MACPLAS INTERNATIONAL
Supplement of MacPlas April/May 2018 - Published by: Promaplast Srl – Centro Direzionale Milanofiori, Palazzo F/3 – 20090, Assago (Milano, Italy) - ISSN 0394-3453
THE MAGAZINE FOR THE PLASTICS AND RUBBER INDUSTRY
NEW RECORDS FOR ITALIAN MACHINERY MANUFACTURERS DESIGNING FOR RE-USE AND www.macplas.it RECYCLING INDUSTRY 4.0 REVOLUTION IN THE THERMOFORMING WORLD OPPORTUNITIES FOR COMPOSITE PROFILES IN THE RESIDENTIAL HOUSING MARKET www.poliblend.it
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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VISIT US IN HALL 22 / BOOTH C141-D142
Drop in, Connect, Inject Fusion®G2 hot runner systems are tailored for economical and high quality production of medium to large parts. • Perfect solution for sequenced applications like chromed grills, bumpers, doors panels, consols & white goods. • Pre-assembled, pre-wired and tested systems ready for production right out of the box. • Multi-zone nozzles up to 1,000 mm provide ultimate process control. • Rapid 24/7 global spare parts, service and technical support network. Contact us or visit milacron.com/fusionG2 to learn more.
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CONTENTS
37
10 27 37
EDITOR’S LETTER NEW RECORDS FOR ITALIAN MACHINERY MANUFACTURERS THE GAME OF TONS GOOD NEWS FROM AFRICA MASTERBATCH MARKET TO HIT 14 BILLION DOLLARS BY 2024
PLASTICS AND ENVIRONMENT 27 30 31 32 33
DESIGNING FOR RE-USE AND RECYCLING INNOVATION AWARD GOES TO ARCTIC BIOMATERIALS A NEW PERMANENT FORUM FOR QUALITY RECYCLING PACKAGING WITH A VISIBLE SUSTAINABLE MESSAGE THE ANSWER FOR CLEAN AND EFFICIENT BIOWASTE RECYCLING
MACHINERY AND ANCILLARY EQUIPMENT 37
47 53 56 59 63 67 70
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27
129
147
MARKETING 10 15 21 24 25
42
6
15
INDUSTRY 4.0 REVOLUTION IN THE THERMOFORMING WORLD MULTIPLE ACTIVITIES IN STEP WITH THE TIMES IN A WORD: RATIONALISATION “TECHNOLOGY IN ACTION” INDUSTRY 4.0: WHAT’S NEW? BLOW MOULDING FOR THE MEDICAL FIELD INDUSTRY 4.0, INNOVATIVE PROCESSES AND AN IMPORTANT ANNIVERSARY PRESSES FOR ELASTOMERS FROM ITALY, MACHINES FOR THERMOPALSTICS FROM CHINA BAGMAKING AT THE TOP FLEXOPRINTING AND BAGMAKING
70 71 72 72 73 74 74 76 76 77 77 78 79 81 86 90 93 99 102 104 107 110 113 116 116 117 118
FROM PET BOTTLES TO FOOD PACKAGING TAILORED EXTRUSION LINES DEDICATED TO IRRIGATION AND FURNITURE FOAM PIPES FOR INSULATION INJECTION BLOW MOULDING FOR PERFECT NECKS MACHINING OF THERMOFORMED PLASTICS ADVANCED MULTISKILLED COMPOUNDING FULLY-INTEGRATED FILM CONVERTING TECHNOLOGICAL INNOVATION AND CORPORATE HISTORY IN A NAME ELECTRICAL MACHINERY FOR PRODUCING DEMANDING PARTS SHIFT ABLE CROSS HEAD FOR TWO EXTRUSION LINES EVERYTHING UNDER CONTROL TARGETING WASTE REDUCTION “BEHIND THE SCENES” OF A MAJOR SUCCESS ENERGY SAVING, SUSTAINABILITY AND SMART MACHINES FULL AUTOMATION IN ACTION “BEHIND EVERY SUCCESSFUL ENTERPRISE THERE IS ALWAYS SOMEONE WHO MADE A BRAVE DECISION” FOUR ROBOTS ON DISPLAY, AMONGST NOVELTIES AND CONFIRMATIONS SPECIAL SOLUTIONS FOR INJECTION MOULDING GIANT MIXER FOR THERMOPLASTIC ELASTOMERS AN INNOVATIVE PRODUCT BECOMES AN IMMEDIATE SUCCESS LATEST GENERATION OF PVC DRY BLEND MIXERS FIFTY YEARS OF QUALITY SCREWS AND BARRELS INNOVATION COMES FROM EXPERIENCE SMALL: THE ADVANTAGE TO BE NIMBLE AND FLEXIBLE L CONFIGURATION AND 7-METRE LONG ROLLS FAST ASSEMBLING AND DISASSEMBLING FOR A WIDE APPLICATION RANGE MACPLAS INTERNATIONAL AT PLAST 2018
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COVER STORY
MACPLAS INTERNATIONAL
118 119 120 120 121 122 122 123 124 124 125 126 126
129
NEW R&D CENTRE AND, SOON, OFFICES IN NORTH AMERICA AND ASIA NO COMPROMISE FOR PIPE CORRUGATORS IR AND UV SOLUTIONS SINCE 1940 PELLETIZERS AT 360° INCREASE THE FLOW RATE OR REDUCE THE ROTATION SPEED HUMAN CAPITAL AND QUALITY PRODUCTS: STRENGTHS FOR 55 YEARS FROM HEAVILY CONTAMINATED WASTE TO HIGH QUALITY FILM CUSTOMIZED SUPPLY FOR COFFEE CAPSULES PRACTICAL AND LIGHT FOOD CONTAINERS READY FOR THE CHANGING INDUSTRIAL REFRIGERATION TURNKEY PACKAGE FOR CONTINUOUS FLOW PROVIDE PROCESSORS WITH INNOVATION, FLEXIBILITY AND SERVICE FILTRATION FOR ALL
MATERIALS AND APPLICATIONS 129 134 136 138 140 140 142 142 143 144 144
146
OPPORTUNITIES FOR COMPOSITE PROFILES IN THE RESIDENTIAL HOUSING MARKET STRONG ADHESION FROM THE VERY START ENHANCED CRYSTALLIZATION RATE IMPROVING AUTOMOTIVE PERFORMANCE PLENTIFUL ARRAY OF COLOURS AND EFFECTS DIRECT INTEGRATION OF RUBBER IN THE FIBRE COMPOSITE MATERIALS AND METAL PURGING COMPOUNDS FOR WASTE EXPANDING MASTERBATCHES FOR INJECTION MOULDING AND EXTRUSION
WHEN COLOURS REPRESENT AN ADDED VALUE MICRO AND FINE GRANULES FOR ROTATIONAL MOULDING FLUOROELASTOMERS 4.0
TRADE FAIRS AND CONFERENCES 146 147 147
MEETINGS & CONGRESSES EXHIBITIONS & TRADE FAIRS INTERNATIONAL APPOINTMENT WITH PLASTICS AND RUBBER INDUSTRIES
MACPLAS INTERNATIONAL AT PLAST 2018
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Supplement of MacPlas April/May 2018 - Published by: Promaplast Srl – Centro Direzionale Milanofiori, Palazzo F/3 – 20090, Assago (Milano, Italy) - ISSN 0394-3453
THE MAGAZINE FOR THE PLASTICS AND RUBBER INDUSTRY
NEW RECORDS FOR ITALIAN MACHINERY MANUFACTURERS DESIGNING FOR RE-USE AND www.macplas.it RECYCLING INDUSTRY 4.0 REVOLUTION IN THE THERMOFORMING WORLD OPPORTUNITIES
FOR COMPOSITE PROFILES IN THE RESIDENTIAL HOUSING MARKET www.poliblend.it
