s most important plastic processing companies and more than 75% of its production is destined to the international markets
times and, generally, products supply reliability. Negri Bossi’s scope of supply includes both injection moulding machines and complete automation systems, enabling Fatra to efficiently supply a final verified product. The machines delivered feature very high precision levels as well as an accurate quality control system. Moreover, the automation system monitors the component weight with any parts out of tolerance being rejected into a dedicated container. After weight checking, a label dispenser adds a bar code label that the system verifies with an optical reader to validate position and readability. The products are then stacked
on a conveyor belt before moving to the warehouse. “At Fatra our focus is always on delivering a very reliable service to our customers. Negri Bossi helps us achieve this and that is why we see them more as a partner than a supplier”, says Jitka Svobodova, project manager of Fatra. The recent investment includes new Negri Bossi 1,100-ton machines to manufacture a completely new product. The 650 and 1,100-ton models are all equipped with robots and automation equipment featuring a labelling system, a conveyor belt, a parts weighing device and a protection cell. www.negribossi.com
Think forward
Transforming ideas into concrete design firsthand “Thinkforward is all about Biesse’s ability to innovate, to provide integrated solutions that are complex but easy to use, allowing us to produce more, better, and at a lower cost. It encourages us to keep looking ahead, to get a better feel for how we need to act today”, stated Raphaël Prati, marketing and communication director for Biesse Group. The company now offers a complete range of machines that can carry out all machining operations on advanced materials: machining centres, panel saws, waterjet cutting Biesse provides technological solutions that are complex but easy to use for producing more, better, and at a lower cost
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systems and sanders. Selco Plast is a range of single line panel saws that meet the most varied production needs. Rover Plast is a range of machining centres for artisans and medium to small industries, which have proven to be extremely reliable and competitive on the market thanks to innovative developments for the machining of advanced materials. Materia is a range of versatile, compact, 5-axis processing centres designed to meet the widest range of machining needs that include elevated velocity milling of advanced materials, mainly meant for the aviation, naval and automotive sectors. Brema Plast is the range for real-time machining of components. Primus Plast is the new waterjet system designed to meet the needs of companies that look for maximum versatility. Viet Plast is the range of sanders that offer specific solutions for working composite, plastic foam or compact materials. The most innovative made in Biesse technologies designed for all phases of machining of technological materials are on display in a showroom spanning over 5,000 square metres at Biesse campus in Pesaro (Italy), allowing visitors to witness the capacity of these advanced machines to transform pure ideas into concrete design firsthand. www.biesse.com
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PROCESSING MACHINERY
NEWS New line from Binova
The possibility to carry out two processing phases in one offers all-round benefits, from greater competitiveness to the improved quality of the final product
Two in one The new BiReC line developed by Binova (hall A6, stand 6207 at Fakuma 2017) is able to execute in a single stage what is normally done in two: recycling and compounding. This technology can process post-consumer polyolefins in the form of grinded sheet coming from a washing line and the resulting pellet guarantees a high-quality final product. Despite the origin, by using dual automatic filtration, it is possible to guarantee to the end user the production of films with thicknesses of about 20 microns. The line in question uses a corotating twin-screw extruder which can reach a production between 1400 and 1800 kilograms per hour,
depending on the material introduced. The plant is able to compound post industrial waste with high residual moisture (up to 8%) with particular blends of pellets. The presence of a high-vacuum degassing system distributed over almost the entire length of the extruder barrel (3 vacuum degassing flues and 1 atmospheric exhaust flue) allows the granulation of
Injection machine from Presma
Single-station moulding machine for large parts A 1,600-ton injection moulding machine was recently supplied by Presma to a major Italian processor. This machine stands out thanks to its ability of co-injecting shots up to 20 kg for the production of sandwich structures. Designed as an automatic moulding cell, the press is worth 1 million euros and will allow the processor to optimize the production of large
bi-component parts both foamed and solid which are now moulded on Presma multi-station rotary machines. This is the first medium tonnage single-station injection moulding press equipped with the “BIC� injection unit, patented in 1981 and since then offered by the Italian manufacturer for the production of thick section parts. www.presma.it The special BIC injection unit is supplied for injection moulding of highthickness articles
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highly printed films (up to 80% of printed area). The mixing of the raw materials, which occurs directly in the machine, leads to a perfectly homogeneous material, able to improve the quality of the final product. The dosing system of the various materials can be both gravimetric and volumetric. A new gravimetric control system for grinded film, even with a bulk density of around 0.05 kg/dm3, guarantees the exact percentage of grinded sheet to be fed to the extruder. The production of this technology is entirely made in Italy, with particular attention to the quality of all the components. Being able to perform this process in a single step makes BiReC lines very competitive. In addition to the reduced handling of the materials inside the factory, another very important aspect is the proven reduction in energy consumption compared to other plants on the market today: for LDPE-based materials, consumption will not be higher than 0.26-0.27 kW/kg, whereas for PP-, PSor HIPS-based materials, consumption will be around 0.22-0.23 kW/kg (excluding the cooling of the process water). Compared to a traditional line with a single-screw, the energy saving amounts to almost 30%, thanks to the corotating twin screw which has a higher degree of optimization. This plant has been designed to meet the specific needs of a customer who wanted to obtain the same product with higher yields, but it is perfectly suited to the requirements of the entire market. www.binovapm.it MACPLAS INTERNATIONAL AT FAKUMA 2017
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PROCESSING MACHINERY
NEWS Mobert looks forward
Ready for new challenges Starting from January 1, 2018, new rules and restrictions with regards to the production of ultralight bags, such as those used for fruit and vegetables, will be introduced in Italy, similar to those already adopted in France at the beginning of this year. In fact, the new article 226-ter of Legislative Decree 152/2006 (Reduction in the Marketing of Ultra-Light Plastic Bags) states that only biodegradable and compostable ultralight bags (according to UNI EN 13432) can be marketed as from January 1, 2018, with a minimum content of renewable raw material of not less than 40%, which will rise to 50% from January 1, 2020, and 60% from January 1, 2021. The use of these new materials for the production of ultralight shoppers (with thicknesses around 10 microns), winded on rolls, requires special settings and adaptations of the machines in order to obtain prod-
ucts with adequate mechanical strength in the welding and die-cutting area of the handles while ensuring good aesthetic appearance of the rolls produced with these particularly elastic films. After gaining extensive experience in bags on roll production in many years of activity, Mobert has successfully tested these new materials and, today, is able to offer customers the choice of two models of machines that can produce biodegradable bags, cut and winded on rolls. The Roller 110 SHP 2M line up to 4 tracks - can produce T-shirt and bottom welded bags, rolled on a cardboard core. This line is highly innovative thanks to the exclusive patented system for controlling the tension of every single track, essential to process very elastic films with which it is difficult to obtain reels with a constant thickness. The machine is also equipped
with an exclusive (patented) punching unit die-cutting system that guarantees perfect cutting of the handles even in the presence of very elastic films. This extremely effective system does not require maintenance, guaranteeing the blades life of several months and does not require any registration, unlike the complex cutting systems often used on competitors’ machines. The line is completed by a sophisticated vision system for real-time control and correction of handle width. The Roller 110 SHP 6M model also produces T-shirt and bottom welded bags. This line can produce rolls with and without cardboard core, thus completing the range of products to fully satisfy market needs. The transition between the two types of workings is extremely simple, making this line one of the most versatile in the wide range of thermowelding machines produced by
The Roller 110 SHP 6M line produces T-shirt and bottom welded bags. The rolls can be with or without cardboard core. This model completes Mobert’s range of products to fully satisfy market needs
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Mobert. With this line it is possible to produce T-shirt bags on 2 tracks and bottom welded bags on up to 3 tracks; a not so common feature. The punching unit system is die-cutting, as previously described. In addition to the above mentioned machines, Mobert boasts many other achievements such as: lines for drawstring bags (Nastrosac), on 1 or 2 tracks; thermowelding Roller machines for garbage collection bags, on 3 tracks; thermowelding Roller machines for freezer bags, with and without cardboard core, up to 4 tracks, with the option of automatic insertion of metal closure strings; lines for fruit and vegetables bottom welded bags on roll, up to 5 tracks; lines for shopper and bottom welded bags collected in pack of bags, up to 6 tracks; thermowelding machines for the production of “block notes” bags, up to 7 tracks; lines for welding and rewinding of industrial bags roll-to-roll; polyvalent thermowelding machines for stacked or winded industrial bags up to 2000-mm wide; lines for the production of 3-sealed pouches and doypacks for the food sector; lines for the production of 3-sealed pouches on roll, with and without cardboard core; lines for pet food bags (side gusseting, pinch bottom, zip); lines for medical pouches (flat and on roll). All Mobert lines are designed for heavy and continuous operations and are built applying the highest strength and reliability criteria and using the most reliable electronic, electrical, and pneumatic components on the market. www.mobert.it
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NOT ONLY WORDS
moving forward Visit us: Hall A7, Booth nr 7115
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star-europe.com
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ANCILLARIES AND COMPONENTS
MORETTO AT FAKUMA
ALL IS 4.0 Moisture Meter measures, inline and in real time, the residual moisture contained in the plastic granules
DURING THE FIVE DAYS OF THE TRADE FAIR IN FRIEDRICHSHAFEN, GERMANY, THE ITALIAN MANUFACTURER EXHIBITS NOT JUST ITS TECHNOLOGY, BUT EVERYTHING THAT DISTINGUISH THE COMPANY BEYOND IT, THAT IS, PASSION, RELIABILITY, RESPONSIBILITY, AND INNOVATION. AND THE MESSAGE IS, ONCE AGAIN, “THE CHALLENGE GOES ON...”
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rom the 17th to the 21st of October Moretto participates in the 25th edition of the Fakuma exhibition, one of the most qualified and technical fair dedicated to plastics processing technologies. During these five days Moretto, a leading company in this sector, is present with a 231 sqm stand (3208, hall B3). Five days to share the latest novelties with visitors and customers and highlight, once more, Moretto’s principles and, in particular, the values which identify the company’s activity: passion, reliability,
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responsibility, and innovation. Highly technological products, totally realized in house, offering customers customized solutions from planning to production, to sale and after-sales support, in order to guarantee the maximum advantage on the investment made. The exhibition is also an opportunity to present the evolution of the Moretto 4.0 project, a smart factory concept that sees interconnected machines and ERP management software that can capture large masses of data from the production processes, to then process MACPLAS INTERNATIONAL AT FAKUMA 2017
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and share them in order to achieve higher levels of efficiency. A factory that can automatically adapt output to market needs, predict machine breakages or stop machines, offering remote control in real time. The products and the solutions of the Moretto 4.0 project enclose all this, confirming the responsiveness of a company that makes customized manufacturing its strength and is ready to face the challenge to move the industry from a series of fragmented services to an interconnected supply chain model.
FEEDING 4.0 From the arrival of material at the company, One Wire 6, Dolphin and KruiseKontrol transportation systems take care of the entire conveying process, seamlessly integrating with business management systems and providing solutions that manage all parameters independently. KruiseKontrol is the Moretto patented system for the automatic control of the speed in conveying systems. It is able to optimize all the parameters involved, adapting them to the characteristics of every single material, regardless of the distance to be covered or the quantity of material to be transported. There are two critical points in the transport cycle: the first one, at the beginning with an empty pipeline, where the granule has a strong acceleration; the second one, in the pipe cleaning phase, due to the granule accelerated motion at the time of opening of the valve for the transport cleaning. KruiseKontrol completely deletes these problems by controlling and maintaining constant the granule speed. It includes 40 profiles of standard materials with predefined transport characteristics and other 40 customized profiles. The user has to select just the type of material and
The Silcontrol storage management system is one of the OMS&P branded products (Original Moretto Systems & Products), a distinguishing mark for Moretto patented devices which stand out for their technological content, concept and design MACPLAS INTERNATIONAL AT FAKUMA 2017
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the machine to serve; all the rest is automatic. Speed control is ensured by an integrated suction unit that adjusts the granule speed inside the pipes. The collateral effects of a conventional conveying system, considering the variables of a standard system and the speed peaks, are: the generation of the “angel hair”, pipe wear, polymer stress, and dust. KruiseKontrol automatically deletes these problems by managing the transport phases and levelling the speed peaks, ensuring an optimal treatment of the materials and improving the quality level of the moulded product. A touch view control with object oriented programming. The user only has to choose the material type and the machine to be fed and KruiseKontrol manages the process automatically.
DRYING 4.0 X Max, Flowmatik and Moisture Meter dryers ensure, together, that the polymer treatment is completely under control, a perfect closed loop that guarantees a tangible quality, and above all, thanks to Moisture Meter, a certifiable quality, item by item, batch by batch. X Max is a flexible, multibed drying system which ensures high efficiency and constant performance. A dryer that bypasses the limits of the existing technologies offering process, management and economic advantages. With a -65°C constant efficiency at dew point value and incomparable performance levels, X Max is one of the few dryers which grows with the company. From a basic system composed of 3 units, it can be widened to 10 units with extreme ease. The customer will not have to worry about production stoppages because, even in the basic version with 3 units, X Max allows operation without any
Gramixo loss in weight dosing system includes the exclusive Vibration Immunity System
production stoppages since 2 units are operating while one is in stand-by mode and will automatically intervene if one of the others stops; the 3 units can be dedicated to the process, offering a backup system. In this way, in case of a unit stopping, a third module automatically activates and intervenes, guaranteeing continuity even in case of ordinary maintenance. The regeneration phase is carried out by rotation every 60 hours, an interval unknown to the conventional systems, which allows for very long process cycles, up to 76 hours. This system ensures a constant dew point of -65°C with consistent advantage in the efficiency of the treatment. The variable airflow is fundamental to adapt to the process necessities, preserving the polymer from thermic stress and viscosity variations. Most of the drying systems available in the market use compressed air and water for cooling, which represents 40% of the total energy expenditure of a typical industrial factory. X Max overcomes this limit and, thanks to its particular circuit, offers the customer a system which works without cooling water and without compressed air. Moreover, the conversion valve ensures the complete recovery of the regeneration heat, bringing about an energy saving of up to 60% compared to conventional systems. A local management PLC with a colour touch view display guarantees a simple and intuitive user interface. Programming means then to choose only the type of material and the throughput, and the machine automatically manages the process
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ANCILLARIES AND COMPONENTS
constantly and maximizes energy efficiency. Moisture Meter is an instrument dedicated to the inline measurement of the residual moisture of the plastic granule during the drying process. An innovative, precise and constantin-time instrument, able to measure the residual moisture contained in the plastic granule and to ensure the certification of every produced batch, Moisture Meter is calibrated in the factory and does not require any further calibration. The user simply selects the polymer to be treated and Moisture Meter provides to the check of the situation minute by minute, sampling the material being processed every two seconds. It includes about 40 material profiles among the most common technical polymers, such as ABS, PMMA, PA6, PA66, PEEK, and many others. The setting of new profiles is also possible in an easy and intuitive way. The installation of the crown device at the entrance of the drying hopper ensures the control of the initial moisture of the granule and compares it with the final moisture, guaranteeing a punctual process quality check and adapting all the variables involved in the polymer treatment process in real time. In this way, a perfect closed loop is created between the dryer, the material and the processing
machine. Moisture Meter is a device which works on the dielectric characteristics of the granule, so the readout in ppm (parts per million) stays constant in time, even in case of a polymer produced by different suppliers. This is the special characteristic of Moisture Meter, a tool which comes from seven years of studies, tests, and the collaboration with two famous universities. Moisture Meter is one of the few devices which gives the data in ppm or in absolute percentage with no need for initial calibration.