Growing, innovating, qualifying It was 1999 when Giancarlo D’Ottavio, Filippo Corradini and Italo Bececchi decided to establish Poliblend (stand C112, hall 9, at Plast 2018) in a small industrial building in Cislago, in the Italian province of Varese. In embarking on this adventure in the distribution and marketing of plastic materials, they were able to draw on knowledge and experience already gained over several decades of work at leading companies in the polyamides sector. As early as the following year, Poliblend, thanks to commercial agreements with several important European dealers, became a point of reference on the market, and at the same time started up its compounding activity. By 2003 it was already necessary to move both the production and offices to a new building in Mozzate, in the province of Como. The following year saw the company obtaining its ISO 9001 certificate, thereby concretely embracing the concept of quality. This stage was followed by a period that saw Poliblend opening up towards non-EU markets and taking over the companies MMT (2006) a well-known name in the moulding of plastic materials, Celloplast (2009) a manufacturer of engineering thermoplastics, and Essetiplast (2009) which was to play a key role in the production of colour masterbatches, both for internal use and for the overseas market. In 2010 the companies moved to new buildings, still in Mozzate. In 2014, to celebrate its fifteenth anniversary, Poliblend opened a branch in Spain and introduced its environmental protection strategy, obtaining ISO 14001 certificate. The following year, it took over Mazzer Grip, a leading producer of thermal break profiles, and then in 2017 opened a new office in Germany so as to be better placed to serve the Central European market. All these companies are now part of the Poliblend Group, a solid organisation and a leader in the field of engineering thermoplastics and polyamide resins. The companies making up the group are: • Poliblend, the parent company and driving force, which manufactures and markets, globally, a variety of PA-, PBT- and POM-based engineering thermoplastics and elastomer-based, reinforced, filled, self-extinguishing and lubricated compounds; • Essetiplast GD, which produces and sells colour masterbatches and specific additives; • Celloplast GD, which specialises in the production of various types of thermoplastic elastomer; • Alfapolimeri, which sells, in central Italy, a wide range of engineering thermoplastics and elastomers, from various expert suppliers; • PAE (Poliblend Asociados España), which sells engineering thermoplastics, additives, colour masterbatches and thermoplastic elastomers throughout the Spanish market; • Mazzer Grip GD, active in the field of thermal insulation of windows, doors and façades; • Weber Kunststoffe, which has marketed thermoplastics since 1994. www.poliblend.it
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MACPLAS INTERNATIONAL
ADVERTISERS’ LIST Supplement of MACPLAS April/May 2018 Editor in chief Riccardo Ampollini Editorial staff Luca Mei, Girolamo Dagostino, Stefania Arioli Sales office Giuseppe Augello Editorial assistant Giampiero Zazzaro Editorial committee Alessandro Grassi, Andrea Franceschetti, Massimo Margaglione, Corrado Zanga Contributors to this issue Amaplast, ChemOrbis, Corepla, Gino Delvecchio, EPTA, Federazione Gomma Plastica, Nova Institut, Plast 2018, Angelo Grassi, Oreste Pasquarelli, PlasticsEurope, SPE Italia, Uniplast 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 CNS Postal delivery: IFS Italy ISSUE PRICE: 8 euro if not sent with mother magazine The managing direction of the magazine declines any responsibility for possible unreliability of editorial articles and notes coming from various sources ASSOCIATED TO:
UNIONE STAMPA PERIODICA ITALIANA ASSOCIAZIONE NAZIONALE EDITORIA DI SETTORE
33 AGRANA www.agrana.com 14 AMUTEC www.amutgroup.com 11 ARBURG www.arburg.com 12-13 BANDERA www.luigibandera.com 29 BD PLAST www.bdplast.com 112 BESTON www.beston-italy.com 101 BFM www.bfm.it 85 BIESSE www.biesse.com 121 BINOVA www.binovapm.it 24 BLAUWER www.blauwer.com 141 BMEC www.bmecsrl.it 127 CAMPETELLA www.campetella.it 145 CARLASSARA www.carlassara.it 26 CM PRODUZIONE www.cmevolutionplast.com 66 COLOR TECH www.colortech.biz 137 COMAC www.comacplast.it 105 COMERIO ERCOLE www.comercole.it 62 DE-GA www.dega-plastics.com 65 DOSS www.doss.it 98 ELASTOMERS UNION www.elastomersunion.it II Cop. EPROTECH www.eprotechsrl.com 106 ERRETI www.purgingit.com 9 EXACT www.exact.it 36 FILIPPINI & PAGANINI www.saldoflex.it 103 FILTEC www.filtec.it 64 FIMIC www.fimic.it 73 FM FILTER www.fmfilter.com 111 FRANCESCHETTI ELASTOMERI www.f-franceschetti.it 20 FRIGOSYSTEM www.frigosystem.it IV Cop. FRIUL FILIERE www.friulfiliere.it 45 GEFIT www.gefit.com 51 GIURGOLA www.giurgolastampi.com 57 GRAFE www.grafe.com 71 GUMMIWERK KRAIBURG www.kraiburg-rubber-compounds.com 58 HELIOS ITALQUARTZ www.heliosquartz.com 31 HERBOLD www.herbold.com 5 IMG www.imgmacchine.it 61 IPM www.ipm-italy.it 52 ITIB MACHINERY www.itib-machinery.com 117 LEISTRITZ www.leistritz.com 148 MACPLAS www.macplas.it 133 MAKLAUS www.maklaus.com 92 MARIS www.mariscorp.com 79 MAST www.mastsrl.it 97 MECCANOPLASTICA www.meccanoplastica.com 32 MERO www.mero.it 109 MOBERT www.mobert.it 4 MOLD MASTERS www.milacron.com 41 MORETTO www.moretto.com 17 MOTOMECCANICA www.motomeccanica.it 25 NORDSON www.nordson.com 143 OMMP-MOULDS www.ommp.it 75 PLAS MEC www.plasmec.it 115 PLASTIBLOW www.plastiblow.it I Cop. POLIBLEND www.poliblend.it 34 POLIVINIL www.rotomachinerygroup.com 23 PRESMA www.presma.it 123 PROFILE DIES www.profiledies.it 55 PROMIXON www.promixon.com 3 RPM www.rpm-srl.it 35 SALDOFLEX www.saldoflex.it 68 SARA www.sarasrl.eu 128 SIPOL www.sipol.com 69 STAR AUTOMATION www.star-europe.com 78 THERMOPLAY www.thermoplay.com 80 ULTRASYSTEM www.ultrasystem.ch 46 VANETTI www.vanettimaster.com 119 WM THERMOFORMING MACHINES www.wm-thermoforming.com III Cop. ZAMBELLO www.zambello.it
INSTITUTIONAL SPONSORS AMAPLAST ITA LI A N PL ASTIC S A N D RU B B ER PRO CES SIN G M ACHIN ERY A N D M O U L DS M A N U FACT U R ERS’ AS SO CI ATIO N
ASSORIMAP AS SO CI AT IO N O F ITA LI A N PL ASTIC S R ECYCLIN G A N D R ECL A IMIN G C O M PA NIES
SPE ITALIA SO CIE T Y O F PL ASTIC S EN G IN EERS
AIPE I TA L I A N AS SO CI AT I O N O F E X PA N D ED P O LYST Y R EN E
CIPAD C O U N CIL O F IN T ER N ATIO N A L PL ASTIC S AS SO CI ATIO NS D IR ECTO RS
UNIONPLAST AS SO CI ATIO N O F ITA LIA N PL ASTIC S PRO CES SIN G C O M PA NIES
IIP ITA LIA N PL ASTIC S INSTIT U T E
UNIPLAST ITA LI A N STA N DA R D ISATIO N BO DY FO R PL ASTIC S
ASSOGOMMA ITA LI A N RU B B ER, CA B L ES, WIR ES A N D SIMIL A R M A N U FACT U R ERS’ AS SO CI ATIO N
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MACPLAS INTERNATIONAL AT PLAST 2018
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EXACT GRANULATORS USED TO RECOVER INLINE EDGE TRIM OR OFFLINE ROLLS. COLD OR HOT TECHNOLOGIES ARE AVAILABLE TO ACHIEVE THIS TASK.