DOSING 4.0 Gravix and Gramixo loss in weight dosing systems are designed not only to dose but to exchange data in a networked environment, manage machine parameters remotely, run production, consumption and costs statistics. Gramixo is particularly suitable for the production of blown film thanks to the weight-per-metre function. It also includes the exclusive Vibration Immunity System technology.
STORAGE 4.0 The Silcontrol storage management system for resin material ensures the integrity of the process by directing each material element to its designated storage, such as external and internal silos, bins, and storage containers. It continuously manages data, events, and records of each storage container. An automatic and safe system which eliminates every possible human error.
COOLING 4.0 The new Moretto’s X Cooler modular and expandable range of refrigeration and temperature control systems are able to fully integrate into cooling management systems by collecting data directly from users. Moretto cooling systems are high-efficiency machines in the cooling of industrial processes. X Cooler is tailor made, with exclusive systems which aim to the maximization of energy efficiency by differentiating from the other systems and products available in the market.
SUPERVISING 4.0
The new Moretto’s X Cooler
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The Mowis integrated supervision software represents one of the most comprehensive and secure Scada systems for the supervision of processes dedicated to the transformation of plastics: real-time monitoring, in-depth analysis of increasingly interactive and predictive data and reports. Mowis is an integrated software package able to give both input and out-
KruiseKontrol is the Moretto patented system for the automatic control of the speed in conveying systems
put and it can be managed by remote control. A Scada ready to manage the smart factory. In conventional machines, the sensors tell what has already happened. Mowis controls the entire factory in an integrated way, monitoring all the automation chain and sending outputs to the system, controlling production in real time. The management capacity of Mowis is 1200 clients and 22 specialized areas, all perfectly integrated. Item-go complete connectivity, prearranged maintenance programme, reporting, all realized according to the “smart factory’’ rules. Mowis permits the user to create the exact layout of its department without any particular programming, guaranteeing an intuitive and immediate view. It ensures the user a simple and intuitive management and activity control system. The immediate set up of the working parameters of every single piece of equipment reduces the possibility of errors. This supervision software offers 10 languages by default: once selected the desired one, all the screens and the alerts will be visualized in the language chosen by the user. The communication with the systems takes place through a protected local industrial connection. At any time the user can print the process and alarm data to prepare reports. Mowis gives the chance to extract and exchange the controlled data at any time. Users can receive assistance directly on their PC where Mowis is installed with a remote connection (modem or IP address). Lastly, Mowis offers complete process traceability, operator’s events traceability, 4 hierarchical operational levels, up to 4 clients servers, up to 10 50-inch info screens for department messages. www.moretto.com MACPLAS INTERNATIONAL AT FAKUMA 2017
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ENGINE-PROOF POLYAMIDES THAT REALLY TAKE THE HEAT Radilon HHR, Radilon XTreme and Radilon Aestus T.
RADILON® enhanced heat-resistant specialities, from the more traditional HHR nylon 6.6 engineering polymers, featuring excellent high heat-ageing resistance at air temperatures of up to 210°C, to the new RADILON® XTreme line developed for hot-air applications at continuous service temperatures of up to 230°C. And, last but not least, the new Radilon® Aestus T polyphthalamide (PPA) family and other speciality PAs, the latest results of our company’s ongoing multi-generation product plan for the development of high performance materials.
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ANCILLARIES AND COMPONENTS
BONDERISING AND MIXING
COMBINING POWER AND VERSATILITY TO SIMPLIFY COMPLICATED PROCESSES A USER OF THE SOLUTIONS PROPOSED BY PROMIXON MAKES TESTIMONY TO HOW, IN A SHORT PERIOD OF TIME, THIS ITALIAN MANUFACTURER BASED NEAR MILAN HAS BECOME ABLE TO MEET PARTICULAR NEEDS WITH TAILOR-MADE SYSTEMS. WHERE INNOVATION, PERFORMANCE AND LONG LIFE BECOME ONE AND THE SAME, AND PROVIDE THE BASIS FOR A SOLID RELATIONSHIP WITH PROCESSORS BY LUCA MEI
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our mixing systems by Promixon have recently been delivered to Pulverit, a specialist producer of powder paints. Collaboration began between the two companies in 2015 with the supply of a complete bonderising system for powder paints, the XBond-MC/1000/3600/B, and continued in 2016 with the purchase of three 2,500-litre FX container mixers. In the first instance, Pulverit needed to bonderise large quantities of technical products using “crumbly” materials, with the risk that the latter would loosen or damage their crystalline structure in case of too high mixing speeds. Promixon then developed a special system that could guarantee excellent bonderising quality along with simple and reliable use for operators of the bonderising system. In the second instance, on the other hand, Pulverit found itself needing to order three FX container mixers urgently to premix thermoset resins with pigments, fillers and additives. Promixon was able to install and commission the machines within the tight deadlines and ensure high quality mixing, extremely easy use and significant savings in cleaning and maintenance times for the mixers.
SAFE AND CONSTANT METALLIC EFFECT The bonderising process can be defined as the adhesion of metallic pigments to thermoset substrates in order to obtain a constant metallic effect even with large batches of pigment on large surfaces. The risk of incorporating the pigments, especially aluminium, is eliminated resulting in a safe operating base for the process (inertisation through nitrogen) and using the best Atex-certified production equipment for use in a potentially explosive environment. The bonderising process can be divided into three distinct phases: adhesion, cooling, and sieving. The first is obtained through heat and softening the powder coating and mixing metallic pigment so all the particles are literally “glued” to the surface of powder particles. The most commonly used method to obtain this effect uses turbomixers: the powder coating and metallic pigment are loaded into the high speed turbomixer (normally provided with a casing to permit a certain level of process temperature control) and then mixed for some minutes at high speed. The mixing energy entails an increase in the temperature of the powder until the softenMACPLAS INTERNATIONAL AT FAKUMA 2017
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ing temperature is reached (between 40 and 60°C) that allows the metallic pigment to adhere to the surface of the powder itself. Normally, the procedure for determining this temperature uses differential scanning calorimetry (DSC) which, however, only analyses a small sample in its optimal state, which is completely different from the actual conditions in the mixing tank. For this reason, Promixon has developed the new X E-Bond feature, which is able, during mixing, to determine the density of material and understand from its variation if it is melting; the bonderising process can then begin at the proper temperature. After the first months of monitoring and development, E-Bond has proven to be extremely efficient: Promixon has in fact found that the Tg (glass transition temperature) and the Tb (bonderising temperature) are aligned with the temperatures of the DSC phase diagram. Once the final mixing point has been reached, the mixture is rapidly unloaded into a cooling device to prevent hardening and freezing. Then the hot mixture must be cooled as rapidly as possible (25°C). For this purpose, a separate low intensity cooler is used, fitted with a water cooling casing able to reduce the temperature of the mass. In the majority of cases, the bonderising quantity is a small batch of a larger batch, so the cooler can also homogenize up to three batches from the bonderiser at the same time. Lastly, as the powder coat-
ing is exposed to heat during the bonderising process so that it can agglomerate. The final product has to be evaluated for the removal of eventual clumps. For this, a 130-150 micron sieve is normally sufficient. The final requirements for bonderised powder coating are represented by excellent recycling of powder during the application stage, thanks to the intimate bond between the metallic pigment and bonderised powder base, the absence of separation in the powder coating during spray application and homogeneous applicability also of the metallic effects on the component.
TWO UNITS, A SINGLE MACHINE
The series of FX container mixers is proposed as the best alternative to traditional high speed mixers when production conditions require elevated levels of versatility and a wide range of different products need When production to be mixed using the requires versatility and requires the same mixer same mixer. Thanks to mix a broad range to the special design of different products, of the mixer, divided the FX container into two separate units mixers provide a valid (mixing head and dealternative to traditional high-speed mixers tachable container), the cleaning time between one batch and another is minimized and, as a consequence, the risk of cross contamination is reduced when switching from one production to another. Mixing, storage and transport are optimized directly using the same container, that can easily be entered into a dosing system with weighing scales or into a dosing feeder for extruders. These con-
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The XBond-MV bonderising system is a combination of the utmost power and versatility, a synthesis of the XM turbomixer and the XV vertical cooler
tainer mixers are used for cold mixing processes: powder polymers or granules with pigments; fillers and additives for processes such as pre-mixing of any type of powder and the production of concentrated pigment masterbatches; engineering polymer compounds of any kind; coating powders; PVC dry-blends. The container mixer can easily be moved using a trolley with wheels and pockets and lifting hooks for forklift truck and hoist. The system is built entirely in stainless steel, and the contact surfaces are polished to minimise material deposits as well as cleaning times. A butterfly valve is used for unloading. The mixing tool was designed to ensure an intense mixing action in order to reduce operating times and ensure perfect dispersion even of heterogeneous products. To boost versatility and ability to adapt to different mixing needs, the machine is available in various configurations. The mixing chamber has a large radius between the bottom and the vertical wall to promote the formation of the best mixing vortex possible and facilitate the dispersion of products. The containers are connected to the mixing head by mechanical safety jacks with worm screws, guaranteeing maximum safety and strength when tipping the container. To this end, the mechanical jacks selected are particularly robust for long life. www.promixon.com
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ANCILLARIES AND COMPONENTS
FILTERING TECHNOLOGY
“IMITATION IS THE SINCEREST FORM OF FLATTERY” 2017 IS A RECORD YEAR FOR FIMIC, THANKS TO ITS RENOWNED TECHNOLOGY, OFTEN THE OBJECT OF IMITATION ATTEMPTS, DESTINED TO FAILURE, THOUGH, AS UNSUPPORTED BY THE EXPERTISE THAT IS ALWAYS BEHIND TRUE INNOVATION
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rica Canaia starts with this sentence. She is the sales director of Fimic, a company renowned in the plastic recycling field for its self cleaning automatic filter changers. Proud of her brand and even more proud of her team, Erica explains, while the advertisement published in Recycling World for the first time will be soon in all the main trade magazines in Europe and overseas. Also, Fimic page on Facebook has recently reached 1,000 followers. The number of Fimic self cleaning automatic filters sold up to the beginning of May 2017 equalled the number of machines sold in the whole 2016, and the current challenge of reaching the highest turnover in 60 years will almost certainly be achieved.
TECHNOLOGY CONSTANTLY IMITATED In the last four years the Fimic filter has in-
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creased its capacity of recycling plastics like PP and PE, even of the most particular kind, thanks to the introduction of innovative technology allowing the filter to screen materials that could not be processed before. For this very reason, however, it has been the object of several imitation attempts. The level of filtration has been a central issue for discussion among plastic recyclers, who continuously strive for higher quality at lower cost. The way Fimic has addressed this issue is an efficient and flexible machine with low operating costs, which has completely eliminated concern among recyclers with reference to the need to shift from manual to automatic technologies. Each plastic material has its own characteristics that need to be respected as well as specific temperature requirements and pressure
Thanks to its innovative technology, the Fimic filter can handle even the most difficult materials with high-quality results. This is the reason why this technology has been the object of many imitation attempts, all of which have proven unsuccessful MACPLAS INTERNATIONAL AT FAKUMA 2017
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settings. And the difficulties increase when the material is not washed. But experience and expertise cannot be imitated. Continuous innovation is what Fimic offers, in an effort to handle materials that are far more difficult than most, such as PVC and EPS. All this is hard to guarantee if you lack the expertise coming from developing, “experiencing”, and testing innovation. The Italian company actually builds its automatic filter from start to finish, keeping a consistent stock of spares so as to be able to ship the same day the order is received. In the last two years, in a constant effort to meet the needs of the recycling sector, Fimic has introduced two new models: one for the filtration of highly contaminated materials and the second for cleaner ones such as, for example, post-industrial materials. With all these options at their disposal, customers can, during the test at Fimic, discuss what the best product will be for them, testing their own material on the company’s testing extruder, which is at customers’ disposal for the whole day. The advertisement on Recycling World aims at stressing the fact that even if orig-
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KNOWLEDGE AND RELATIONSHIP: A LONG-TERM ASSET
The Canaia family, at the head of Fimic
inal and imitation products might look exactly the same, simply judging by their physical appearance, even if they are both made in Italy and resold in the USA, in reality, behind each product there must be dedication, passion, a strong desire to investigate that become evident in years of collaboration with customers and in the lasting quality of the products.
The sale of even a single machine which is the result of imitation by a competitor brings dissatisfaction to the customer. Instead, multiple machines in multiple lines, supplied by Fimic to its customers over time, build a long-term asset, made up of valuable knowledge and relationship. As an example, an Italian customer of Fimic’s is now considering a second Fimic filter, to process HDPE material with MFI of 0.4 g/10 min at 1700 kg/h with 100 microns filtration. Thanks to the Fimic large filtering area, wider than in any other similar technology according to the manufacturer, Fimic can process, with a single laser screen, not only highly contaminated materials (main contamination being represented by metal, aluminium, paper, wood), but also very tough materials, like this HDPE for pipes production. For material on the other side of the spectrum, like PP with MFI of 200 g/10 min, used for the production of bituminous membranes, filtration 500 microns, Fimic has been able to process about 4,500 kg/h on a twin-screw extruder. www.fimic.it
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ANCILLARIES AND COMPONENTS
THE FIFTY YEARS OF PLAS MEC
A GREAT GOAL! HALF A CENTURY OF CONSTANT INNOVATION AND EXPANSION ACROSS THE WORLD HAS TURNED PLAS MEC INTO ONE OF THE MAJOR PLAYERS IN ITS FIELD WORLDWIDE
T
he 50th birthday represents an important milestone for Plas Mec, confirming the company as a worldwide renowned and acclaimed leader in the manufacture of mixing plants for plastics. A result brought about by passion, experience, customer dedication as well as features such as the quality and efficiency of its machines. All in all, a great job over the years.
THE MILESTONES FROM THE BEGINNING Managing director of Plas Mec, Massimo Grigolon
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1967 was the year in which Plas Mec started its activities, founded by Filadelfo Marinello and his brothers in Lonate Pozzolo, in the province of Varese, Italy. Production mainly consisted of accessories for the plastics industry: transport systems for granules, small mixers and dispensers, dryers. 1977 saw the start of the development of mixers and coolers for PVC, which were launched then, encountering remarkable success. The following years were marked by an increase in sales abroad, exceeding those on the domestic market. In 1983, the first horizontal high-efficiency cooler for PVC was launched. Since it was the first of its kind on the market, quite different from what was being proposed by competitors, it soon proved to be a hands-down winner. In
1986, Plas Mec needed more space and therefore expanded its current site in Lonate Pozzolo so as to accommodate the new production requirements. In 1992, new mixer equipment was introduced to increase the efficiency and productivity of the plants. In 2000, new modern offices were built. In 2004, the founder of the company passed away and his sons carried on the business. The company continued to develop thanks to the quality of its products and to the growth of the international market, reaching its highest point in 2008, before the onset of the effects of the international financial crisis. In 2013, a company reshuffle began a rationalisation process aimed at making Plas Mec more efficient and competitive and readying it for future challenges. In 2015, some key technical innovations were implemented on the machines, in particular by introducing the new and more efficient version of the HEC cooler.
THE CHANGES IN THE MARKET IN FIFTY YEARS The market has changed completely in the last fifty years. It has become much more demanding and selective, and this is due to several factors: the evolution of automation proMACPLAS INTERNATIONAL AT FAKUMA 2017
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The TRR mixers are the ideal alternative to traditional turbomixers when production conditions require high levels of flexibility and involve a wide range of different products to be mixed with the same machine
cesses, the demand for higher productivity and efficiency, workplace safety, regulatory constraints, and competition. These are all aspects that have led to a transformation in the approach by the manufacturer and by the user of the plants, and Plas Mec has continued to keep pace with the needs of the customer and the market. Today, for example, Industry 4.0 is a further evolutionary step in the market.
THE FEATURES OF PLAS MEC’S BRAND Reliability, which is a combination of quality and solidity. Plas Mec is known for manufacturing sturdy, long-lasting machinery that maintains the highest levels of production quality. This also stems from the decision to keep a key part of production within the company, so as to keep a watchful eye over every detail of the machinery. There is much talk, nowadays, about “make or buy”, but Plas Mec has decided to stick to the traditional line, opting for “make”. The “make” option offers the advantage of being able to keep a close check on production and product quality, and it also helps to safeguard industrial secrets. The “buy” option, on the other hand, has the advantage of lower fixed costs and leads to less fixed capital. However, there
were no doubts at Plas Mec: the heart of its machinery had to be designed and constructed within the company.
THE LATEST NEWS AND THE NEXT STEPS The most significant technical innovation concerns the new cooler, introduced in 2015, which significantly reduces cooling times by increasing the productivity of the plant and the quality of the final product. “We have been working on innovative projects in the field of additives for plastics for a long time, in partnership with inter-
national companies, and we will soon pass from the experimental to the industrial stage. This will broaden our range of applications and allow us to better diversify our products”, said Massimo Grigolon, Plas Mec’s managing director. The company will be participating in numerous trade fairs in Europe, Africa and the Middle East in the coming months. Its policy is to improve its technological relationship with customers, so it is gradually increasing the number of industrial tests held in its R&D department. The aim is to fully incorporate the customers’ requests and be able to offer a tailor-made product while fostering customer loyalty. Also, looking carefully into the increased internationalisation of the company, Plas Mec is on the verge of completing an agreement with an important foreign group, aimed at increasing its share in the Asian market. www.plasmec.it
www.f-franceschetti.it
BORN AMBITIOUS. is the commercial brand of our products, all obtained with sophisticated mixing processes. Our product portfolio includes: TPE-S and TPO compounds based on SBS and SEBS. MARFRAN®... a world of possibilities !
Beware of imitations.
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ANCILLARIES AND COMPONENTS NEWS Extrusion equipment
The advantage of being “small” The advantage of having the size of a small-medium enterprise along with a bit of craft, is that it is helpful when it comes to moving around with more agility and flexibility. A company that knows this well is Eprotech (hall A2, stand 2115 at Fakuma 2017). It was established in 2010 on a solid foundation of technical know-how and customer relations dating back to the years of economic boom in Italy leading up to the early 1980s. Today, Eprotech produces tools and accessories for extrusion lines used for the most diverse applications in PVC production. The outlet markets are, without distinction, foreign - generating approximately 60% of revenues and divided between EU and non-EU countries (South America, Argentina, Russia,
to name just a few) - and the Italian market, which generates the remaining 40%. Eprotech has made the upgrade of extrusion tools a strategic and practical service. A choice that has met with approval in the form of market demand, to the point that company revenue is generated more or less equally at the rate of new tool sales and upgrades of used tools. One of its projects involves combining reclaimed and virgin materials through a process of co-extrusion. The company supplies tools for producing profiles using different percentages of virgin and recycled material without distinction, reducing the cost of manufacturing by 28%. The plastic processing segment, for some time now, has
Sergio Oleotti, technical director and customer relations manager, in front of the extrusion line installed at Eprotech for testing the different tools the company makes
experimented with the use of recycled materials, and the presence of reclaimed polymer material has become very common, even in a complex context like packaging for the food industry. The world of “secondary materials” (namely reclaimed materials) presents a number of positive aspects. In this context, Eprotech has developed another technology worthy of note that regards the use of polyolefin mix, that “awkward” portion derived from differentiated waste collection which until recently had a sole destination - the landfill. In
collaboration with other extruder manufacturers for compounds, the Italian company has developed a specific technology for producing extrusion tools for so-called “plasmix”, and establishes itself amongst the few industrial realities that can supply everything needed to process this material. In 2011, together with Icma San Giorgio, TPM, Polytechnic of Milan and Itia-CNR, Eprotech won an EU tender (called Ecoimpatto) dealing with extrusion and the co-extrusion of technical profiles using “plasmix”. www.eprotechsrl.com
Central cooling system process pump
Efficiency with low energy consumption On August 15, Frigel (hall A5, stand 5108) announced the adoption of advanced 3PR control technology and variable frequency drives (VFD) for its new Aquagel GPV process pump sets, which ensure that the pumps operate at peak efficiency with the lowest possible energy consumption while offering outstanding control of the units and thus optimal performance. The enhanced Aquagel GPV is part of Frigel’s family of pumping, reservoir and filtration systems designed for fast, economical expansion in use with its central cooling systems - Ecodry or Heavygel. 3PR allows users to readily access full operating schematics that monitor pump performance in terms of pressure, flow rate and VFD capacity and to make adjustments on the fly. Real-time data, combined with trouble-shooting capability, give users the ability to gain precise control of the system. 3PR functionality includes: alarm and fault indicators and dated history log to identify any potential system is-
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sues; all pump values including pressures, calculated flow rates and temperatures; real-time data for pressures versus set points; pump variables in real-time including speed, frequency, and electrical consumption. The VFD pumping assembly on the Aquagel
The new Aquagel GPV central cooling system process pump sets
GPV pump sets automatically equalizes pressure depending on process cooling demands, taking into account the number of machines as well as pressure and flow rate requirements. As such, the units deliver optimal performance while ensuring the highest energy efficiency. Additional highlights of the Aquagel GPV pump sets include: - modular bolt-on capabilities that easily integrate into Ecodry or Heavygel central systems; - multiple selections of high-efficiency pump and motor assemblies to meet any system requirements; - a pre-wired inverter drive per pump (range 40-60 Hz); - manual mode operation available with each inverter; - automatic pump cycling, including standby pumps, to equalize running times; - complete factory supplied trim with non-ferrous wetted surfaces. www.frigel.it MACPLAS INTERNATIONAL AT FAKUMA 2017
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ANCILLARIES AND COMPONENTS NEWS NOVELTIES FROM STAR AUTOMATION
Towards Industry 4.0 The TZ-1500HM side-entry robot displayed by Star Automation at Fakuma 2017 (stand 7115, hall A7) is working on a BMB ekW16pi injection moulding machine, re-confirming the cooperation between the two companies as perfectly performing. In fact, the two controllers of both the unloader and the injection moulding machine are displayed on the same screen. This integration represents a new step in the sector, as with such a system it is much simpler for the operator to control both the machines at the same time, above all through an easily displayed and operated interface. As Industry 4.0 requires, signals of the working conditions of the two machines are displayed on a dedicated screen, thus showing the possibilities of remote-monitoring that Star Automation offers. The compact design of the TZ-1500HM side-entry robot allows it to be installed even in narrow spaces (such as that of the booth), and the telescopic structure of the entry arm is a boost to its speed, which means this machine can reach an extract dry cycle of only half a second. Moreover, thanks to its special chain features that guarantee minimum dust production and a low level of noise, this robot is often used in cleanrooms. The robot extracts from the two-cavity Otto Hofstetter mould two cubic one-litre containers with a wrapped-around label, and then palletizes them on a conveyor belt with its vertical palletizing axis. The injection moulding machine is also accompanied by peripherals by Piovan and refrigerator by Industrial Frigo. Walking some metres through the company stand it is possible to find its XW-1200VI top-entry Cartesian robot displayed on a support. Being Star Automation’s top of the range series, XW-VI robots are suitable not only for pick-and-place, but above all for important automations, such as metal insert loading, interfacing with automations beside the injection moulding machine and IML. Processors might have probably noted the XW-1000VI performing IML at MecSpe exhibition in Parma, Italy, and EOAT rapid change at FIP exhibition in Lyon, France. This time they are able to check a bigger model of the series from any angle: suitable for injection moulding machines between 200 and 650 tons and with an extract dry cycle lower than 1.2 seconds, this certainly is a robot which can satisfy many of processors’ needs. The Stec-520 controller, the newest in the company range and easily connectable to PC via Ethernet in order to answer to Industry 4.0 requirements, offers several monitoring and remote-maintenance functions. www.star-europe.com
XW-1200VI top-entry Cartesian robot
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Since 1940
Infrared and UV solutions Helios Quartz Group (hall A4, stand 4201) has been a family-owned company with two production plants, one in Italy (Helios Italquartz) and one in Switzerland (Helios Quartz Group), combined with distribution channels in the US, in South America and in Asia to become a major international supplier for quartz glass processing and the manufacturing of infrared emitters and ultraviolet lamps. The company also produces specialized equipment for industrial, scientific, and medical applications. TÜV certified, Helios Quartz is a very flexible and dynamic group, which is deeply oriented towards internationalization, and which is living a strong and stable growing phase with great momentum: following the opening of many commercial branches in Usa (Helios Quartz America), in China (Shenyang Helios Tech), and Hong Kong (Helios Quartz Asia), a new branch dedicated to Turkey region, Helios Quartz Turkey, has been opened in 2016. Over 70 years of experience in the industry, highly qualified and prepared staff, multidisciplinary know-how, approach that values the needs of customers, the ability to carry out projects and develop customized solutions allow Helios Quartz to offer always the highest quality products, as well as efficient and professional services. Thanks to its long track record and to its cutting-edge testing laboratory located in the historical Helios Italquartz plant in Cambiago (Italy), Helios Quartz can advise customers and provide them with the best
Ageing test simulator Inve 2000
solution for every specific application. The company product range includes: IR quartz emitters (single and twin tube) in short, medium and fast medium wavelength; IR modules; quartz tubes, plates, disks and customized articles; UV lamps and polymerization equipment for UV reactive inks, lacquers and paints; UV kit and systems; ageing test simulator Inve 2000. Helios Quartz products are able to meet all the most common needs of plastic and rubber processing and forming. Below, some of the most common fields of application of Helios Quartz IR emitters: welding of plastic parts; heating of prepreg composite materials; laminating; IR heating for PET preforms (blowing machine); shrinking of plastic foil; stretching of plastic films; thermoforming of plastic parts; deburring of moulded parts; embossing process; drying of plastic pellets; crystallization and drying of PET, PPS, PLA; curing of paints on plastic; softening process; forming process; bending process; vulcanization processed in rubber industry; drawing of plastic tubes; sealing process; gluing process… and many more. www.heliosquartz.com
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HRSflow at Fakuma 2017
Hot runner technologies for complex challenges The presence of HRSflow (hall A2, stand 2217) at this year’s Fakuma focuses on servo driven Flexflow One hot runner technology which does not require an additional control unit during the injection process, and the new range of Full Compact Nozzles with a reduced constant external diameter over their length. Thanks to newly developed pressure blocks, the hot runner can be used to provide support in the mould, while the new Thread Safe Kit prevents damage during disassembly of screwed-in hot runner nozzles. Premiered at K 2016, the servo driven Flexflow One needle valve systems for hot runner nozzles have a simple driver module that replaces an otherwise necessary control unit. In its current design, this module comes with a default setting that fully opens/closes the needle. Using an External Smart Interface (ESI) that is connected for this purpose, needle stroke and velocity can be individually set for specific applications, including multiple steps, if required. Up to 24 valve pins per system can be individually programed using this ESI. Once these parameters have been saved in the driver module, the system is ready to produce high-quality moulded parts
consistently without a control unit. As an additional safety factor over Highlights of HRSflow at Fakuma 2017 include the servo hydraulically driven systems, a max- driven Flexflow One hot runner technology which - set by an imum torque is set for the servomo- External Smart Interface (top right in the picture) - does not tor at the time of manufacture. When require an additional control unit this value is reached, the electronics shut down to prevent damage to the hot run- heating devices and two thermocouples. Availner system and mould and thus long, costly pro- able gating options are torpedo, free flow and duction downtime. In addition, all Flexflow One valve gating. systems are connected with a Safety Interface HRSflow’s recently introduced pressure block Box (SIB) which communicates with the injec- clamping plates are positioned between the tion moulding machine controller to ensure safe hot runner system and mould where, thanks to their low thermal conductivity, they ensure a working conditions. Full Compact Nozzle is HRSflow’s name for a more uniform temperature profile in the hot runnewly developed family of screwed-in hot run- ner system and help to bring about a distinct inner nozzles which allows the achievement of a crease in mould stiffness. They can be flexibly space-saving heating system, the nozzle seat positioned without any negative impact on the diameter having been reduced from 33 mm to temperature profile of the hot runner system. 28 mm over its entire length. They are optimized Another recently introduced product, the Thread for producing small, delicate parts such as loud- Safe Kit unscrewing aid, reduces maintenance speaker grilles and are also suitable for reverse costs by helping to ensure easy nozzle removal gating from the ejector side. Lengths range from without thread damage. In particular when pro75 mm to 450 mm with internal diameters of 6, cessing critical thermoplastics such as PMMA 8 and 10 mm. They can be equipped with one and PC, it stops the screwed-in nozzle from or two heating zones and are available in Classic seizing. Line and Fail Safe versions, the latter with two www.hrsflow.com
Gearbox for extruder drive
Substantial investments in new production sites The Italian manufacturer of gearboxes for extruder drive Zambello Riduttori (hall A6, stand 6105) has just made substantial investments in two production sites (Magnago, near Milan, and Lendinara, near Rovigo) in order to achieve very important objectives so as to consolidate its leadership worldwide. Both production sites have been expanded, with an increase of around 65% of the total covered surface, which now take up nearly 20,000 square meters of the overall 100,000 square meter area. In order to considerably increase production capacity and to further shorten delivery time, new CNC
Zambello Riduttori has recently invested in two new production facilities, in Magnago (Milan) and Lendinara (Rovigo) to consolidate the company’s leadership worldwide
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machinery, ensuring high precision and productivity, as well as other super-efficient equipment, such as the new massive automatic warehouse system that will revolutionize order processing for customers located all over the world, have been installed at the sites. Over the last few years, remarkable results in terms of performance have been achieved, with the introduction of new products such as the gearboxes for twin screw extruders (both counter-rotating and corotating), now available also with torque density of the highest level. Amongst the new products in the range are also the gearboxes for conical twin screw extruders. But the activity to widen the range, including additional sizes, is still going on. www.zambello.it
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ANCILLARIES AND COMPONENTS NEWS State-of-the-art machining centres
A life for screws and barrels Often it is said that the manufacturers of plastic processing components have a double commercial soul which, because of the nature of their product, will meet the needs of both system manufacturer and processors. This double soul belongs to Mast, a company based in Como (Italy) which in 2017 celebrates 50 years in operation in the production of screws and barrels for the plastics extrusion sector. 75% of its revenue is generated in Italy. Its customers, whether system manufacturers or plastics processors, work primarily for the compound sector, using co-rotating single and twin screw extruders. The latter today represent the company’s main market, but it is also working on projects involving new biodegradable materials. The years of work spanning two generations have brought experience that has, over time, had to adapt to the use of new techniques and materials. In particular, it is now widespread practice to process highly filled and reinforced materials, with decreasing resin content and an increasing high abrasive component. Today, sintering materials are used not only for the construction of milling inserts, but also for the complex mechanical parts which may Screw elements for co-rotating twin screw extruders
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include, in this case, plasticisation screws. Traditional steels, vulnerable to the aggression of fillers, lose validity and this is why, at this point, screw manufacturers have a new problem to face, namely identifying processing parameters and technical solutions for processing increasingly less conventional steel, with respect for - obviously specifications from the extrusion line manufacturer, in this case the client. The machining centres installed at Mast are state-of-the-art: Weingartner, particularly well suited for milling screws, which company’s managers are very proud of, and which represent the true added value of the finished product. While historic technical know-how and continual innovation in the methods used to process materials are vital factors for the present and the future of the company, communication is essential in today’s world. Breaking out of the mould means getting on the internet and marketing the company brand online. Also in the context of marketing, in 2017 Mast hosted an open house to celebrate 50 years in business and opened the doors to everyone who was interested, and also showed off the shed dating back to the early twentieth century, a former textile factory, the
Barrel and screw profiles for co-rotating twin screw extruders
current home of the company’s offices. Communication also means attending the largest trade shows. Mast regularly participates at Plast in Milan and at K in Düsseldorf, events where there is an effective possibility of meeting almost all of its customers and when it has an opportunity to lay the foundations for broadening its portfolio of potential buyers. Expansion on foreign markets is another objective on the company’s agenda. If we consider that 75% of Mast revenues come from sales in Italy, what might happen if the company could achieve a similar result on foreign markets, too? Collaboration and synergy with other Italian companies are also important. A topic that is always a delicate one, especially for companies operating in Italy. Trust, overcoming mistrust, the ability to share objectives, are the Achilles heel, the reason Italians often get envious of their German competitors who (it is no secret) know how to turn out for grand occasions but also for individual commercial opportunities - united and tight. That said, Italian companies do want to team up; they just need to get some concepts right.