COLD SYSTEM CYKLOP 30 CYKLOP 20 EVOLUTION 10 R6/GOLD R6/JUMBO
HOT SYSTEM EXTRUDER E-60
Exact s.r.l. - Street Venezia 18, 24040 Zingonia (BG) Italy - Tel: + 39 035 883672 - www.exact.it
Stand A111 – Hall 15 009_Exact_ADV.indd 9
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EDITOR’S LETTER
“
FULL SPEED AHEAD! THIS IS OUR YEAR! The curtain is going up on Plast 2018, and for the sector of machines, equipment and moulds for plastics and rubber processing, the economic backdrop for the show simply couldn’t be better. Last year ended on a high note - in fact 2017 was our best year ever! - with all the macroeconomic indicators recording double-digit growth: production (+10%), exports (+12%) and imports (+14%). Italian manufactured goods were boosted by strong overseas sales, which accounted for 70% of total sales, but it was also buoyed up by the domestic market, which has been showing clear signs of a recovery for more than a year now, thanks in part to the measures to support investments in capital goods implemented within the National Industry 4.0 Plan. Justifiably, then, the expectations for 2018 reflect a certain degree of optimism: obviously it will not be possible to repeat the performance levels of last year, but a few percentage points of growth can certainly be expected. What is more, a great many companies - especially those that build large machinery and plants have already received orders that will keep them busy for (almost) the entire year. And so on to Plast, an unmissable event for anyone wanting to see (in operation) all the most innovative technologies for plastic and rubber processing. Digitalisation of factories through machines designed for Industry 4.0; process technologies designed to concretely support the “circular economy”, predictive maintenance - these are just some of the topics that will be addressed at the fair, not only through the exhibition of machinery, but also in the various conferences that will be held during Plast 2018. Finally, I feel I must mention the enormous effort that has gone into creating “The Innovation Alliance”: five specialist events (Plast, Ipack-Ima, MeatTech, Print4All and Intralogistica), each a leader in its particular sector and all five complementing each other perfectly. In short, what we have here is a flourishing industrial community that, through leading national and international brands, is for the first time showcasing itself in an organic event devoted to the industry as a whole. In short, this year’s Plast will be a fair “par excellence” - the fair - and you simply can’t miss it!
Alessandro Grassi, president of Amaplast 10 010_Editoriale_Grassi.indd 10
”
MACPLAS INTERNATIONAL AT PLAST 2018
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PLAST 2015
MARKETING
AMAPLAST - 2017 CONSOLIDATED RESULTS
NEW RECORDS FOR ITALIAN MACHINERY MANUFACTURERS THROUGH ITS STATISTICAL STUDIES CENTER, THE ITALIAN TRADE ASSOCIATION AMAPLAST (BRINGING TOGETHER ABOUT 170 MANUFACTURERS OF PLASTICS AND RUBBER PROCESSING MACHINERY, ANCILLARY EQUIPMENT AND MOULDS) HAS COMPLETED ITS YEAR-END BALANCE SHEET FOR 2017, INCORPORATING FOREIGN TRADE DATA FROM ISTAT (ITALIAN INSTITUTE OF STATISTICS)
D
ouble digit increase over 2016 in all macroeconomic indicators means new all-time records for the sector. Lacking objective statistical surveys, Amaplast’s analysis show production sustained by excellent performance in exports, the destination for 70% of the Italian-made products in the sector, as well as by the domestic market, which is showing clear signs of recovery, probably explained by the measures implemented by the National Industry 4.0 Plan to support investment in capital equipment. The expansion of the domestic market has also been signalled by quite positive performance in imports. Regarding macro-areas, the geography of exportation has witnessed overall growth in European destinations, mainly within the EU, where the top two export markets, Germany and France, have grown by more
MACPLAS INTERNATIONAL AT PLAST 2018
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than 20 percentage points since 2016. However, impressive numbers are also seen much further down in the rankings, specifically in tenth place, where Romania records a whopping +69% with a surge in purchases during the last quarter that once again dislodged Russia from the top ten (by just one spot) after it had clawed its way back last September. Nevertheless, the Russian recovery still continues apace (+67%) with the value of Italian machinery exports nearly reaching 100 million euros. The trend in sales to Asia has not been particularly brilliant due to a slowdown in exports to the Middle East (especially Saudi Arabia and Iran), and only modest growth (less than +5%) in sales to the Far East, where the two major markets have slipped somewhat: China (-2.5%) and India (-6%).
“The order portfolio horizon for Italian manufacturers”, underscores with satisfaction Amaplast president, Alessandro Grassi, “has been considerably extended. Many companies are able to plan production at least to the end of the year, and there are quite a few that are actually having difficulty keeping up with customer requests”
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MARKETING
As regards the two major North American markets: • s ales to the United States record final growth of 20%, following peaks as high as +30% during the year; • s upplies to Mexico, on the other hand, have fallen by approximately 17%, which at least took some of the edge off the more than 20 point losses in previous months. No one expected the 2016 boom to last forever. The Trump administration’s threat to impose import duties on various product categories is not expected to affect plastics and rubber processing machinery, equipment and moulds. US production in this sector cannot meet demand from local manufacturers and the duties would only
TABLE 1 - ITALIAN MARKET OF MACHINERY, EQUIPMENT AND MOULDS FOR PLASTICS AND RUBBER (MILLION EUROS)
be counterproductive. In South America, the recovery in the flow of supplies to Brazil continues unabated, approaching +40% with respect to 2016 for overall
The Innovation Alliance is ready to kick off
Five trade shows for the entire supply chain The total area occupied by “The Innovation Alliance” trade show is almost 130,000 m2. Expectations are high for this new trade fair, which will take place from May 29 to June 1, 2018, at Fiera Milano, Italy. The event include, for the first time, five events linked by a common thread, i.e. the supply chain logic: Plast 2018, the reference event for the plastic and rubber industry; Ipack-Ima, the leading event for processing and packaging technologies; Meat-Tech, the event specialised in meat processing and packaging; Print4All, the new format dedicated to the commercial and industrial printing industry; Intralogistica Italia, the event that combines innovative solutions and integrated systems for industrial handling, warehouse management, material
storage, and picking operations. The Innovation Alliance focuses on an innovative cross-cutting supply chain, increasingly oriented towards new integration perspectives, even thanks to the growing popularity of Industry 4.0. At the same time, it showcases leading industrial segments, which make Italy the world’s second manufacturer of industrial machinery. The Innovation Alliance occupy 17 pavilions, essentially the entire area of the Fiera Milano exhibition district, representing the largest event ever dedicated to industrial machinery in Italy and one of the leading sector events in Europe. An insight into highly innovative markets, which together, in Italy, record a turnover of 24 billion euros and over 70,000 employees (the 2017 preliminary consolidated results are provided by the associations Acimga, Amaplast, Anima, Argi and Ucima) and, in most cases, they have an export level close to 70%, thus offering an example of the great appreciation that Italy’s industrial products have around the world. More than 3,500 exhibitors, from 65 countries, attend the show ready to welcome 150,000 expected visitors, including 1,000 top buyers, coming from 66 countries. Five exhibitions running simultaneously in 17 pavilions, covering almost 130,000 m2 at Fiera Milano
16 015_016_Amaplast.indd 16
2016
2017
∆ 2017/2016
Production
4,230
4,670
10%
Export
2,960
3,310
12%
Import
850
970
14%
Domestic market
2,120
2,330
10%
Trade balance
+2,110
+2,340
11%
value once again over 50 million euros. As regards goods categories, worth noting is the particularly positive trend in sales abroad of all the main types of machinery for primary processing and for moulds, which traditionally represent just under one third of Italian exports for the sector. The entire range of plastics and rubber processing lines, machinery, and auxiliary equipment are exhibited by hundreds of Italian and foreign companies - naturally along with raw materials, semi-finished products, finished products, and other articles - at Plast 2018, taking place in Milan from May 29 to June 1. And it is precisely the figures regarding foreign participation - at the moment registering a growth exceeding 20% over the previous edition - that confirm the renewed interest in the Italian plastics and rubber processing industry, and also operators’ interest in the Italian three yearly show, which thus reaffirms its international stature. “Participants at Plast 2018”, said Amaplast’s president, Alessandro Grassi, “are particularly confident that they will be able to do significant amounts of business and expand their order books directly at the fair. Several thousand operators have already pre-registered for their visit and our office worked to organize delegations of buyers from some thirty countries”. www.amaplast.org
TABLE 2 - DESTINATION AREAS OF THE ITALIAN PLASTICS AND RUBBER MACHINERY, EQUIPMENT AND MOULDS EXPORT (%) 2016
2017
Europe (UE)
58.7 (49.5)
60.7 (51.7)
Asia/Oceania
16.7
15.1
North America/ NAFTA
14.4
13.7
Central/South America
5.5
5.6
Africa
4.7
4.9
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® S.r.l.