Following true to the best Italian tradition, in the context of technology, rather than being an objective, quality is a brand. The “tailor-made” approach at Mast entails a greater sacrifice, a warehouse that is virtually non-existent, but the reward is customer loyalty, confirming the importance that the customer attributes to the relationship with a supplier of essential components, such as screws and barrels for extruders. The Mast client portfolio came over time to contain major names, companies who adopt honest and perceptible commercial behaviour, starting with regular payments, which, frankly, is not to be underestimated. At the basis of the reciprocal supplier-client confidence lies a decision the company made that might be considered counter-productive in an age when image is everything: it has given up on ISO 9001 quality certificate, after years of pursuing it. The decision was made for purely commercial reasons and especially because, as things stand now, from a marketing point of view, this certification brought no added value in terms of image, as the latter had already been earned in the field by facts rather than a label. www.mastsrl.it
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since 1959 automatic bag-making machine for plastic film
serie
The original italian technology to compete and win
series
roller SHP 110
Multipurpose line at 2/3/4 tracks for the production of T-shirt and bottom welded bags on rolls with or without carton core. 100001001010001010110110100100011011000100010010001000100
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series
nastrosac 130 DUO
Line at 2 tracks for the production of bottom welded bags with draw string. Speed up to 150 meter/min.
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roller 2M ECO 110--130
Line up to 6 tracks for the production of pre-cut bottom welded bags on roll with carton core. Speed 300 cuts/min.
Mobert srl - Via Buonarroti 2 - 21053 Castellanza (VA) Italy phone +39 0331 500407 - fax. +39 0331 505207 www.mobert.it - info@mobert.it 063_Mobert_ADV.indd 63
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ANCILLARIES AND COMPONENTS BDMP screen changers engineered for traditional 3-layer blown film line
NEWS Screen changers and downstream equipment
Solutions for compounders and multi-layer extrusion lines Highly customized screen changers and downstream equipment compose the products range of BD Plast. The BDLG simple manual ratchet type screen changer is displayed with a built-in elbow. This solution is particularly appreciated and integrated on multi-layer extrusion lines. Upon request, the elbow can be provided with a removable bushing allowing easy cleaning of the melt channel and extruder screw extraction through the screen changer. The BDO FT hydraulic screen changer now comes in a new compact version with the cylinder in mid-lower position allowing a dramatic size reduction. Special care has been taken to protect electrical
wiring that has been optimized by using fast connectors to the thermoregulation control board. Furthermore, BDO FQ is displayed in a tailor made version having oval filtering area Ø 170 x 300 mm. This solution, specific for twin-screw extrusion lines and compounders, allows a perfect transition avoiding possible stagnation points. Special safety guards and protected wiring are available on this unit too. Continuous flow filtration is possible with the BDOx2 double plate system coming with integral covers and a completely interchangeable sealing system. This sealing solution allows onsite service, minimizing costly downtime. The easy and simplified air
venting grants perfect flow continuity even without melt pump when working polymers at very thin thickness. BD Plast’s traditional product range is completed by a melt pipe network and BDMP adapters engineered for a traditional 3-layer blown film line. These internally engineered components can be easily integrated with the company’s screen changers and static filtration housings (mono or multi cartridge and leaf disc). In the last few years, BD Plast has delivered many complex turn-key solutions allowing OEM’s to save substantial engineering costs. Finally, a couple of products de-
High quality moulds for caps and closures
Provide processors with innovation, flexibility and service To anticipate market needs and keep up with the times, Giurgola Stampi (hall A5, stand 5117) has continually worked to pro-
A multi-cavity mould from Giurgola Stampi
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vide processors with innovation, expertise, flexibility, service and, of course, high quality moulds. Primary emphasis has been placed on the moulders’ production requirements. Although it remains a mouldmaker, the company feels it is necessary to expand its competence from the co-design of the processor product to the complete quality control of the moulded part, through the whole testing phase and pre-production, with the aim to provide processors with an answer to any need and a solution to any problem. The company takes part in several international exhibitions with the aim of strengthening its presence in the European and international market, from both productive and commercial points of view. It shows the latest technologies applied to moulds
veloped by the company long ago have been re-engineered. BDCF is a fast die changing system particularly suitable for profiles. This unit originates from BD Plast hydraulic screen changers and minimizes downtimes, and is in demand to replace the extrusion dies. Last but not least, the BDVR melt flow non-return ball valve allows the polymer melt flow to run in the direction of extrusion only. If polymer counter pressure occurs, the ball moves backwards, immediately blocking the melt flow. Thanks to 3D modelling, the melt channel has been improved dramatically. www.bdplast.com
for closures, destined to sectors such as food and beverage, personal care, body care, pharmaceutical and medical, all of great interest to the company. Caps are displayed with all their possible combinations, with unscrewing thread, pull thread, seals, flip top with and without closing of the lid in the moulding machine, mono, bi and three colour, realized using rotating and tilting technologies in the mould, completely designed and manufactured by the company to meet the needs that emerged from a particularly demanding processor. Equipment constantly updated and managed by qualified and dynamic people allows the company to expand its commercial presence in Europe and around the world, looking for continuous growth opportunities in a changing socio-economic reality. The company is trying to move the boundaries in mechanics using inventiveness and imagination to create solutions and pass on to processors its capability of being a reliable partner. www.giurgolastampi.com
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Plasticizing package for highly-filled composites
Enhancing throughput and part quality in injection moulding
Refrigeration
A record summer Two record installations for Frigosystem this year, both delivered between the beginning and the end of summer 2017 to a renowned Spanish plastic film production group. The latest generation installations of two-megawatt refrigeration capacity were installed one in the southern part of Spain and the other in Texas, with the support of the American subsidiary of Frigosystem: two areas of the world where the climatic conditions are particularly heavy during the Summer. New I-RES water chillers were used, with magnetic levitation centrifugal compressors (Turbocor technology) and a flooded evaporator, leading to energy savings of around 50-60% compared to conventional technologies. The I-RES series, in particular, is one of the most efficient and reliable solutions available today and is the result of Frigosystem’s many years of experience in the application of Turbocor technology. The cooling capacity range covered by I-RES extends up to 1,700 kW, with models featuring unbeatable efficiency and low noise levels. These are R134a refrigerant units for the production of chilled water with “oil-free” centrifugal compressors that allow a significant improvement in performance. The I-RES solution adapts itself to different load conditions, as a result of precise thermoregulation and the use of a com-
pressor with continuous variation of speed thanks to the inverter control. The condensing water loop is completed by ACE (Adiabatic Cooling Energy) heat exchangers, which work through an adiabatic process. Coils, working in closed circuit with no water consumption, as opposed to cooling towers, are free of contamination. The Frigosystem adiabatic system, with easily removable PVC panels with fabric-treated honeycomb structure, also guarantees maximum efficiency in high ambient temperatures and dusty industrial sites such as the site of the Texas plant, also thanks to the patented adiabatic distribution system named “shower”. The whole Frigosystem installation can be remotely managed (supervision) and it is possible to operate and solve any problems through a teleservice system, even via smartphone. Both the ACE heat exchanger and the I-RES chiller are 100% “4.0 ready”. “In fact our management systems are able to provide all the data needed to network Frigosystem machines. Of course, it is up to the customers to structure themselves to manage such data, to restore them and to share them within the so-called “smart factory”. We can provide our control devices with both OPCUA (OLE for Process Control - Unified Architecture) protocol and with another protocol, currently under study, probably simpler than the OPC-UA”, said the CEO Alessandro Grassi. www.frigosystem.it
The I-RES series is the result of Frigosystem’s many years of experience in the application of Turbocor technology MACPLAS INTERNATIONAL AT FAKUMA 2017
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A new plasticizing system for compounds with high levels of glass fibre reinforcement provides wear-resistance, high throughput, and gentle mixing, enabling injection moulders to meet the requirements of metal-replacement and other high-strength applications while enhancing productivity and part quality. Introduced by Nordson Corporation (hall A6, stand 6109) at Fakuma 2017, the Xaloy High Glass Filled Polymer System is designed for injection moulding a wide range of The Xaloy resins with filler Pulsar I Mixing Screw content from 10 wave-style root geometry enhances distributive and dispersive mixing to 60%. Applications include automotive, marine, electronic, and other parts that require very high levels of strength and stiffness. Components in the Xaloy package system include: - Xaloy Pulsar I Mixing Screw, whose wave-style root geometry enhances distributive and dispersive mixing, providing continually varying, localized high- and low-pressure areas that yield complete melt homogenization with low shear; the resulting gentle mixing minimizes fibre breakage and thus maximizes part strength; - Xaloy X-8000 Screw Encapsulation, a nickel-based alloy with high tungsten carbide content that provides twice the abrasive and corrosion wear life than standard high-velocity oxy-fuel (HVOF)-applied coatings; Nordson uses HVOF technology to apply the coating to the entire screw geometry, then fuses the alloy to the parent metal of the screw, forming a metallurgical bond; in addition, the Xaloy X-8000 encapsulation is double the thickness of standard HVOF-applied coatings; - Xaloy X-800 Barrel Inlay, a liner combining a nickel-based alloy with tungsten carbide that provides a high degree of abrasion and corrosion resistance and functions compatibly with the Xaloy X-8000 screw encapsulation; - application-specific valve, designed to accommodate the viscosity and flow properties of highly filled compounds. “Wear-resistance is only one of the requirements for successfully processing the highly filled compounds called for in metal-replacement and other high-performance applications”, said Mark Colella, global product manager for Nordson’s Xaloy brand. “Our new Xaloy plasticizing system enables moulders to overcome the challenges to productivity and part quality posed by today’s increasingly higher loadings of glass fibre reinforcement”. www.nordson.com
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For over 20 years we have been offering a wide range of compounds and masterbatches suitable for any field of application: electronics, automotive, furniture, toys, packaging and many more.
TECLAN ® ABS TECRAL ® ASA TECSTIL ® SAN TECSTIR ® PS TECLUX ® PC TECBLEND ® PC/ABS TECLENE ® PP TECRIL ® PMMA TECBATCH ® MS COLOR TECH S.R.L. Via dell’Industria, 6 31020 San Polo di Piave (TV) Italy T. +39 0422 85 66 44 F. +39 0422 20 61 19 WWW.COLORTECH.BIZ
guud.it
AZIENDA CERTIFICATA ISO 9001 E ISO 14001
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MATERIALS AND APPLICATIONS
Additive manufacturing allows Swift to produce parts with increasingly complex geometries
CASE STUDY IN THE COMPOSITES INDUSTRY
TIME SAVING BY EMBRACING 3D PRINTING FOR SACRIFICIAL TOOLS “STRATASYS’ ADDITIVE MANUFACTURING SOLUTIONS ALLOW US TO SAVE TIME AND COST WITHIN OUR COMPOSITE PART PRODUCTION PROCESS, WITHOUT COMPROMISING PART QUALITY OR PERFORMANCE”, SAID SWIFT ENGINEERING’S PRESIDENT, RICK HEISE
O
ver the last 30 years, composite materials have become increasingly relevant for a number of industrial sectors for applications that demand high performance without the weight associated with metal materials. During this time, there have been many advancements, but producing critical (and often complex) parts with composite materials can be challenging and requires specific expertise and in-depth knowledge. Traditionally, for example, producing sacrificial tools for composite parts involves a multi-step process, which, by implication, means that it can be extremely time-consuming and expensive.
EVOLVING INNOVATION Based in San Clemente, California, Swift Engineering works on the cutting edge when it comes to composite materials. For more than three decades, Swift has been MACPLAS INTERNATIONAL AT FAKUMA 2017
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developing next-generation composite parts for a broad customer portfolio in the automotive, aerospace and defense sectors. As a result, the company has continued to evolve its innovative approach to producing composite parts and is always looking for what is next in terms of materials, processes and techniques, enabling Swift to be a consistent market leader. In partnership
with Stratasys and using its Fortus 3D Printers, the latest technique that Swift Engineering has adopted is additive manufacturing for sacrificial tooling applications. Often overlooked, tooling applications are proving to be amongst the most effective applications of additive manufacturing today, and Swift is one company that is real-
The US company Swift has a long heritage of developing next-generation composite parts for motorsport applications
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Prior to bagging for cure, the ply lay-up is completed
izing this benefit, along with the many other advantages that it brings.
A GAME CHANGER FOR TOOLING The company Swift Engineering has long used FDM (Fused Deposition Modelling) technology for prototyping, and even some final production parts, according to Rick Heise, Swift’s president and chief strategy officer. More recently, the Swift team has benefited tremendously from using 3D printing to produce the sacrificial tooling required for complex composite parts. “For us, Stratasys’ additive manufacturing solutions represent a real game changer because they are allowing us to save a lot of time and a lot of cost within our composite part production process, without compromising part quality or performance”, Heise said. It is at the front end of the composite manufacturing process that additive manufacturing has proved so valuable. It has allowed Swift to eliminate the time-consuming, multi-piece bonded assemblies traditionally associated with trapped tooling approaches and reduce the lead times for tool production by up to 90 percent. Now, as the part is designed, a one-piece corresponding sacrificial tool can be designed in parallel, and 3D printed using Stratasys’ ST-130 material with custom-designed fill patterns that can withstand consolidation pressures in excess of 90 pounds per square inch (620528 Pa, or about 6 bar). The sacrificial tool is then easily dissolved after curing, which eliminates secondary processes and accelerates composite part fabrication. Left to right: 3D printed tool as-built, sealed tool and final resulting part
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Depending on part complexity and size, the tool build can take just days to produce, and frequently less than 24 hours. This, compared with the traditional four to six weeks, or even months, for a machined or cast wash-out tool assembly, affords Swift unprecedented levels of flexibility. These time savings not only permit Swift to meet the increasing demands of shorter client lead times, but also allow much greater design freedom and product iteration cycles that result in innovative part performance and functionality.