R I D U T T O R I D I V E L O C I TÀ RIDUTTORI PER ESTRUSORI MESCOLATORI CALANDRE PER GOMMA EXTRUDER DRIVES RUBBER MIXING DRIVES CALENDER DRIVES
20168 T S PLA9/5 – 01/0 41 2 3B1 1 d stan
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MARKETING
AMAPLAST MEMBERS AT PLAST 2018 (Italian Machinery Manufacturers)
ADLER AMUT AMUTEC BANDERA BARUFFALDI BAUSANO & FIGLI BD PLAST BFM BG PLAST BIESSE BINOVA BMB BORGHI B-TEC CACCIA CAMPETELLA CANTONI CARLASSARA CATTORINI CIBRA NOVA CMG SPA CMG SRL CMS COFIT COLINES COMAC COMERIO ERCOLE COMERIO RODOLFO COMI COSTARELLI CRIZAF DEGA DELIA
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HALL STAND 22 A 21 13 B/C 111/112 15 C 61 15 A/B 121/122 13 B 101 13 B/C 41/42 15 B 61 15 A 131 13 C 162 13 A/B 101/102 15 B/C 41/42 22 A/B 101/102 13 D 52 13 C 136 22 C 112 22 A/B 41/42 22 D 111 13 B 162 15 B 141 15 B 35 22 B 11 15 A/B 31/32 13 C/D 121/122 15 D 71 15 A/B 01/02 13 B 72 11 A 61 11 B 41 13 A/B 121/122 15 C 41 24 D 112 24 D 32 11 C 35
DOTECO ELBA ELECTRONIC SYSTEMS ENGIN PLAST ERGOMEC ERHARDT + LEIMER EUROCHILLER EUROTECH EUROVITI EXACT FB BALZANELLI FILTEC FOLCIERI FRIGEL FRIGOSYSTEM FRIUL FILIERE GAMMA MECCANICA GAVO MECCANICA GEAF GEFIT GEFRAN GIMATIC GREEN BOX HELIOS QUARTZ HF MIXING GROUP ICMA SAN GIORGIO IMG INDUSTRIAL FRIGO IPM ITIB MACHINERY
HALL STAND 15 C/D 91/92 15 C 121 15 B/C 111/112 15 C 45 13 A/B 141/142 15 B 31 15 B 22 22 C 62 15 A 161 15 A 141 15 A 111 13 D 82 15 A 21 15 B 72 24 D 92 15 B 82 13 C/D 11/12 15 B 21 15 B/C 71/72 13 A 112 24 B 101 24 C 22 24 C 122 24 B 82 13 B 62 13 C 169 11 B 71 13 C/D 71/72 11 A/B 41/42 24 C/D 41/42 24 D 12 13 D 62 13 C 142
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AMAPLAST MEMBERS AT PLAST 2018
LASERPIN LTL LUNARDON MACCHI MAGIC MP MAICOPRESSE MAKLAUS MARIS MAST MATEX VARESE MECATECNO MECCANOPLASTICA MOBERT MORETTO MOSS NEGRI BOSSI OLMAS OMG OMIPA OMMP-MOULDS OMS OMSO PERSICO GROUP PIOVAN PLAS MEC PLASTIBLOW PLASTIC SYSTEMS POLIVINIL ROTOMACHINERY PRESMA PREVIERO PROFILE DIES PROMIXON RAIMA
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HALL STAND 15 B 142 24 A 32 13 C 62 15 B/C 81/82 22 A/B 31/32 24 C/D 21/22 15 C/D 111/112 13 C/D 21/22 13 B 66 13 A 162 15 D 72 22 B 71 15 C/D 101/102 22 A/B 81/82 22 B 52 24 C/D 121/122 13 C 101 13 B 82 13 C 61 22 B 76 24 C 101 22 A 51 22 A 71 24 B/C 71/72 13 C/D 41/42 22 A/B 01/02 24 C 32 22 B 61 22 B 81 15 A 51 13 B 61 13 C/D 151/152 22 C 82
REG-MAC RIPRESS RIVI MAGNETICS ROBOLINE ROMPLAST SALDOFLEX SARA SCAE EUROPE SGS ITALIA SICA SIMA SIMPLAS SMC ITALIA SPM ST SOFFIAGGIO TECNICA STAR AUTOMATION SYNCRO T2 TECNODINAMICA TECNOMAGNETE TECNOMATIC TECNOVA TECOM TEKNOMAST TERMOSTAMPI THERMOPLAY TOSH TRIA ULTRA SYSTEM UNILOY MILACRON UNION ZAMBELLO
HALL STAND 15 C 55 24 B/C 01/02 11 B 66 24 B 61 24 C/D 141/142 13 B 52 15 A/B 41/42 13 C 88 15 C/D 171/172 15 C 81 13 C/D 111/112 13 C 51 15 C 21 11 C 112 11 A 91 22 B 122 24 C/D 81/82 15 A 81 13 B 21 11 C 122 24 A 122 13 D 102 15 B/C 41/42 15 A 61 13 B 161 13 C 72 24 D 102 22 B 91 22 A 61 22 B101 22 C/D 141/142 13 B 01 13 B 92
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FRIGOSYSTEM S.r.l. rl Via J.F. Kennedy, 240 21042 Caronno Pertusella - (Varese) Italy Tel. +39 02 9658610 - Fax +39 02 9650723 info@frigosystem.it - www.frigosystem.it 020_FrigosYstem_ADV.indd 20
Efficient Solutions for Heating & Cooling 24/05/18 21:05
PLAST 2018 Amcor
MARKETING
NEW PRODUCTION CAPACITIES FOR POLYMERS WILL AFFECT THE GLOBAL MARKETPLACE
THE “GAME OF TONS” WHAT ARE THE STRATEGIES OF CHINA, AGAINST WHOM WILL THE UNITED STATES COMPETE AND WHAT WILL THE FUTURE BRING TO US? THE CONSULTING FIRM CHEMORBIS INFORMS THAT THERE ARE INVESTMENTS AND NEW PRODUCTION CAPACITIES – ESPECIALLY IN REGIONS WITH ACCESS TO RAW MATERIALS AT AFFORDABLE PRICES – THAT WILL SOON HAVE A GROWING IMPACT ON GLOBAL MARKETS BY EZIO FILIPPI*
T
here are a number of investments and new capacities that will incrementally affect the global marketplace over the next few years. All regions with advantaged feedstocks, like the Middle East, Iran, Russia-CIS, China (both with CTO/MTO, and with imported feedstock) have ambitious expansion plans and keep pushing to complete planned and ongoing projects. While we already got used to “waves” of capacities from traditional supply regions of the Middle East and Iran, the one with serious disruption potential to watch right now is North America (see figure 1). North America is expected to add nearly 9 million tons of PE in the following years and increase exports by another approximately 5 million tons. On the other hand, apart from the strong position of Middle Eastern producers in China, Iran has been a key supplier for many PE grades to China for a long time. Besides, on top of the existing PE capacities well exceeding 3 million tons a year, Iran has embarked on expanding new capacities alongside the 2600 km long West Ethylene pipeline. One after the other, new plants and capacities in MACPLAS INTERNATIONAL AT PLAST 2018
021_022_ChemOrbis.indd 21
the range of 3-4 million tons are expected to flood the markets over the next 5 years. Well, China, importing slightly less than 50% of PE and traditionally being the battle-field for high volumes of cargoes, has already started seeing extreme covert operations with the aim of re-shaping the market structure. It is well
accepted that the task of increasing market share in China will be the most challenging one among all available markets. All suppliers will need to be prepared for serious margin losses as all low-cost-producers will fight to preserve their existing shares and/or create new shares of pie. Spring 2017 has brought
Fig. 1 - Unlike the past, in terms of production capacities for polymers, the only one with serious disruption potential to watch right now is North America
US USPE PE Capacity Capacity Addition Addition (KT)
30000 30000 20000 20000
USPE PEExport Export2020 2020est. est.(KT) (KT) US
10000 10000
00
US-PE (KT) (KT) US-PE 2015 2015
2020 2020
9000 9000 8000 8000 7000 7000 6000 6000
2,5times times 2,5 increase increase
5000 5000 4000 4000 3000 3000 2000 2000 1000 1000
0
0 2016 2016 Lat-Am China Asia (ex. China) Europe Lat-Am China Asia (ex. China) Europe
2020 2020 Africa Africa
Others Others
Source:: ACC, ChemOrbis Production News, ChemOrbis StatsWizard Source:: ACC, ChemOrbis Production News, ChemOrbis StatsWizard
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MARKETING
some interesting developments about Iranian cargos being imported to China (figure 2).