IMPROVED PERFORMANCE AND DELIVERY Kerry Dang, manufacturing manager at Swift Engineering, says that a number of the company’s key applications are benefiting from the Stratasys’ sacrificial tooling solution, including brake ducts, hood scoops, leading edges and bell housings. “These are hollow parts with complex geometries that need to be sealed”, Dang explained. “As an example, the air duct was manufactured using
Swift uses composite parts for innovative aerospace applications to reduce weight
the Stratasys’ additive manufacturing sacrificial tool procedure. We were able to remove the tool easily without leaving seams inside of the part because the complex tool is built in one piece and requires less post-production work”. Nate Ogawa, Swift’s director of product development services, added: “This is critical for the optimum inner surface quality of the part and means that functionality is improved, compared with traditional sacrificial tooling methodologies that use multiple parts bonded together to achieve the same shapes”. Based on the success experienced with Stratasys’ sacrificial tooling solution at Swift Engineering, Ogawa said: “We are starting to rely heavily on additive manufacturing for all our fast turnaround applications”. Each time the company does, the rewards translate to happy customers benefiting from getting their innovative composite parts faster and more efficiently. www.stratasys.com MACPLAS INTERNATIONAL AT FAKUMA 2017
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Eprotech Srl Via Vittorio Veneto 71/73 21050 Lonate Ceppino (Va), Italy Tel. +39. 0331.81 01 86 Fax +39. 0331.86 05 95 www.eprotechsrl.com eprotech@eprotechsrl.com
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MATERIALS AND APPLICATIONS
BROADENING OF THE RADILON RANGE
LONG-CHAIN POLYAMIDES FOR TECHNICAL APPLICATIONS RADICIGROUP PERFORMANCE PLASTICS (HALL A1, STAND 1106, AT FAKUMA 2017) IS SHARPLY FOCUSING ON PA 6.10, PA 6.12 AND PA 5.10 LONG-CHAIN POLYAMIDES (LCPA), WHICH NOT ONLY MEET THE HIGH TECHNICAL PERFORMANCE NEEDS OF THE MARKET, BUT ALSO SATISFY THE GROWING DEMAND FOR PRODUCTS OBTAINED FROM TOTAL OR PARTIAL BIOLOGICAL SOURCE MATERIALS
D
uring the second edition of the conference Performance Polyamides 2017 (Cologne, June 6-7), Erico Spini, Europe marketing director of RadiciGroup Performance Plastics, and Nicolangelo Peduto, R&D director, presented a new range of important specialties, highlighting the advances in the development of new high-performance polyamide formulations and applications. “Some of the products are totally new for RadiciGroup, while others have been in our portfolio for some time”, Erico Spini said. “However, the most important aspect we want to stress is that market demand is shifting towards new niche products and that RadiciGroup is ready to satisfy any specific customer request. We have also developed a number of solutions for the automotive sector, the most demanding industry from a technical performance point of view. Our solutions meet the need for both technical and sustainable performance”. Indeed, RadiciGroup Performance Plastics has widened its Radilon product range by adding a number of PA 6.10 (Radilon D), PA 6.10/6.6 (Radilon CD) and PA 6.12 (Radilon
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Air pipes for pneumatic brake systems made of Radilon D 40EP25ZW 333 BK
DT) products, which are ideal for fuel, air or oil systems and feature excellent mechanical properties, excellent processability, low water absorption and good dimensional stability. Compared to traditional PA 6 and PA 6.6, these new polyamides also boast higher chemical resistance - a crucial property for certain automotive applications, as well as other uses. Moreover, RadiciGroup Performance Plastics is presently working on a prospective non-automotive field of application for these LCPA (Long-Chain Polyamides) products - water management. Changes in the government laws already place (or will place in the future) restrictions on the use of conventional polyamides. Excellent hydrolysis resistance,
lower moisture absorption and superior processability make the LPCAs the ideal solution compared to other products already on the market. Last, but not least, is the extrusion market. For this kind of applications, RadiciGroup has developed and obtained the required approval for Radilon DT22, a PA 6.12 product, whose excellent processabiliy, elastic recovery and chemical resistance make it ideal for personal care applications (bristles for toothbrushes and mascara brushes). DT 22 was also developed to offer an intrinsic competitive advantage: improved abrasion resistance. The special chemical resistance and elastic recovery properties of PA 6.10’s, as well as the resulting increased durability, make it a MACPLAS INTERNATIONAL AT FAKUMA 2017
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Amongst applications of Radilon DT22’s, there are bristles for toothbrushes and mascara brushes
commonly used material for the production of monofilament for industrial applications, such as paper mill equipment. A specifically formulated version of this PA, featuring high intrinsic burst resistance, can also be used for the manufacture of fuel system pipes. “The intrinsic properties of LPCAs, which are combined with a specific formulation during the polymerization stage, give us the capability to satisfy an increasingly greater number of customer requirements”, Nicolangelo Peduto noted. “Our know-how in the polymerization process upstream of the production chain, together with our compounding technology downstream, is a powerful competitive advantage enabling us to keep pace with the trends of the market, which is always in search of products featuring ever higher performance”.
AIR PIPES FOR PNEUMATIC BRAKE SYSTEMS With regard to air pipes for pneumatic brake systems, RadiciGroup has developed the extrusion grade radilon D 40EP25ZW 333 BK. The material has particularly high flexibility in order to facilitate the installation of the pipes, which, especially with trucks, can reach a considerable length. Furthermore, it is heat-stabilized, which means that components made from it can be exposed to high temperatures even over a prolonged period of time. To gain approval for application in air pipes for pneumatic brake systems, the materials have
to comply, amongst other things, with the requirements of DIN 74324 and ISO 7628 standards. The data shown below stem from tests carried out in accordance with these standards. The subject of the tests were pipes with a nominal diameter of 8x1, manufactured with the tolerances defined in the standards on conventional industrial machines. The values calculated according to DIN 74324 for the basic stress are above the given minimum of 20 N/mm2. After thermal aging in air (70 hours at 150°C), the basic stress increases. Furthermore, the behaviour of the part after
Fig. 1 - Burst pressure after exposure to media that trigger stress cracking, and after aging in artificial light
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Pipes for in-tank fuel lines used in automotive
contact with liquids, including aggressive chemicals, was also examined. Based on the burst pressure curve up to a temperature of 125°C, the material is suitable, according to ISO 7628, for lines at a nominal pressure of up to 10 bar and up to 12.5 bar. Figure 1 shows the burst pressure after the contact with media that trigger stress cracking, and after aging in artificial light. To examine the stress cracking resistance, the installed pipes were first exposed at 60°C to an increased air humidity of 85%, then bent by a given diameter and dipped, at regular intervals, into a corrosive solution. No cracks are allowed to develop and the value for the burst pressure must be at least 80% of the original value. The corrosive solution is made up of 50% water, copper chloride, sodium chloride, potassium chloride, and zinc chloride. For aging in artificial light, the pipe was irradiated with xenon lamps for 750h at 65°C. Also in this case, the burst pressure must be at least 80% of the original value. www.radicigroup.com
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MATERIALS AND APPLICATIONS
TPEs FOR ADVANCED PRODUCT PACKAGES
FROM DOSING VALVES TO LEAKAGE PROTECTION CURRENT CHANGES IN THE PACKAGING MARKET NECESSITATE NEW MATERIAL SOLUTIONS THAT FAVOUR THE INCREASED USE OF THERMOPLASTIC ELASTOMERS (TPE). KRAIBURG TPE HAS RECOGNISED THESE TRENDS AND IS RESPONDING TO THE REQUIREMENTS OF ITS CUSTOMERS IN THE PACKAGING INDUSTRY WITH A BROAD SPECTRUM OF MATERIALS AND SERVICES
D
ue to their good elastic properties and ease of processing, thermoplastic elastomers are now used in numerous packaging applications. They have good haptic properties with a non-slip surface and are soft and pleasant to the touch. In addition, they are easy to colour, which makes them ideal for high-contrast two-component injection moulding applications in hard/soft combination with other thermoplastics. Especially manufacturers of consumer products are increasingly striving to use their packaging to provide functional unique selling propositions. At the same time, the increase in shipments of single liquid products as a result of e-commerce, as opposed to conventional large-scale distribution on pallets, increases the requirements for packaging with a reliable seal.
INTELLIGENT AND FUNCTIONAL PACKAGING “A classic soft-touch surface that conveys a high-quality product character to the consumer is no longer enough”, says Josef Neuer of prod-
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uct management EMEA at Kraiburg TPE. “That is why we insist on market- and customer-oriented formulations in the development of our materials that pave the way for innovative packaging solutions and speed up the market launch”. An innovative application for thermoplastic elastomers is the use of dosing valves, which allow leak-proof packaging of viscous foodstuffs and cleaners or care products. The valve opens only when pressure is applied, allowing controlled removal of the contents - with no dripping or accumulations. Menshen (Finnentrop, Sauerland region, Germany), a worldwide leading manufacturer of high-quality closures, developed the one2serve dosing valve (figure 1), which opens only when pressure is applied to the bottle or tube. As soon as the pressure decreases, the dosing stops and the opening slots seal again, which not only keeps the contents from leaking, but also prevents penetration by dust or dirt. The dosing valve is manufactured as a one-piece finished product using the two-component injection moulding process. The outstanding adhe-
sion of the TPE to the hard component ensures a cost-effective and reliable manufacturing process, resulting in a hygienic and leak-proof valve.
CUSTOM ENGINEERED COMPOUNDS The German company Kraiburg TPE supports this process with diverse custom engineered products, featuring balanced elasticity and resiliency as well as low tackiness and migration behaviour in contact with foodstuffs. The TPE formulations for use as dosing valves feature elasticity throughout the entire life cycle that is comparable to that of typical silicones of competitors. The hysteresis or elastic-plastic deformation behaviour of these compounds shows a significant decrease in deformation compared to standard TPEs, in which the stress and relief curves are further apart. To ensure that higher dosing pressure is not needed when the valve is opened for the first time even after months of storage, the TPE materials are also specially designed to prevent the slots from clogging. “Dosing valves are just one more milestone in MACPLAS INTERNATIONAL AT FAKUMA 2017
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Table 1 - Suitability of thermoplastic elastomers for contact with different foodstuffs based on migration tests with simulants, in accordance with Directive (EU) No. 10/2011
the customer-oriented success story of our TPEs for the packaging market. We use only pure white oils, such as those used in the medical industry”, Neuer adds. All products are free of PVC, latex and heavy metals.
GUARANTEED COMPATIBILITY WITH FOODSTUFFS “In addition to lab and field data on the application-oriented selection of our TPEs, we support our customers with a comprehensive service package from the product idea through to series production, including mould optimization, processing recommendations and detailed migration tests for applications with food contact”, Josef Neuer explains. The new Thermolast K materials fulfill the stringent requirements of the Code of Federal Regulations, Title 21 (CFR21) of the US Food and Drug Administration (FDA) and of the Directive (EU) No. 10/2011 for plastic materials that are intended for contact with foods. Directive (EU) No. 10/2011 is a regulation that contains an extensive positive list of monomers and additives. It applies to materials and objects made of plastic that are intended for use in contact with foods and defines an Overall Migration Limit (OML) of 10 mg/dm². That corresponds to 60 mg per kilogram of food with a conventional surface/volume ratio of 6 dm²/kg. The migration test is conducted for different foodstuff classes by means of food simulants. In general, compliance with the limits is more difficult in applica-
Classification
Food types
Simulants
Thermolast K compounds
A
Hydrophilic character
Ethanol 10 %
Ok with Thermolast K compounds
B
Hydrophilic character, pH < 4,5
Acetic acid 3 %
Ok with unfilled Thermolast K compounds
C
Hydrophilic character, alcoholic foods (< 20 %)
Ethanol 20 %
Ok with Thermolast K compounds
D1
Lipophilic character, alcoholic food (> 20 %), dairy products
Ethanol 50 %
Ok with selected Thermolast K compounds, every individual case has to be considered
D2
Fatty food
Vegetable oil
E
Dry food
Tenax
Possible, under certain circumstances and with selected compounds, every individual case has to be considered
Simulant (A)
Simulant (B)
Simulant (C)
Simulant (D1)
Simulant (D2)
Simulant (E)
Hydrophilic
Hydrophilic, pH (< 4,5)
Hydrophilic, alcoholic (< 20 %)
Lipophilic, alcoholic (> 20 %), dairy products
Fatty food
Dry food
tions with a high surface/volume ratio. However, each single application must be analysed on an individual basis. Kraiburg TPE provides in-depth customer support in this respect. Table 1 summarizes the suitability of TPE compounds for applications with food contact. TPEs are suitable for applications in contact with hydrophilic and alcoholic foodstuffs, and also for dairy products. However, a migration test is necessary for all plastic materials and
components that are used in food production. This test presents a special challenge for TPEs, especially in the case of fatty foods (migration test with simulant D2 - vegetable oil). The Kraiburg TPE portfolio includes numerous compounds for fatty food applications for which the formulation can be adapted to the specific surface/volume ratio. Even so it should be noted that Directive (EU) No. 10/2011 applies only to plastics and TPEs,
Kraiburg TPE at Fakuma 2017
New materials and consistent customer orientation In addition to market-specific compounds, advanced development processes at Kraiburg TPE have produced new TPE technologies. As the latest innovation of this type, the company presents a new TPE material with outstanding adhesion to EPDM at Fakuma 2017 (stand 5303, hall B5). The new compounds of the Thermolast K product group combine excellent adhesion to EPDM with high resistance to UV radiation and weather influences, in addition to good flow properties. The new material series is ideal for automotive exterior applications. Pilot projects include window seals consisting of EPDM profiles with moulded TPE corner joints. Another new development that already attracted attention at this year’s Chinaplas exhibition is a
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new type of TPE for use in consumer electronics. For this field of application Kraiburg TPE developed thermoplastic elastomers with soft velvety surfaces and superior adhesion to polar thermoplastics, as well as outstanding mechanical properties. The company is a respected specialist for custom engineered TPE solutions and provides local support to its customers in the form of a special service bundle. The spectrum includes project-specific advice on which materials to use, including the colour and application-specific effects, as well as processing recommendations and efficient sampling and colour matching. Local and global contact persons ensure a smooth customer management process with short delivery times. All materials are manufactured at production sites in Europe, Asia-Pacific region and North America, according to the same certified quality standards. On the baThe new TPE sis of specific innovative applications, trade compounds with fair visitors can see the convincing results of adhesion to EPDM this customer-oriented strategy, which also are developed for automotive exteriors includes special applications.
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but not to the silicones predominantly used in these applications in the past, for which the suitability for food contact is determined based on national regulations. As opposed to silicones, the excellent flow and adhesive properties of TPEs make them much more suitable for the manufacture of various “hard” plastics from polyolefins to diverse technical thermoplastics - by means of two-component injection moulding. In addition, the thermal properties of thermoplastic elastomers ensure that they are recyclable. This means that products manufactured from Thermolast K can be returned to the general materials cycle after the end of their useful life.
OUTSTANDING RESILIENCY Packaging in the growing e commerce sector, which has to be absolutely leak-proof, benefits from the cost-effective two-component injection moulding process. “The increase in single shipments by post or parcel service necessitates packaging solutions with very good sealing properties”, Neuer explains. “For these applications we have developed special materials that ensure an optimal and permanent seal even in packaging with small dimensions”. To document this, Kraiburg TPE measured the
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Menshen
Fig. 1 - Polypropylene one2serve cap with integrated dosing valve of Thermolast K, manufactured with twocomponent injection moulding for optimal adhesion and hygienic sealing properties
compression-stress relaxation of material samples. The results confirm that seals made of these materials retain their outstanding resiliency even after the repeated application of pressure over a period of several weeks. The specially developed series for these applications are easy flowing, which also allows the filling of the cavities in the injection mould and prevents problems with weld lines. The specific formulation can be adjusted to individual requirements. Due to their good cold elasticity, the materials also retain their sealing function during transport and storage at low temperatures.
CONCLUSIONS New applications from the Thermolast K
portfolio, such as dosing valves and packaging seals, illustrate the diversity of this TPE technology for increased functionality and performance in view of new trends and challenges in the packaging market. Crucial for market success is the careful matching of materials to the particular application, which necessitates market expertise and active customer support. This also involves “lending an ear to the market” in order to meet future requirements. In this context, Josef Neuer sees the necessity for development of TPEs in a softer Shore range for fatty foods, as well as compounds with adaptable surface friction for seals. www.kraiburg-tpe.com
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MATERIALS AND APPLICATIONS
Fig. 1 - Technipol PA/G for folding operations in the footwear industry
POLYAMIDE HOT-MELT ADHESIVES
AN UNQUESTIONABLE INNOVATION CONTENT THE ADVANTAGES OF DIMER FATTY ACID-BASED CO-POLYAMIDES AND THEIR HIGH CONTENT OF RENEWABLE SOURCES COMPARED TO STANDARD CO-POLYAMIDES CONVINCED SIPOL TO INVEST IN THE PRODUCTION OF THIS CATEGORY OF HOT-MELT ADHESIVES
T
he core business of Sipol, a privately owned Italian company, is the polymerization of high performance polymers for both the adhesive and the engineering plastics segments. The traditional activities of the company were the development and manufacturing of specialty co-polyesters (hot-melt and TPC-ET). However, in 2012 the company made an investment to add co-polyamides to its product portfolio because the main market segments where Sipol operates with hot-melt adhesives (footwear, filter bonding and textile lamination) often use both co-polyesters and co-polyamides. Therefore, the R&D team developed some proprietary polyamides molecules and scaled them up to a new polymerization plant which started operations in 2015. Nowadays, thanks to its complete portfolio of co-polyesters and co-polyamides, Sipol operates in several fields, such as automotive, footwear, packaging, and electronics.
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DIMER FATTY ACID-BASED CO-POLYAMIDES The best known and most common polyamides are often called “Nylon” (the trade name given by the first manufacturer, DuPont) and these are aliphatic polyamides (e.g. PA 6, PA 6.6, PA 12), widely used in engineering plas-
tics for various applications. They are obtained from the condensation reaction of lactams, diamines and dicarboxylic acids. On the other hand, polyamides hot-melt adhesives are a small niche of the bigger polyamide world, and they can be divided into two categories: • co-polyamides, built with lactams, diamines and short chain dicarboxylic acids, similar to “Nylons”; • dimer fatty acid-based co-polyamides. The Italian company Sipol focused on dimer fatty acid-based co-polyamides because of their unquestionable innovation content. In
TAB. 1 - COMPARISON BETWEEN “NYLON 6” (PA 6) AND DIMER-BASED CO-POLYAMIDES
Structure Colour Viscosity Melting T/Softening point range Tg Density Elongation at break Strength at break
Nylon 6 (dry as moulded)
Dimer-based co-polyamides
Semicrystalline
Amorphous
White
Yellow - amber
100 - 400 (240°C) Pa·s
0,5 - 50 (230°C) Pa·s
222°C
100 - 210°C
50°C
-40 - 15°C
1,12 g/cm3
0,95 - 1,00 g/cm3
65%
50 - 800 %
80 MPa
5 - 15 MPa
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fact, these kinds of polyamides are synthesized combining dimer acids with other short chain dicarboxylic acids and various diamines. The nature and the relative molar amount of each component (co-monomer) influence the properties of the polymer (e.g. softening point, viscosity, mechanical performances, and adhesion behaviour).
PROPERTIES Hot-melt polyamides provide an excellent adhesion on porous substrates (leather, paper, wood), some synthetic materials (treated polypropylene and polyethylene, ABS, PVC and other vinyl resins) and also metals (heat pre-treatment needed). Polyamides, ensuring high thermal stability and good chemical resistance to solvents, plasticizer and oils, find application in the automotive, textile and electronic industries. In addition, one more specific advantage, among others, provided by polyamides versus other hot-melt adhesives is their higher mechanical flexibility on glued junctions. In comparison to standard hot-melt polyamides (“Nylon” type), dimer-based polyamides have a much higher content of mono-
Fig. 2 Technipol PA 2202 for oil filters manufacturing
mers from renewable sources and they are lactam-free (lactams bring some limitation in the VOC emission tests). In fact, dimeric acid comes from dimerization of ricinoleic acid, obtained by hydrolysis of vegetable oils. This is why all these polyamides have a content of renewable sources higher than 70%. Table 1 shows an overview of the properties between Nylon 6 (PA 6) and dimer-based co-polyamides.
APPLICATIONS The described features make hot-melt polyamides an ideal adhesive in the following fields:
• automotive: designed for air, oil and diesel filters (figure 2); also used in encapsulation, overmoulding, electrical insulation and interior trim; • footwear: used in lasting and folding operations, together with toe puff printing operation (figure 1); • electronics: used for credit cards and waterproofing connections; • telecommunications: used in electric or telecom cable; • metallic packaging: bonding and seaming; • wood assembly: thread coating, knots repair and edge-banding; • textile lamination: for car interiors, apparel, flooring. Polyamide granules can be extruded in films, webs and rods, coated and also applied in powder (powder scattering).
TECHNIPOL PA AND SIPOLTEX PA Sipol portfolio of polyamide adhesives covers a range of viscosity from 0.5 Pa·s to 50 Pa·s (230°C) with softening point from 100°C to 210°C. www.sipol.com
C
M
Y
CM
MY
CY
CMY
K
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MATERIALS AND APPLICATIONS
MASTERBATCHES AND ADDITIVES
THE PURSUIT OF COLOURS AT THE FAKUMA TRADE FAIR - STAND 5306, HALL B5 - GRAFE DESIGN CENTER PRESENTS THE TREND COLOURS FOR 2018 WITH AN INTERACTIVE STORY. THE PLASTICS SPECIALIST IS ALSO EXHIBITING A NEW GENERATION OF BLACK BATCHES FOR POLYOLEFINS AND A MATTING AGENT FOR THE REPRESENTATION OF VARIOUS SURFACE EFFECTS IN A SINGLE STEP
The new Black³ has a novel, extreme depth of colour, which is able to create a “piano black finish”
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“T
he Pursuit of Colours” with Grafe. That is the motto of this year’s presentation of the 2018 trend colours by the Grafe Design Center. A creative highlight as always, the orchestration of this year’s colour preview features the wellknown Thuringian poetry slammer Andreas in der Au, otherwise known as Aida. He has created an exciting adventure story in twelve chapters that will take the reader on a journey around the world, month by month. A calendar illustrates the trend colours and embodies the visualized accompaniment to the truly colourful story. On the website www.pursuit-of-colors.com exclusive chapters will be unlocked every month by solving twelve puzzles which also offer the chance to discover a great treasure in the form of a fabulous journey. Registered readers can accompany the
protagonist, Ben, and his friend Kara on an interactive search for colours that will take them through the most diverse and inspiring regions of the world. The fast-paced hunt for different shades, nuances and colours coupled with the battle against colourless monotony and drab uniformity culminates in a breathtaking finale. On their tour through the world of colours, the heroes of the story will find 2018 to be a year characterized by intense ambivalence. Autumn and winter are marked by reserved blue, green and brown tones. The most salient aspect of these colours is their naturalness. In addition, they will also find metallic colours in a wide array of nuances. Pastel colours will appear more self-assured and intense, almost a bit synthetic. The combination of what is seemingly incompatible results in interesting contrasts and sets unMACPLAS INTERNATIONAL AT FAKUMA 2017
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mistakable accents. Matt-textured colours will play an important role, leading to velvety, cozy-warm and soft hues. These matt textures can also create a light shimmer. Blue will also display some dominance in spring and summer 2018, as it ranges from very light to deep and dark. There is a new interpretation of pastel colours, on the one hand, very delicate and gently wafting, and on the other a move towards much stronger and livelier variations. Very deep, dark hues, almost black in appearance are also a point of focus. All in all, the coming season reflects a fragile optimism paired with deep mystery. Born in Erfurt, Andreas in der Au (Aida) is one of the most active slam poets in the German-speaking world with extensive stage experience from over 1,000 performances. He has qualified for the German-language championships six years in a row and received a national award for the promotion of tolerance in 2013. His anthology “Poetry Slam in Thüringen” was published in 2016. Aida is on the board of the company Highslammer and organizes and moderates poetry slams along with workshops nationwide.
BLACK, ULTRABLACK AND BLACK³ We are all familiar with the colour black. It is often associated with somber, gloomy and negative emotions. Yet in the packaging industry, black imbues many products and packages with more compelling attributes. Here, more so than in other areas, the colour
Different surface effects can be represented with a single tool thanks to the new matting agent developed by the Grafe specialists
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reflects elegance, importance, respectability and modernity. In order to lend the colour black the requisite intensive and valuable nuances, the Grafe Group has developed a new generation of black batches for polyolefins. The new product, called Black³, has a new and extremely intense depth of colour, which is able to create a “piano black finish” in polypropylene and polyethylene. As a leading colour specialist, Grafe has the expertise to adjust the black intensity to the wishes of its customers. The colouring is especially suitable for polyolefins, where the black intensity can be adjusted individually from normal black to Black³, depending on the colour depth setting. The striking result of this “ultrablack” is unprecedented in its intensity. There are many different areas of application in injection moulding and extrusion and the new colour is optimal for processing matte and shiny surfaces. The material complies with all relevant standards of the cosmetics industry allowing for very special and high-quality optics in the packaging sector. “In the area of packaging, the colour black represents exquisite and modern products, symbolizing strength and stability. Our new Black³, with its incredible depth of colour, provides a clear contrast to the previous black batch and presents a range of products in an amazing colour intensity”, explains Julia Canzler, Design & Packaging at Grafe Group.
ADDED VALUE THROUGH MATTING ADDITIVES The trend towards matte surfaces is still continuing. For a few years now, new vehicle models with an extremely matt surface have become more
The Thuringian poetry slammer Andreas in der Au has created an exciting adventure story in twelve chapters for Grafe. A calendar illustrates the trend colours and embodies the visualized accompaniment to the truly colourful story
common on the market, standing out clearly from the previous cars that had a metallic finish. This trend is, however, also noticeable in the consumer goods sector and is desired by many consumers when it comes to elegant, exclusive surfaces. In addition to the requirements of a modern, matte appearance, though, demands for a resistant, scratch-resistant surface are also increasing at the same time. So far, however, this impression has only been possible by means of an expensive reworking or treatment by painting, sandblasting or the use of soft paint or IML films. The Grafe Group from Blankenhain, Germany, has developed a matting agent with which different surface effects can be represented with a single tool. The addition of this additive occurs directly in the manufacturing process of the plastic component (injection and extrusion). “With the help of our matting agent, glossy and matt surface effects can be realized in a single tool”, says Danny Ludwig, director of the Grafe Design Center. “As a result, plastics processors can dispense with the use of an eroded or etched injection mould. This not only saves costs but also adds production flexibility”, the expert explains. The matting agent is embedded in the plastic melt and produces a diffuse light refraction/ scattering, even in the case of polished mould surfaces. “This creates a matte, satin finish with a velvety feel”, adds Ludwig. However, the product can do even more - it also provides somewhat improved scratch resistance. This not only enables customers to generate added value in their process but finished components are also easier to handle, and the final consumer receives a single, efficient product with an optimized service life. www.grafe.com
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MATERIALS AND APPLICATIONS
NEWS Ceremony for Grupa Azoty
TPEs for the medical and pharmaceutical sectors
A NEW R&D CENTRE IN TARNÓW
The antimicrobial value of the Marfran.Med Au family
Recently, a cornerstone laying ceremony officially marked the start of construction of Grupa Azoty’s new research and development centre in Tarnów (Poland). The project will allow the company to expand its own research activities as part of the group’s R&D efforts, and is consistent with the group’s strategy to generate and implement innovation. It will also improve the competitiveness of Grupa Azoty’s products. Special guests who attended the ceremony included Jarosław Gowin, Deputy Prime Minister and Minister of Science and Higher Education, and Jadwiga Emilewicz, Under-secretary of State at the Ministry of Development. The key outcome of the efforts to develop the R&D infrastructure in Tarnów will be expansion of the group’s own research activities and creating an environment where results of the research could be verified at pilot-plant scale. Twenty new members of the staff, including five holders of PhD degrees, who are to be employed at the centre, will strengthen Grupa Azoty’s R&D human resources. Other expected effects of the project will include establishing and expanding cooperation with startups, research organizations and non-governmental organizations. The new facility, a two-storey building, will house laboratories and office space, with a total area of more than 5,500 square metres, and a pilot-plant hall with a total area of more than 2,400 square metres, connected to the main building. The project will involve construction and installation work as well as site development, including internal roads, car parks, pedestrian paths, indoor and outdoor mechanical and electrical systems, furnishing of premises, purchase of modern research and analytical equipment for the laboratories, installation work and auxiliary utilities for the pilot-plant hall, as well as plant and equipment for bench-scale and pilot testing and research. The project is to be completed by the end of 2018, and it is co-financed with a grant received from the Ministry of Development as part of the support for investment in R&D infrastructure under the relevant measure within the Polish Operational Programme Smart Growth. www.grupaazoty.com
Thermoplastic elastomers are suitable for a range of uses and have a series of advantages. The main one is that their hardness can be modulated; then, two equally important advantages are their soft feel and the fact that they can reach very high transparency. These features, all interesting from the perspective of the medical sector, are guaranteed by Marfran.Med compounds, which were first marketed in 2014 by the Italian company Francesco Franceschetti Elastomeri (stand 5212, hall B5, at Fakuma 2017). As part of this range of elastomeric compounds, the company has recently developed a family of antimicrobial materials (denoted by the extension “Au”); these are still SEBS-based materials, but the difference is that the Brescia-based company’s R&D department has succeeded in incorporating usnic acid into their matrix; usnic acid is a derivative of dibenzofuran, naturally present in some species of lichens. Usnic acid is also an important natural antibiotic, and even though it is slightly thermolabile, the technicians at Franceschetti Elastomeri have nevertheless managed to introduce it into their Marfran.Med Au products in such a way as to obtain materials that can be compounded in the normal way, in terms of the production process. The compounds produced in this way can thus be used to obtain thermoplastic articles that possess good natural antimicrobial properties. Recent laboratory tests performed on Marfran. Med Au compounds have shown their high antimicrobial power, which, in the case of Gram-positive bacteria, exceeds 99.90%; this has allowed the Italian company to exceed the levels envisaged by the ASTM E2180-07 standard, and at the same time to guarantee a
The new R&D Centre will be developed around the Chemical Technology Research and Development Centre, i.e. an existing unit within the structure of Grupa Azoty in Tarnów (Poland)
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“The entire Marfran.Med range is manufactured in accordance with the ISO 9001 and 13485 standards. Furthermore, we certify each compound according to the European ISO 10993 standard and the American USP Class VI one. This means that it is totally biocompatible”, says Francesco Franceschetti, general manager of Francesco Franceschetti Elastomeri
product with a good ability to counteract the growth of Gram-negative bacteria too. For the record, Gram-negative bacteria are those that remain pink in colour after undergoing Gram staining, unlike the Gram-positive type that appear blue or violet at the start of the staining process. First treated with crystal violet, the bacterial cultures are then washed with a mordant: Lugol’s solution. After this, a bleaching agent, such as ethyl alcohol, is used. If the previously violet or blue bacteria lose their colour after being treated with this bleaching agent, then they are defined Gram-negative. Although these single-cell microorganisms are fundamental for the balance of the biosphere, they are certainly not healthy when they proliferate in the body of a sick person. In actual fact, the possible applications of Marfran.Med Au still remain to be explored. For the moment, the Italian company has developed several compounds for the dental and medical prophylaxis sectors. But it is important to remember that, for Franceschetti Elastomeri, customisation of the commodities it produces is more than just a slogan - it is a concrete approach from which its numerous customers in the medical sector stand to benefit. www.f-franceschetti.it MACPLAS INTERNATIONAL AT FAKUMA 2017
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Polyolefins, styrenics, PC, PU, PMMA and alloys
Compounds and masterbatches for any kind of industries Set up in 1997, the Italian company Color Tech aims at keeping pace with the continuous evolution of the plastics market by producing customized compounds and masterbatches that fully satisfy each request with specific technical and colorimetric characteristics. All Color Tech’s products are subjected to careful checks and studies to ensure their compliance with certifications and the highest quality level. The company boasts a laboratory where all tests are carried out to provide physical, rheological, thermal, mechanical and colorimetric evidence with regards to both finished products and incoming raw materials. The different production units ensure high quality standards for both small and large quantities of product, thus offering the highest levels of flexibility in terms of production and suitably responding to all of customers’ requests. Compounds and masterbatches by Color Tech can be used for different applications and
industries, such as home appliances, automotive, electrical and electronics, toys, household goods, furniture components, food, and packaging. The compounds are based on ABS, SAN, ASA, PS, PC, PP, PMMA, and various alloys, amongst which PC/ABS and PC/ASA. All products are available with different technical characteristics: high impact, heat-resistant, flame retardant, reinforced and filled with various minerals, natural or coloured, with special effects and with different types of additives. For most of these compounds, Color Tech is able to provide, on demand, different versions, using environmentally friendly materials, completely or partially regenerated and carefully selected. With regards to the masterbatches, there are different kind of colours and effects: white, black, sample colours, RAL, Pantone, NCS, transparent, fluorescent, metallic, pearlescent,
All compounds and masterbatches by Color Tech are available on different carriers (PE, PP, PS, SAN, PC, PA, PU, PMMA etc.), depending on the material and the industrial process in which they are used (such as injection moulding, blow moulding, extrusion etc.)