CONSEQUENCES OF SECURITY AND POLITICAL PROBLEMS - THE IRAN CASE According to ChemOrbis StatsWizard tool, China’s PE imports have hit a record high for first half (1H) of 2017 since the beginning of this millennium. As the PE market has been growing year over year, Iran sustained its share in this growth too until the end of 2016. And then, in 2017, when overall PE imports in China are estimated to post a record of 17.5% growth year over year, Chinese importers and sellers of Iranian PE started seeing increasing rejections from the banks to open L/Cs (credit letters) for any Iranian originated cargoes. Volumes measured in hundreds of thousands of tons and in millions on annual level suddenly needed to be paid on cash terms for any transaction to take place. Of course, the havoc on Iranian and Chinese traders’ side was followed by the rush to find solution but many deliveries were caught in between. Accordingly, Iran’s growth share in the rapidly growing Chinese market
6 000 000
21,23%
5 000 000
4 000 000
3 000 000
2 000 000
1 000 000
0 2013
Source:: ChemOrbis StatsWizard
16 000 14 000 12 000 10 000 8 000 6 000 4 000 2 000 0 1
Source : ChemOrbis StatsWizard
22 021_022_ChemOrbis.indd 22
2
Fig. 4 Turkeymonthly HDPE imports in 2017 (tons)
16 000 14 000 12 000 10 000
fell to 4% on 8 000 an annualized 6 000 basis. Chem4 000 Orbis analyzed 2 000 the impact of these devel0 1 2 opments on China’s import market in the related months (figure 3). Often being the biggest supplier of HDPE to China and at least the number one in the early months of 2017 (preceding the issues that erupted in April), Iran suddenly fell to the third position in May and afterwards. It lagged behind Saudi Arabia and the United Arab Emirates. It was only in September 2017 that Iranian volumes took over United Arab Emirates to stand at the second poFig. 2 - China HDPE imports (tons) and Iran’s share in 2017 sition after Saudi (market growth: +17,5%; Iran’s share: -4%) Arabian HDPE. So, as it often hap25,00% pens, Iranian pro23,74% 22,42% 22,20% ducers and traders 20,00% 19,44% were very quick to look for alternative 15,00% routes and naturally shifted their 10,00% attention to one of the “joker” mar5,00% kets, its neighbour Turkey, another tra0,00% ditional trade part2014 2015 2016 2017 (7 Months) ner (figure 4). Total Iran Iran % In the same months when crisis with Fig. 3 - China monthly HDPE imports in 2017 (tons) China took its effect, Iran succeeded in increasing its share in the Turkish PE market, with the HDPE example in figure 5 (circled in red) showing its jump to the number 1 position, taking over Saudi Arabia. Here, this case shows a few 3 4 5 6 7 important lessons Saudi Arabia Iran Uzbekistan to remember for the future:
3
4
Saudi Arabia
Iran
5
6
7
Uzbekistan
Source : ChemOrbis StatsWizard
1. China is the biggest investor in Iran in many sectors, with the petrochemicals industry being one of the majors. Only one holding petrochemical investments company in Iran, as per their reports and presentations at ChemOrbis conferences, secured financial support exceeding 7 billion dollars for completing 11 petrochemical projects in Iran, many of which are underway. Well, can China afford to invest in countries from where they will not be able to bring products to its own market? ChemOrbis’ analysts don’t think that anyone can buy into that idea. 2. China comprises multi-million tons of PE import business. No overseas supplier can expect to develop an alternative market to China, at least not soon and not on this planet. Alternatives are there but when you sum up major potential alternatives taking part in global PE trade, including forthcoming South East Asia (Indonesia and Vietnam), Africa, Turkey, Latin America, you hardly come up for an alternative to China’s import volumes. Therefore, all suppliers are keen to maintain and increase their share in China. However, there will be time and we will increasingly witness it as uncontracted, idle volumes will “look for” new customers in the years to come. But for how long? Well, this world will need more investments even before this new wave is over. This is because another 4-5 million tons of PE are needed every year to cover the volume generated by the global demand growth. So, sooner than we can even think of, we will talk about the needs for new capacities. www.chemorbis.com *Chief representative of ChemOrbis in Italy MACPLAS INTERNATIONAL AT PLAST 2018
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MARKETING
NEWS Plastics industry in Algeria and Nigeria
Good news from Africa ...and the sky is always bluer...
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Organised by Fairtrade and Messe Düsseldorf, Plast Alger 2018 took place from March 11 to 13 in Algiers. It closed on a positive note: the show covered an area of 3,274 square meters net (vs. 2,566 in 2016), the exhibitors raised to 210 (166 in 2016) and visitors increased up 15% to 5,003 (4,250 for last edition). The accelerating industrialization process, including massive investments in the automotive industry in Algeria, and the Maghreb area, were ingredients for great optimism and exhibitor survey showed high satisfaction rates; in fact, 91% intend to participate in next Plast Alger too. Algeria’s import of plastics technology sharply rising; as a matter of fact is the second largest importer of plastics technology on the African continent, right after South Africa; but while South Africa’s import have stagnated, between 132 and 153 million euros in the past five years, Algerian import has grown by 75% over the same period. The plastics processing industry is made up of around 2,200 companies, including branches of large companies based in Algeria. About 40% are active in the injection sector, 20% in extrusion and 40% in packaging. The economic policy of the Government of Algiers aims to reduce the imports of finished products and to stimulate homemade production, which means that the processing industry will increase investments in the sector. Plastics and rubber machinery industry confirms significant double-digit growth for the Maghreb countries, as well as West African countries such as Nigeria. From March 27 to 29, Plast, Print and Pack Nigeria, organized by Fairtrade, took place at the Landmark Centre in Lagos. The area covered was 1,300 square meters net, the exhibitors 142 and visitors
A discussion between customer and supplier at PPP Nigeria
were 1,700. Nigerian plastics, printing and packaging sector enjoys staggering growth 40% expansion 2013-2017. Estimated CAGR 7% for 20182027 (source: McKinsey). It has grown rapidly in recent decades, from around 50 companies in the 1960s to more than 3,000 manufacturers currently, according to the National Agency for Food and Drug Administration and Control. Processors are mostly SMEs; 15% have sufficient financial resources to invest in high quality technology. Packaging (food) is undoubtedly one of the most developed sectors of the country, just as the closure of Chinese borders to the import of plastic waste has given a very strong boost to the local recycling industry. The increase in investment is not surprising, given the surge in demand for plastics in Nigeria, particularly from packaging and recycling firms. Besides a protectionist policy is in place to protect local producers of plastic articles and semi-finished products, to the detriment of imports from abroad of the same products. In 2017, Italian machinery export to Nigeria reached almost 9 million euros, nearly triple compared to 3 million in 2016. This is the highest peak of the last decade, with the sole exclusion of 2013, when 14 million were touched. www.macplas.it
MACPLAS INTERNATIONAL AT PLAST 2018 07/05/18 16:30
24/05/18 21:08
Clariant AddWorks
Economic forecasts
Masterbatch market to hit 14 billion dollars by 2024 According to a new research report by Global Market Insights, masterbatch market is expected to surpass 14 billion US dollars by 2024. This market is likely to grow at a CAGR of over 5.4% in the forecast timeframe; rising usage of plastic alternative to metal in automotive will accelerate growth. Government investment plan and stable policy framework for automobile manufacturers in Asia Pacific will significantly impact market growth by 2024, together with growing per capita income in the region. Growing percentage of agricultural land due to increasing population will enhance the demand for agricultural films. This film is manufactured by polymers which comprises bio-based masterbatch that helps to degrade polymers. Rising trend for eco-friendly products among the industrial players and consumers is driving bio-based masterbatch market, further excel-
lent moisture shielding and protecting properties had increased crop productivity which is significantly driving the market. Market growth is challenged by rise in prices of masterbatch products influenced by changing market dynamics such as heavy demand from end-user industries and growing price of raw material. The demand for masterbatch product will be negatively impacted by these factors in the forecast period. Moreover, implementation of stringent regulation by several government across the globe for guiding application of certain pigments in food packaging and holding material will decelerate market demand in coming years. Black masterbatch product is significantly growing with a CAGR of around 5.7%, owing to increasing application in automotive industry. It is highly consumed product in various end-user industries. Second largest segment is colour
masterbatch, which have widespread application in various consumer goods and packaging products. Shift in consumer preference toward packaged food product is augmenting market demand for polymers, which is favouring the market. Automotive industry holds highest market share in terms of revenue with 6.3 billion dollars in 2016, the industry is witnessing high growth in Asia Pacific and Europe. China is majorly dominating the market owing to government automotive mid and long-term development plan. In addition, government is highly investing to develop electric vehicle which will drive polymers market in coming years. Agriculture is estimated to grow with CAGR of around 6.0%; the market growth is significantly driven by growing percentage of cultivation land and rapidly increasing population. Followed by agriculture, consumer good segment will
The masterbatch market is highly fragmented, comprising numerous local and global manufacturers, suppliers and distributors operating worldwide
witness substantial growth in coming years with increasing application of polymer in home appliance products. Asia Pacific, primarily China, is expected to grow at a significant rate during forecast timeframe. Automotive, consumer goods and packaging are growing industries of Asia Pacific. The region is witnessing high investment in construction and automotive industry, which will gain significant demand for plastic favouring masterbatch market. Europe is second highest country in terms of market share with CAGR of around 5.6%; high automobile production and improving market condition post rescission is likely to grow the market. www.gminsights.com
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25 24/05/18 21:08
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24/05/18 21:08
PLASTICS AND ENVIRONMENT
Finecki/Fotolia/PlasticsEurope
DRAFT RECOMMENDATION FROM WORKING GROUP 11 “PLASTICS RECYCLING”
DESIGNING FOR RE-USE AND RECYCLING T
he linear model of economic growth followed in the past needs to evolve in order to meet the more rational and efficient needs of society in today’s globalized world. In the future it is will be necessary to abandon the linear “throw-away” model, as many resources are not infinite and it is essential that they are used in a sustainable manner, both for the economic and environmental good. The transition towards a “circular economy” is vital, as it means that the value of the manufactured goods and raw materials can be maintained for longer. Which translates into more effective use of resources. Waste levels have already been reduced and production technology is continually being improved for the purpose of “reuse” and “recycling”. The true driving factor behind this process (see figure 1) was the publication of Directive 94/62/EC on packaging and packaging waste. This aim of the directive was the free circulation of products within the European Community in order to create a single market and introduced the principle of “shared responsibility” of all those involved in the actual life cycle of a product. It also envisaged specific packaging waste recovery and recycling objectives, which had to be reached by 30th June 2001. The aims laid down for this first five-year period were in fact as follows: • at least 50% - and not more than 65% - of the weight of the packaging waste from member states must be recovered; this quantity being deducted from the normal flow of waste sent for disposal; • a minimum of 25% and a maximum of 45% of the weight of all the packaging materials must be recycled; MACPLAS INTERNATIONAL AT PLAST 2018
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THE SUSTAINABLE DEVELOPMENT OF THE EU ECONOMY IS CLOSELY LINKED TO THE AVAILABLE RESOURCES. IN THE FUTURE IT IS NECESSARY TO IMPROVE THE COMMITMENT IN A DIVERSIFIED, AND ABOVE ALL, A MORE SUSTAINABLE MANNER BY ORESTE PASQUARELLI
• the recycled quantity must not be less than 15% for each packaging material. Directive 94/62/EC was subsequently updated and the following versions issued: Directive 2004/12/EC (adopted by member states on 18th August 2005); Directive 2013/2/EU (modification of annexes, adopted by member states on 30th September 2013). For plastics, Directive 2004/12/EC set out the target of recycling
22.5% of packaging waste weight by 2008. At the present time Europe does not recover, and therefore dumps into the environment, approximately 600 million tons a year of waste that could potentially be recycled or reused. It is estimated that only 40% of the waste generated by EU families is actually recycled. Therefore, with a view to greater efficiency in resource management, it is essential to con-
Fig. 1 - The European Commission’s legislative package for circular economy
Waste Framework Directive
Packaging and Packaging Waste Directive
Landfill Directive
Legislative procedure is ongoing
ELV WEEE
(End of Life Vehicles)
BATTERIES
Legislative Source: Bosmans, European Commission, November 2016
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PLASTICS AND ENVIRONMENT
sider the waste as secondary raw material. This possibility is an essential aspect in the creation of a more circular economy. So that the new common objectives outlined by the European Union for future years are as follows: the recycling of 65% of urban waste by 2030; the recycling of 75% of packaging waste by 2030; reduction to maximum 10% of the waste actually sent to landfills, again, by 2030.
THE ROLE OF CEN CEN (Comité Européen de Normalisation) has been created in order to draw up the standards to be adopted and shared by all the member countries. At present over 30 countries, both European and non-European, form part of this committee. Each country that wishes to participate in the unification operations, must be represented by its official standardization body. Italy for example is represented by UNI, Italy’s national standardization agency. The member countries have a different “weight” in the document ratification process, which is proportionate to the number of its inhabitants. For example, Italy, France, the United Kingdom, Germany and Turkey have a “weight” equivalent to 29, while the “weight” of Iceland and Malta, that are at the bottom of the table, is equivalent to 3. The standards drawn up must be accepted by at least “50%” of the members and the “weight” must be over 70%. The approved texts are not mandatory regulations, but provide a valid contribution to the standardization of the production processes and products in the individual countries, in order to facilitate the exchange of
technical know-how and best practice. A series of CEN standards have been officially adopted in the packaging waste recovery sector in conformity with Directive 94/62/EC and therefore in this case, these standards have been integrated into the laws of the member states. On 19th February 2005 a EU Commission notice in relation to the European Parliament and Council Directive 94/62/EC on packaging and packaging waste was published in the GUCE (Official European Community Gazette), which included the following titles and harmonized standard references in accordance with the packaging directive: • EN 13427 - Requirements for the use of European standards in the field of packaging and packaging waste; • EN 13428 – Requirements specific to manufacturing and composition - Prevention by source reduction; • EN 13429 - Reuse. Packaging used several times for materials transportation/storage; • EN 13430 - Requirements for packaging recoverable by material recycling (by which is meant mechanical recycling to produce new reuseable material); • EN 13431 - Requirements for packaging recoverable in the form of energy recovery, including specification of minimum inferior calorific value; the level having been decided as being of 5 MJ/kg; allowing for the combustion of packaging waste, without the addition of any other combustive substances; • EN 13432- Requirements for packaging recoverable through composting and biodegra-
Fig. 2 - Life cycle consideration with plastics Life cycle of products that contain inter alia plastics:
Converters, , s tr y e r u s tu r il nd ufac ic a an e m ics m h C a st pl
Plastics production
Mechanical Recycling
Raw material feedstock CO2
Chemical Recycling
Energy Recovery
Landfilling, illegal dumping, littering
Use phase Automotive light weight
Source: PlasticsEurope
027_028_Pasquarelli.indd 28
OEMs: packaging, B&C, Auto Product etc. manufacturing
Reuse, Repair
Post-use phase
28
Further p of halfsw rocessing suppliers are, , tiers
Energy
Renewable feedstock Fossil feedstock
processors
Efficient pack’g
Insulation for B&C