and special effects with different additives. The products can also be supplied in microgranules, which improve dispersion and plasticizing with the material used. All chemical compositions are free of heavy metals and comply with the RoHS Directive and the Reach Regulation. According to specific requirements, Color Tech’s products conform to the norms and regulations of the various national and international standards in the fields of food and toys. In 2016 the company obtained ISO 9001 and ISO 14001 certifications for its quality and environmental management systems. www.colortech.biz
Mould maintenance
Anti-corrosion protectant for moulding applications Amongst its wide range of products, at Fakuma 2017 (stand 4309, hall B4) ChemTrend presents Lusin Protect G 31 F, recently added to its broad line-up of high performance mould maintenance products for the thermoplastics processing industry. Lusin Protect G 31 F is an anti-corrosion protectant developed specifically for use in the packaging industry and is applicable for food grade applications where incidental food contact is possible. The new product creates a dry film which provides significant benefit over typical
oil-based rust inhibitors. The dry film does not creep between mould plates, slides and core adjustments and can be easily removed from the mould cavity by the simple process of part moulding, allowing for time and labour savings. Additionally, unlike typical oil-based rust-inhibitors the new product does not produce “oil marks” on transparent and optical parts. Lusin Protect G 31 F is NSF registered and conforms to H1 category code and therefore complies with FDA 21 CFR §178.357. The newly de-
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veloped anti-corrosion protectant, which works in an innovative way to prevent rust on metal parts over both the short and long-term, can also be used as a lubricating agent, providing additional benefits to the end-user.
Lusin Protect G 31 F produces a dry film which protects injection moulds from corrosion
Founded in 1960 and part of Freudenberg Group, ChemTrend is a global leader in the development and production of high-performance purging compounds, release agents and other processing aids. www.chem-trend.com
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Fermapor CC polyurethane foam seal shows high water resistance
MATERIALS AND APPLICATIONS NEWS World debut from Sonderhoff
Closed-cell-sealing technology for high water resistance The Sonderhoff Group, part of Henkel since July this year, presents the newly developed FIP CC (FormedIn-Place Closed-Cell) technology at Fakuma 2017 (stand 5109, hall A5). It combines the high water resistance of the silicone world with the attractive material costs of the polyurethane world. The FIP CC technology is demonstrating live with the new DM 402 CC mixing and dosing system, in conjunction with the new polyurethane (PU) foam Fermapor CC. The new Fermapor CC foam sealant system is based on polyurethane and is intended for applica-
tions requiring very high resistance to water. It closes the gap between high-priced predominantly closedcell materials such as silicone foam, and lower-priced mixed-cell PU foam. It also offers current users of 1-component sealing technology a less expensive alternative. Fermapor CC is a room temperature crosslinking 2-component system that forms a predominantly closed-cell PU soft foam seal with the newly developed FIP CC foaming process. The foam structure is comprised of very fine-cells, which are dense and particularly uniform. Thanks to its closed-cell structure,
Heat-resistant material
Solid silicone rubber for automotive and oven components From October 17 to 21, in Friedrichshafen (Germany), Wacker is premiering its new Elastosil R plus 4350/55 solid silicone rubber at the international trade fair Fakuma (stand 6310, hall A6). An outstanding property of this extrudable and addition-curing silicone grade is its high resistance to heat. The new solid silicone is therefore suitable for components used in oven and stove doors or in engine compartments, for example, which are exposed to heat repeatedly or over lengthy periods. Elastosil R plus 4350/55 is a silicone rubber for formulating heat-resistant, addition-curing silicone elastomers. It reveals its properties to optimum effect in combination with heat stabilizers of the Elastosil AUX Stabilizer H series, which are added
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the Fermapor CC foam seal has a very high resistance to water absorption, and is 90% less air-permeable than mixed-cell PU foam. With a smooth, slightly shiny surface, the seal also makes a good visual impression. In addition, it is significantly more resistant compared to conventional PU foam beads. Even if the surface should be damaged due to the application, the water intake will only be slightly affected, as proven by practical tests and laboratory tests. Fermapor CC PU foam fulfills the Reach/EC regulation 1907/2006 and RoHS and is used for the sealing of components as a rule at temperatures between -40°C and +80°C, even up to +160°C for short periods of time. Furthermore, Sonderhoff has patented a new sealing technology
to the base rubber. The type of stabilizer and the amount used have a significant influence on the thermal properties of the cured rubber. The silicone grade is easy to process in extruders. Elastosil R plus 4350/55 can therefore be used to make extremely heat-resistant tubing and sealing profiles that withstand temperatures of up to 300°C for several days - and even temperatures of up to 400°C for short periods - without any damage. Heat tests at 200°C and 300°C, respectively, show that key mechanical properties such as Shore hardness and elongation at break change very little even after 2,000 hours, i.e. 80 days. In this way, manufacturer’s specifications for products, such as the sealing profiles used in modern ovens, are clearly exceeded. After it has cured, Elastosil R plus 4350/55 achieves a Shore A hardness value of 55, which is ideal for manufacturing heat-resistant profile gaskets, such as for oven and stove doors, or for engine-compartment parts. The new silicone rubber also features good resistance to superheated steam. Carefully post-cured grades comply with the requirements of the German Federal Institute for Risk Assessment (BfR) and the US Federal Drug Administration
with the DM 402 CC mixing and dosing system for the metering of Fermapor CC. The application process itself follows the well-known FIPFG process, which is a production standard in many industries. What is new is the ability of the sealing foam to reach its full size shortly after being applied onto the component. A process-oriented quality control can thus determine, immediately after the sealing application, whether the seal has been applied to the desired height over the entire component contour. With the Fermapor CC sealing foam and the FIP CC technology, a further developed FIPFG process is now available to processors, which opens up new fields of application for automated foam sealing. www.sonderhoff.com
Sealing profiles and tubing made of Elastosil R plus 4350/55 resist temperatures up to 400°C
(FDA) for food contact. Wacker supplies Elastosil R plus 4350/55 as a base rubber blend without additives such as colourants or heat stabilizers. As a result, processors can customize the rubber blend exactly to the specific application. In this regard, Wacker can provide processors with an extensive portfolio of additives. www.wacker.com
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Purging compounds
Efficient colour changes Masterbatches, biodegradable & non-biodegradable
Colours that respect the planet
Biomasterbatches with biodegradable “ingredients” are now used in a variety of different industries, from shopping bags to packaging and even for more technically demanding products
Plastics converters have to face important losses directly linked to frequent colour change and material change operations. It is now a well-known fact that a good purging compound will sensibly diminish the impact of such operations, directly reducing production costs and increasing the efficiency of the machinery. Ultra Plast purging compounds, manufactured by the Swiss company Ultra System (stand 7120, hall A7, at Fakuma 2017), are at the forefront of technology in their sector. The purely chemical cleaning action removes the residues on the screw and in the hot runners systems without damaging the metal parts of the machine. Thanks to important investments in R&D, Ultra System has constantly extended its product offer. With three product ranges, Ultra Plast has the best solution for ev-
ery converter and every situation. In fact, Ultra Plast can be used on all types of machinery for cleaning operations up to 400°C, without generating smokes or smells. In compliance with strict legislation on food-contact plastic items and white-room productions, the entire Ultra Plast assortment is adapted to every possible application. The new Qualipurge CS product range, with the new strengthened formula, has recently been developed to obtain the best results even in the most difficult situations. Tests performed in laboratories and in production lines confirm the benefits deriving from the use of the Qualipurge CS range, which allows a reduction of up to 85% in production costs. Ultra Plast is available worldwide thanks to its official distributors. www.ultrasystem.ch
Colours take on new depth and elegance today, even a new look, iridescent in the sunlight. New effects are created for the technical areas where new colours represent an added value to the final product, allowing the customer to be proactive with new chromatic lines. Since 1971, Vanetti has been committed to fulfilling every possible customer requirement with regard to colourings and additives for plastics in the fields of extrusion, injection moulding and blow moulding. Its passion for colour and its customer service are just two of the reasons why processors choose Vanetti. The Italian company (based in Marnate, Varese) use technologically advanced equipment and carefully select only the finest quality raw materials, so its masterbatches can guarantee outstanding performance. Furthermore, Vanetti is fully aware of environmental issues and the need of safeguarding our planet, which is why its technicians have always selected eco-compatible raw materials to use in the company’s products. With all this experience, Vanetti has recently perfected the range of WITHOUT WITH WITH its biodegradable products, Biomasterbatches (registered tradeAVERAGE VALUES ULTRA ULTRA ULTRA mark), developing a second generation for these biopolymers, moPLAST PLAST PLAST-CS lecularly modified and rendered even more adaptable to processing. Neutral material (kg) 350.00 30.00 25.00 In recognition for its work, the Italian company received the “Vinçotte Cost of neutral material (€/kg) 1.30 1.30 1.30 OK compost” certificate which attests to the quality of the BiomasUltra Plast (kg) -20.00 10.00 terbatches and ensures their suitability for colouring new-generation Cost of Ultra Plast (€/kg) -9.00 11.00 biopolymers. The greatest advantages of using Biomasterbatches are the ease of dispersion and easy processing during production, 219.00 142.50 Purging cost (€) 455.00 in compliance with the latest European regulations governing bio(-51.9%) (-68.7%) degradation. These products are designed for application with PLA, Time for purging (h) 3.00 0.50 0.30 Mater-Bi, and all the new biodegradable polymers. Down-time cost (€/h) In addition to masterbatches and biomasterbatches, Vanetti also Including operators cost, energy, 100.00 100.00 100.00 offers customers a 360° service for the processing of plastic maamortization, production loss terials. Its additives, for instance, supplement the basic molec50.00 30.00 Total cost of down time (€) 300.00 ular aspects when added to plastic during the production of a (-83.3%) (-90%) finished product, thereby creating a new product with technical 269.00 172.50 TOTAL COSTS (€) 755.00 characteristics specifically designed to satisfy the processors’ (-64.4%) (-77.2%) requirements. Test carried out with Ultra Plast PO-C and PO-CS on a 60-mm screw diameter, cleaning of screw and hot runners, 24 cavities; colour change from blue to white. The company will surely exhibit its products at Plast 2018 (Milan, Made in Germany at caps manufacturer. Prices for the European market. Italy, May 29-June 1), the most important European plastics and rubber trade show of next year. www.vanettimaster.com MACPLAS INTERNATIONAL AT FAKUMA 2017
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TRADE FAIRS AND CONFERENCES
PLAST 2018 EXHIBITION & THE INNOVATION ALLIANCE
OVER 1,000 EXHIBITORS ALREADY REGISTERED THE TWO EXHIBITIONS PLAST AND IPACK-IMA, PART OF THE INNOVATION ALLIANCE TO BE HELD AT FIERA MILANO FROM MAY 29 TO JUNE 1, HAVE SPAWNED A NEW SATELLITE SHOW DEVOTED TO INNOVATIVE MATERIALS AND PACKAGING, ORGANISED IN COOPERATION WITH MATERIAL CONNEXION ITALIA
M
ore than 1,000 companies have confirmed their participation in Plast 2018, the international exhibition for the plastics and rubber industries that will take place in Milan (Italy) from May 29 to June 1, 2018. “With just under a year to go, on June 30 nearly 90% of the available space has been reserved”, commented the satisfied president of Promaplast, the organizer of the event, Alessandro Grassi, “with a significant increase in the space requested by foreign participants (+34% with respect to three years ago), confirming the international stature of the fair. So we have high expectations for the final results of Plast 2018”. The overall number of direct exhibitors has also increased, with particular reference to those coming from abroad (+15%). The increase in reservations is spread across all geographical quadrants. And the trend is also analogously positive for all goods categories represented at the fair: machinery, equipment, and moulds for the various manufacturing processes (injection moulding, extrusion etc.), raw materials (plastics and rubber), additives etc. Plast 2018 is a member of “The Innovation Alliance”, bringing five international fairs together for the first time (Ipack-Ima, Meat-Tech, Plast, Print4All and Intralogistica Italia), accessible MACPLAS INTERNATIONAL AT FAKUMA 2017
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with a single admission ticket. In a logic of unified supply chain and sectorial affinity, these events will showcase the technological excellence of the different industries: from plastics and rubber processing to industrial moulding, from manufacturing to packaging, from custom graphics for packaging and labels to goods handling and storage. Together with the four parallel trade shows in The Innovation Alliance, Plast 2018 will occupy all halls at FieraMilano, representing the second largest event to be hosted there, after Salone del Mobile. “Plast will thus represent the most important European date in 2018 for the plastics and rubber industry”, added Grassi, “with the hope that it will still benefit from a favourable economic context like the one that currently characterizes the Italian plastics and rubber processing machinery industry, which, in the first quarter of 2017, recorded double-digit growth in both exports and imports”. In fact, the interest in Plast 2018 registered by businesses is an important signal, complemented by the moderate optimism expressed in recent weeks by companies in the plastics and rubber industries, especially machinery manufacturers and processors surveyed by Amaplast
The 3D Plast satellite hall made its debut at Plast 2015, the last edition of the trade show. Dedicated to additive manufacturing, rapid prototyping, modelling software, 3D printing and similar technologies, it attracted significant interest
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TRADE FAIRS AND CONFERENCES
(Italian plastics and rubber processing machinery and moulds manufacturersâ&#x20AC;&#x2122; association) in its last studies (see article at page 13). The positive attitude of operators toward the domestic market is particularly significant. This is at least in part attributable to positive expectations for the National Industrial Plan 4.0, which sets forth instruments to provide support to companies for investments in operating assets - in the first place super-amortization, hyper-amortization, and the â&#x20AC;&#x153;Nuova Sabatiniâ&#x20AC;? capital equipment law.