dation - Test scheme and evaluation criteria for the final acceptance of packaging. In April 2016 a meeting was organized between the UE Commission, DG Environment, and the CEN TC 261 Packaging committee, in order to evaluate the updating of the following aspects in relation to the evolution of environmental issues and circular economy: • Directive 2015/720 for the revision of Directive 94/62 concerning the measures to be adopted to reduce plastic carrier bag consumption; • Activating a collaboration between the EU commission, European Parliament and the Regional Committees, in order to devise a mutually agreed plan for the development of the circular economy; • Drawing an EU directive for the updating of Directive 94/62/EC on packaging waste. The issue of plastic material recycling was tackled by a specific working group (WG 11 “Plastics recycling”) within the CEN 241 “Plastics” committee. This working group published an interesting document in March 2017, outlining a series of measures and initiatives in order to improve recovery and recycling operations, and thereby accelerate the passage from the linear to a circular economy. The suggestions made by WG 11 are as follows: evaluation of a closed loop process for the recycling of post-consumer PVC doors and windows; expansion of the field of competence of the WG, from “Plastics Recycling” to “Plastics & Environmental Aspects”; suggestions to TC 249 to develop initiatives and collaboration in order to draw up a strategy for plastic materials in the development of the circular economy. With the aim of providing detailed insight into the potential for the creation of a circular economy in the plastics sector, a report by Ingo Sartorius (PlasticsEurope) was also annexed, which for each of the various stages, listed below, of the plastics life cycle (from non-renewable fossil sources or from renewable sources), also indicates the potential for the improvement in the actual production cycle (see figure 2): 1. P lastics production – Specific chemical industry 2. Production of manufactured and semifinished goods – Specialized conversion industries 3. Final use of plastics - Sectors: light packaging, automotive (weight reduction), building (thermal insulation), agriculture 4. P ost-consumer – Reuse, mechanical recycling, chemical recycling, energy recovery. To be reduced: landfills. These initiatives are common knowledge nowadays, but they need to be further improved and increased, as they constitute the only means of switching from a “linear” to a “circular” economy. www.macplas.it MACPLAS INTERNATIONAL AT PLAST 2018
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PLASTICS AND ENVIRONMENT
NEWS “Bio-based Material of the Year 2018”
Innovation award goes to Arctic Biomaterials The Innovation Award “Biobased Material of the Year 2018” was awarded to three innovative bio-based materials. The competition focused on new developments in the bio-based economy, which have a market launch in 2018. The winners (see pictures) were elected on May 15 by the participants of the “International Conference on Bio-based Materials” in Cologne (Germany), organised by nova-Institute. 205 participants, mainly from the industry and representing 22 countries, met in Cologne on May 15 and 16 to discuss the latest developments in the sector. 21 companies presented their products and services at the exhibition.
Number 2 - Cashew nutshell residual-based blocking agent NX-2026 is an ultra-high purity 3-pentadeca-dienyl-phenol recently developed by Cardolite
Nova / PvP
Number 1 - Degradable PLA reinforced with glass fibre ArcBiox BGF30-B1 is a Polylactic Acid (PLA) that is reinforced using LFT (long fibre) technology with a special degradable glass
fibres. This innovation makes it possible that bio-based plastics can be used in technically demanding durable applications and still have the option of biodegradation at the end of life. The reinforcement is a glass fibre developed by Arctic Biomaterials Oy (ABM, stand C165, hall 13, at Plast 2018, inside the stand of the Italian distributor 2Mila) and can also be used for several other bio-based polymers. This composite material reduces the carbon footprint and use of non-renewable energy of a composite product drastically compared to fossil-based reinforced plastics. This reinforced PLA is compostable and certified by the seedling mark from DIN Certco.
Award Ceremony “Bio-based Material of the Year 2018” (from left to right: Asta Partanen, nova-Institut; Michael Carus, nova-Institut; Pillar Villanueva, Aimplas; Tomi Kangas, Arctic Biomaterials; Koenraad Debouck, Cardolite Corporation, Gordana Hofmann-Jovic, Sponsor InfraServ Knapsack)
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Collage of winning products
through advanced proprietary process technology. 3-pentadeca-dienyl-phenol is the main component distilled from cashew nutshell liquid, a renewable and non-edible resin extracted from the honeycomb structure of the cashew nut. NX-2026 has been successfully introduced to the coating and adhesive market as a non-toxic isocyanate (NCO) blocking agent that is a suitable replacement for petrochemical phenols. NCO systems blocked with NX-2026 provide lower viscosity and deblocking temperature than equivalent systems blocked with phenols. Moreover, NX-2026 blocked NCO prepolymers can be used in 2K epoxy systems to improve bond and T-peel strengths while maintaining good cure properties. Number 3 - Bio-based and biodegradable nets for green beans A packaging material which is more than 80% bio-based and more sustainable than conventional polyethylene nets but has similar linear weight and mechanical properties. The innovative product developed by Aim-
plas Instituto Tecnológico del Plástico (Spain) is a biodegradable net suitable for green beans packaging. A compound has been developed through reactive extrusion and the combination of different biodegradable materials and additives. Chemical modification was made by grafting low molecular weight units, such as oleic alcohol, obtained by the fermentation of sugars extracted from vegetable waste (watermelon). Special award for the best bio-based concept The Warka Water project provides an alternative water source (The Warka Water Tower) for rural populations that faces challenges in accessing drinkable water. The bio-based tower is 11 m tall and weighs only 80 kg. The triangulated frame structure, made with bamboo, is optimized for lightness and strength and offers both stability and robustness. Inside the bamboo structure hangs plastic mesh that collects droplets of water from high humidity in the air (fog) and the collector for dew and rainwater. www.nova-institute.eu www.bio-based.eu
MACPLAS INTERNATIONAL AT PLAST 2018
24/05/18 21:11
Italy at the forefront of the European strategy on plastics waste
A new permanent forum for quality recycling The plastic materials processing sector has embraced the EU’s “Plastics Strategy” and embarked on a joint endeavour with leading institutional, environmental and supply chain figures in order to address the current problems in a structural manner, adopting a modern and constructive approach. To this end, on April 10, representatives of various Italian associations Federazione Gomma Plastica, Ippr, Conai, Corepla, Ispra, Enea and Legambiente - set up the Permanent Forum for Quality Recycling (Tavolo Permanente Riciclo di Qualità), with the aim of promoting better quality recycling. The EU’s “Plastics Strategy” is counting largely on the end-of-life plastic recycling market to take on the task of extending the useful life of these materials through the circular economy, reducing the levels of oil and energy consumption deriving from the use of virgin material, limiting carbon dioxide emissions, and reducing the quantity of plastic present in the environment, or disposed of in landfills. Italy already makes considerable use of recycled plastic, thanks to the research and innovation work that this processing industry has been carrying out for several years now. 2017, compared with 2015, saw a general increase in the use of recycled polymers: +10% for PET (mainly used to produce food containers); +5.5% for PE (bags, tubes and pipes, packaging); +3.5% for PP, and, remarkably, +75% for PS, used mainly in the construction industry for thermal insulation. The recycling industry has already evolved sufficiently, in a cultural sense, to rise to the challenges of the “Plastics Strategy”, but this will
nevertheless demand common coordinated action on several crucially important fronts: - improving the quality of the polymers deriving from recycling, so that these can be used more extensively in place of virgin materials. In parallel, it will be necessary to increase the value of the material and try to contain the supply chain costs, so that these materials can compete with virgin materials, also taking into account the drop in the average prices prompted by the embargo on Chinese imports and those from intermediary destination countries (such as, The Netherlands, Slovenia, the Czech Republic); - broadening the range and boosting the use of recycled polymers, and supporting, in both the private and public sectors, the development of a circular economy mentality that recognises the environmental value of recycled materials; - conceiving and designing plastic products in such a way as to lengthen their life and simplify their end-of-life recycling, reducing the use of composite and mixed materials in favour of single polymer materials; - raising awareness, among citizens, consumers and industry, of the importance of managing plastic waste correctly, of not dumping it in the environment, and of separating waste correctly in the home and at work, providing separate waste collection bins for this purpose. The Permanent Forum, promoted by Federazione Gomma Plastica, aims to define the correct strategies and actions to be adopted in order to address these challenges. This initiative is innovative not only in its underlying principle, that of constructive feedback, but also