SATELLITE HALLS AND NEW SERVICES For the first time together, five international exhibitions (Ipack-Ima, Meat-Tech, Plast, Print4All and Intralogistica Italia) will offer to their respective professionals, with a single entrance ticket, a showcase of technological excellence from different manufacturing worlds, with a strong focus on the entire supply chain. Furthermore, within Plast 2018, for completing the technical offer of our sector, three satellite-shows will be hosted: Rubber (in its third edition, with content true to its name and organized in cooperation with Assogomma), 3D Plast (second edition, focusing on 3D printing and related technologies), and Plast-Mat (debuting in 2018 and dedicated to innovative plastic materials solutions). Considering last edition (attended by 1,584 exhibitors from 57 Countries and 50,087 visitors from 115 Countries), Plast will be the
In 2015 the Rubber hall dedicated to elastomers increased the exhibition space by about 30% in comparison to the previous edition
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main date for plastics and rubber industry in Europe in 2018. Wide support for the initiative has also come from institutions, including the Ministry for Economic Development, which will finance a promotion plan to attract the most qualified buyers from abroad, also in collaboration with the ICE Agency and its network of offices all over the world. Incentives are also confirmed, like in the past, for live demonstrations of machines, on the condition that the exhibitors register in a timely fashion, provide all the required technical information by a set date, and ensure that the machinery will be in operation for a suitable period of time during the event. Fiera Milano will also provide concrete support to the organisers in an effort to offer even more innovative and usable services for exhibitors and visitors, as well as In addition to technological and material innovation, a for the press. Exhibitors will be ofnumber of curiosities will be featured in the halls of the fered several renewed services, Milanese triennial fair dedicated to plastics and rubber including: insertion in the internet portals Expopage and Smart Catalog of Fiera this show will be entirely devoted to innovaMilano; free wi-fi connection on site, one free tive materials solutions including raw materials, car park for each exhibitor and carpet along the semi-finished products and components for aisles in the halls, beside other services on a high value-added products and packaging and forfeit basis and the promotional activities of the innovative containers. It will serve as a melting organizing secretariat. Improvements are also pot of ideas and creative inspirations for strascheduled for catering and reception services, tegic corporate areas from R&D to marketing. travel and hotel reservations, and so forth. To meet the needs of companies and give the The organization office started the assignment best possible coverage to the various product phase - dividing the halls by category - and sectors, the event will be divided into two seccommunicated the assignment to exhibitors. tions located in the Plast and Ipack-Ima halls Of course, it is still possible to sign up for Plast at the centre of the Rho-Pero exhibition area: 2018 as long as spaces are available. In this first Plast-Mat and Ipack-Mat. phase of assignments, those who act quickly The first will be devoted to innovation in plascan still be guaranteed a place within the hall tic materials, with a strong focus on environdedicated to their specific goods category. Af- mental sustainability and advanced technical ter this phase, interested companies may par- performance. The second will focus on adticipate only if there are residual spaces and will vanced packaging solutions, with a specific have to wait until all stand assignments have emphasis on anticounterfeiting, smart packbeen settled for previously registered exhibitors. aging and high value-added and/or low environmental impact packaging. As well as the exhibition area spanning two INNOVATIVE MATERIALS ON DISPLAY Innovative and functionalised materials and halls, Innovative Material Solutions 2018 will products for the premium segment are the fo- also feature an exhibition presenting an overcus of Innovative Material Solutions 2018, the view of all companies taking part in the ininew Plast and Ipack-Ima satellite show which tiative and displaying the most significant will make its debut at Fiera Milano as part of the products. Initiatives will also be organised for companies offering and searching for adevent Innovation Alliance. Presented on February 2017 at the Triennale vanced solutions and materials for product Design Museum, in Milan, and organised in design, manufacturing and packaging. collaboration with Material ConneXion Italia, www.plastonline.org MACPLAS INTERNATIONAL AT FAKUMA 2017
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TRADE FAIRS AND CONFERENCES
Plastics
One of the fastest growing industries in Turkey The next edition of Plast Eurasia, organized annually by Tüyap in cooperation with Pagev (Turkish Plastics Industry Foundation), will take place on December 6-9, 2017, at the Tüyap Fair Convention and Congress Center, in Istanbul. It will host the latest technologies and innovations about plastics machinery, chemicals, raw materials, auxiliaries, heat and control equipment and moulds. Plast Eurasia Istanbul 2016 brought together 957 companies from 41 countries and 48,725 professional visitors from 84 countries. It hosted committees from 26 countries, including Azerbaijan, Bosnia Herzegovina, Bulgaria, Croatia, Egypt, Georgia, Greece, Iran, Iraq, Jordan, Kazakhstan, Kosovo, Lebanon, Macedonia, Moldova, Morocco, Palestine, Romania, Russia, Serbia, Slovenia, Sudan, Syria, Tajikistan, Ukraine and Uzbekistan. Visitors came mostly from Iran, Algeria, Bulgaria, Iraq, Saudi Arabia, Ukraine, Azerbaijan, Morocco and Germany. They represented several sectors such as packaging, raw materials, automotive, and recycling. Plastics industry, one of the most important growing industries of the Turkish economy, gained widespread attention in 2017, reaching a production value of 35 billion dollars in 2016. The production of plastics articles all along the first quarter of 2017 posted a 14% increase, compared to the same period of 2016, reaching 2.3 million tons, for a value of 8.8 billion dollars. Exports exceeded 1 billion dollars, for 389,000 tons. As regards applications, packaging turns out to be at the first position, with a production of 936,000 tons, followed by building/construction, with 515,000 tons. In January-March 2017, Italian exports of machinery, ancillary equipment and moulds towards Turkey topped 24 million euros, with a positive trend especially for flexographic printing machines, plants for mono/multi filament, injection moulding and blow moulding machinery. www.plasteurasia.com
Inauguration of Plast Eurasia’s last edition, in 2016
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EXHIBITIONS & TRADE FAIRS 2017
October 24-28 - IPF (Tokyo, Japan) November 1-3 - JEC Asia (Seoul, South Korea) November 7-10 - Ecomondo (Rimini, Italy) November 7-10 - Plastimagen (Mexico City, Mexico) November 13-16 - Adipec (Abu Dhabi, United Arab Emirates) November 15-18 - Plastics & Rubber Indonesia (Jakarta, Indonesia) November 16-18 - Complast South Africa (Johannesburg, South Africa) November 21-24 - Expoplast (Sibiu, Romania) November 21-24 - Iplas (Guayaquil, Ecuador) November 22-24 - Central Asia Plast World (Almaty, Kazakhstan) December 5-7 - Plastpack West Africa (Accra, Ghana) December 6-8 - Additive Manufacturing Americas (Pasadena, United States) December 6-9 - Plast Eurasia (Istanbul, Turkey) December 6-9 - VietnamExpo (Ho Chi Minh City, Vietnam) December 11-14 - Plastivision Arabia (Sharjah, Saudi Arabia) December 14-16 - PPES, Plastics Processing Exhibition & Summit (Bangkok, Thailand) December 15-17 - India Rubber Show (Gandhinagar, India) December 15-18 - Plas Print Pack Myanmar (Yangon, Myanmar)
2018 January 18-21 - Plastex (Cairo, Egypt) January 21-24 - Saudi Plastics & Petrochem (Riyadh, Saudi Arabia) January 23-26 - Interplastica (Moscow, Russia) January 23-26 - Tehranplast (Tehran, Iran) January 31 - February 3 - IPF Dhaka Plas Print Pack Fair (Dhaka, Bangladesh) February 1-3 - Samuplast (Pordenone, Italy) February 7-12 - Plastindia (Gandhinagar, India) February 12-14 - Egyps (Cairo, Egypt) February 20-22 - Tire Technology Expo (Hannover, Germany) March 1-3 - Complast Vietnam (Ho Chi Minh City, Vietnam) March 11-13 - Plast Alger (Algiers, Algeria) March 14-16 – GRTE, Global Rubber Technology Expo (Bangkok, Thailand) March 20-22 - Plastics & Rubber Vietnam (Ho Chi Minh City, Vietnam) March 22-24 - Mecspe (Parma, Italy) March 24-25 - Color & Chem (Lahore, Pakistan) March 27-29 - PlastPrintPack (Lagos, Nigeria) March 27-30 - Midest (Paris, France) April 3-5 - Plast Expo UA (Kiev, Ukraine) April 5-7 - Compotec (Carrara, Italy) April 11-14 - Vietnamexpo (Hanoi, Vietnam) April 24-25 - Plastics Recycling Show (Amsterdam, The Netherlands) April 24-27 - Chinaplas (Shanghai, China) May 7-11 - NPE (Orlando, United States) May 8-11 - Hispack (Barcelona, Spain) May 10-12 - Complast Myanmar (Yangon, Myanmar) May 29-June 1 - Plast 2018 (Milan, Italy) May 29-June 1 - Ipack-Ima (Milan, Italy) May 29-June 1 - Print4All (Milan, Italy) June 11-14 - Argenplas (Buenos Aires, Argentina) June 11-15 - Achema (Frankurt, Germany) June 27-28 - Plastics Recycling World (Essen, Germany) July 2-5 - DKT (Nuremberg, Germany) MACPLAS INTERNATIONAL AT FAKUMA 2017
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TRADE FAIRS AND CONFERENCES
MEETINGS & CONGRESSES Austria March 14-16, 2018 - Wien: International Automobile Recycling Congress (IARC) - ICM (http://www.icm.ch/iarc-2018)
Belgium February 7-8, 2018 - Brussels: Petcore Europe Conference - Petcore Europe (www.petcore-europe.org)
Germany November 14-16, 2017 - Cologne: Waterproof Membranes - AMI (www.ami. international/events/event?Code=C832) November 28-29, 2017 - Berlin: European Bioplastics Conference - European Bioplastics (www.european-bioplastics.org) December 6-7, 2017 - Cologne: BCC, Biocomposites Conference Cologne - NovaInstitut (www.nova-institut.de) January 18-19, 2018 - Düsseldorf: Future of Polymers - ACI (http://www.wplgroup.com/
aci/event/polyolefins-conference) February 14-15, 2018 - Düsseldorf: The European Biopolymer Summit - ACI (www.wplgroup.com/aci/event/biopolymerconference-europe) March 7-8, 2018 - Düsseldorf: World Elastomer Summit - ACI (www.wplgroup.com/ aci/event/elastomers-conference)
Italy March 14-16, 2018 - Rome: The European Thermoforming Conference - SPE (www.e-t-d.org)
Saudi Arabia March 6-8, 2018 - Yanbu Al Sinaiyah: Saudi Downstream Forum - Sabic (www.saudidownstream.com)
Spain November 29, 2017 - Madrid: European Rubber Automotive Suppliers Conference -
Consorcio del Caucho (www.consorciocaucho.es, or Assogomma, www.federazionegommaplastica.it) January 24-25, 2018 - Madrid: Maximising Propylene Yelds - ACI (www.wplgroup.com/ aci/event/maximising-propylene-yields) April 16-18, 2018 - Madrid: Stretch & Shrink Film - AMI (www.ami.international/events/ event?Code=C872) May 16-17, 2018 - Madrid: The VinylPlus Sustainability Forum - PlasticsEurope (www.vinylplus.eu)
United States November 15-16, 2017 - Knoxville (Tennessee): JEC Forums - International Conference on Automotive Technology (www.jeccomposites.com) March 13-14, 2018 - Coral Springs (Florida): Polymer Sourcing & Distribution - AMI (www.ami.international/events/ event?Code=C894) May 7-10, 2018 - Orlando (Florida): Antec Orlando - SPE (www.4spe.org/Events)
PVC4cables conference in Lyon
Regulations, innovations and environmental impact of PVC PVC4cables, part of ECVM, will organize its first conference on October 26 in Lyon (France) when hot topics, such as construction products regulation and environmentally responsible innovation, will be debated at the one-day event. Discussion among selected country experts will centre on the technical and environmental performance of PVC cables and their beneficial properties, recycling technologies and the impact of regulatory frameworks on the PVC cable market in different EU countries. Taking the theme of “Sustainability, Innovation, Market - The new horizons of the PVC cables industry”, the event’s prominent speakers will also be exploring new solutions in stabilisers, plasticisers and fire retardants. As the European Council of Vinyl Manufacturers (ECVM) platform
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dedicated to the PVC cables value chain, PVC4cables brings together the producers of PVC resins, stabilisers and plasticisers. It is open for participation by PVC compounders, PVC cables producers and all players in the value chain. The organisation aims to drive environmentally responsible innovations in the PVC cables sector and provide a valuable point of reference for the entire PVC cables value chain and its stakeholders: compounds and cable producers, regulators, specifiers, installers, electricians, media and the general public. Commenting on the programme, Zdenek Hruska, ECVM public affairs senior manager and PVC4cables project manager said: “PVC accounts for 46% of the cables market in Europe, making it the most used polymer for electric and telecommunication cables thanks
“Thanks to the European PVC industry’s sustainability programmes, the PVC cables value chain is well positioned to steadily moving towards a true model of circular economy”, underlined Carlo Ciotti, president of the Italian PVC Forum and PVC4cables spokesperson
to its advantages in terms of best cost/performance ratio, sustainability and recyclability. This provides technical and functional benefits for final users and consumers. PVC cables are also one of the main sources of recycled PVC, with more than 127,000 tons recycled from cables in 2016 within the VinylPlus voluntary programme.
Speakers will include Arjen Sevenster, ECVM, providing an update on RoHS and BEMP (Best Environmental Management Practice), Francesco Tarantino from VinyLoop on cables recycling and legacy additives, and Daniel Martinz, technical marketing and development manager, Specialty Vinyls at Inovyn, highlighting how innovation can ensure a bright future in cable applications. “The PVC cables value chain is engaged in the research and development of new formulations to enhance technical performance and provide innovative solutions to the market”, underlined Carlo Ciotti, president of the Italian PVC Forum and PVC4cables spokesperson. The role of nanotechnologies in performance improvement and innovation will be addressed by Enrico Boccaleri, Università del Piemonte Orientale, while Gianluca Sarti from the Compounds for Cables Group of the Italian PVC Forum will illustrate how formulations can influence the PVC cables’ fire behaviour. www.pvc4cables.org
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EDITORIAL CONTRIBUTORS
THE FOLLOWING COMPANIES ARE MENTIONED IN THIS ISSUE: COMPANY/ASSOCIATION/INSTITUTE PAGE AMAPLAST 10; 13 ARBURG 33 ASSOBIOPLASTICHE 26 BASF 27 BD PLAST 64 BIESSE 43 BINOVA 44 BMB 60 CERESANA 20 CHEM-TREND 81 COLOR TECH 81 DOWDUPONT 21 ECVM 90 EPBP 27 EPROTECH 58 EXXONMOBIL 30 FAKUMA 16 FIMIC 54 FRANCESCHETTI ELASTOMERI 80 FREEDONIA 18 FRIGEL 58 FRIGOSYSTEM 65 FRIUL FILIERE 37 GAMMA MECCANICA 42 GIURGOLA STAMPI 64 GRAFE 78 GRUPA AZOTY 80 HELIOS ITALQUARTZ 60 HRS FLOW 61 INDUSTRIAL FRIGO 60 INSTITUTE OF CHEMICAL RESEARCH OF CATALONIA 28 KRAIBURG TPE 72 MACPLAS 23 MAST 62 MOBERT 46 MORETTO 48 NEGRI BOSSI 43 NORDSON 65 NOVA-INSTITUT 28 PCI WOOD MACKENZIE 18 PIOVAN 60 PLAS MEC 56 PLAST 2018 85 PLAST EURASIA 88 PLASTIBLOW 40 PRESMA 44 PROMIXON 52 RADICIGROUP 70 SALDOFLEX 42 SIPOL 76 SMITHERS RAPRA 20 SONDERHOFF 82 SPANISH NATIONAL RESEARCH COUNCIL 26 STAR AUTOMATION EUROPE 60 STRATASYS 67 SWIFT ENGINEERING 67 SYNVINA 27 ULTRA SYSTEM 7; 83 VANETTI 83 WACKER CHEMIE 82 ZAMBELLO 61
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