MACPLAS INTERNATIONAL AT PLAST 2018
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The signatories of the agreement to set up the “Permanent Forum for Quality Recycling” (clockwise, from top left): Giorgio Quagliuolo, president of Federazione Gomma Plastica and Conai; Antonello Ciotti, president of Corepla; Angelo Bonsignori, president of Ippr; Roberto Morabito, department director at Enea; Stefano Laporta, president of Ispra; Stefano Ciafani, president of Legambiente
in its approach: the key issues on which the forum’s activity will be focused will be decided by its own members, and short and medium-term objectives will be set for each one. Once a year, the results of the forum’s activity will be presented at an open meeting, reviewed and then implemented. www.federazionegommaplastica.it
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NEWS Renewable raw materials
Packaging with a visible sustainable message At the Cosmetic Business 2018 (Munich, June 6-7), the bioplastics specialist FKuR Kunststoff will be presenting its portfolio of biobased and biodegradable plastics for the production of bottles, tubes and jars as well as for films and blisters. In addition, the company will be explaining how a holistically sustainable concept can be implemented with bioplastics. According to Patrick Zimmermann, director Marketing & Sales at FKuR: “Due to an increased environmental awareness, consumers are now gathering more detailed information on the ingredients and the packaging of a product. Aspects such as sustainability, waste reduction and recyclability influence purchasing decisions. Companies, in turn, anchor sustainability in their strategy and development of products that contain renewable or organically grown raw materials. They also want to use suitable packaging”. Cosmetic manufacturers can substantiate their holistic concept with a packaging made of bioplastics and communicate it clearly to the consumer. Dependent upon factors such as design, disposal route and recyclability, the appropriate biobased and / or biodegradable plastic is selected. Third party institutions test and measure the biobased content of the packaging, which is shown by authorized seals on the packaging. Cosmetic manufacturers benefit from the clear labeling because it visibly distinguishes their packaging from the competition and consumers can easily identify the products. Company’s portfolio offers alternative biobased and bioplastic solutions for packaging. These solutions include plastics from renewable raw materials that are either recyclable or biodegradable. Plastics derived from renewable raw materials include Braskem’s biobased polyethylene (PE) “I’m green”, Fenc’s BioPET Eastlon and the partially biobased polypropylene compound Terralene PP. These bioplastics do not differ in their technical performance nor processing in comparison to petroleum-based plastics and are versatile in use, e.g. for film extrusion with subsequent thermoforming applications or for the production of injection molded articles, even with complex shapes. Bio-Flex and Biograde are biodegradable plastics made from renewable raw materials that can be processed on standard production lines. The natural basis of Bio-Flex is e.g. corn, sugar cane or castor oil. Biograde is manufactured on the basis of cellulose. Packaging made from Bio-Flex and Biograde stand out due to their valuable haptics and offer an innovative and complete packaging concept for cosmetic brands. www.fkur.com Packaging for cosmetics products made from renewable resources by FKuR
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Bags made of Mater-Bi
The answer for clean and efficient biowaste recycling An efficient, hygienic and clean organic waste collection is actually possible by using bags made of Mater-Bi, Novamont’s biodegradable and compostable bioplastic. The bags are perfectly suited for any organic waste collection and processing system currently in use in Europe. This is shown by several European municipalities and Novamont presented these case studies at Ifat, the German trade fair for water, sewage, waste and raw materials management, held in Munich from May 14 to 18, 2018. Under the Mater-Bi brand, Novamont manufactures and sells a wide range of bioplastics that are biodegradable and compostable in accordance with the European EN 13432 standard, obtained from starches, cellulose, vegetable oils and their combinations through the use of proprietary technologies. They help in diverting organic waste from landfills and create quality compost, a major ally in fighting desertification and soil erosion. Europe produces 96 million tons of organic waste, only 30% of which is properly recycled, while 66 million tons are still sent to disposal, at considerable environmental, economic and social costs. In fact, organic waste in landfills can become extremely dangerous, since it produces methane gas and leachate potentially polluting the groundwater and negatively affecting human health and the climate. The recently revised EU Waste Framework Directive, is mandating the recycling of organ-
ic waste in all Member States by the end of 2024. Moreover, it is prescribing that from 2027 only organic waste separated at source will actually be accountable for the recycling targets, and by 2035 a maximum allowance of 10% organic waste sent to landfill will be set. In the next years it will therefore be essential to set up efficient and successful collection models, such as the one Novamont is presenting at Ifat. Among European cities having adopted organic waste collection with Mater-Bi compostable bags there are Milan, Parma, Treviso (Italy), Copenhagen, Roskilde (Denmark), Geneva (Switzerland), Kristiansand (Norway), Barcelona (Spain), Paris, Grenoble (France), Cardiff, Manchester (UK) and several London districts, with a total of around 5,350,000 inhabitants involved and around 312,000 tons of wet waste collected. www.novamont.com
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The Mater-Bi bags are perfectly suited for any organic waste collection and processing system currently in use in Europe
We STARCH your plastics. Made in Austria.
AMITROPLAST ® THERMOPLASTIC STARCH BIOBASED. COMPOSTABLE. SUSTAINABLE. PERFORMING. COST COMPETITIVE. FOR YOU. AMITROPLAST® allows you to incorporate 50 % or more of thermoplastic starch in your compound for film extrusion and injection moulding. AGRANA.COM
bioplastics.starch@agrana.com
THE NATURAL UPGRADE
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THE ETD CONFERENCE 2018 IN ROME
INDUSTRY 4.0 REVOLUTION IN THE THERMOFORMING WORLD AMONGST HIGHLIGHTS OF THE EUROPEAN THERMOFORMING CONFERENCE - SPE’S ANNUAL EVENT HELD FOR THE FIRST TIME IN ROME - INDUSTRY 4.0 AND SUSTAINABILITY PLAYED THE “LION’S SHARE”. A LOT OF NEW TECHNOLOGIES WERE PRESENTED AND, ON THE LAST DAY OF THE CONFERENCE, THE WINNERS OF THE COMPETITION FOR BEST THERMOFORMED PARTS WERE ANNOUNCED
T
he European Thermoforming Division of SPE (Society of Plastics Engineers) held their eleventh bi-annual conference on March 14-16 at the Marriott Park Hotel in Rome. This was the third time that the conference has been held in Italy, after Venice and Viareggio a few years ago. The eleventh European Conference was noted for a number of reasons, firstly as there were around 250 attendees who came from all over Europe, the United States, Middle East, China and India. Secondly the support shown by the suppliers to the industry in sponsoring as well as showing their products in the exhibition hall, but most of all by the technical presentations that took place during the two-day conference. The conference was opened by the chairman Antonio Staffoni (OMV Polytype), who intro-
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duced the theme of this year - Thermoforming 4.0 - which was discussed and developed in the various presentations that followed.
INDUSTRY 4.0 IN THERMOFORMING TECHNOLOGY The first presentation was made by Ruggero Frezza (M31) and entitled “Industry 4.0, the revolution beyond efficiency”. Taking the moves from ants tactics to find food and also car navigation systems, Frezza explained how big data, block-chain protocols and internet can improve the world of industry. He talks about service: brought examples of “servitization”, i.e. machines paid “by the meter” as opposed to capital equipment expenditure. Projects carried out in bottle caps industry, where comparable machines “talk” to each oth-
er to solve problems and share their experience to set to the best recipe depending upon the raw material fed. Most interesting was his excursion into the “innovators dilemma”, that is the challenge of moving to the emerging technology at the right time. With Industry 4.0, “products generate data”. As a mind-blowing example, “The Plastic Bank” was mentioned: this start-up conceives plastic as a currency rather than waste, providing the incentive to collect and recycle - especially in poor neighbourhoods. Biodiversity of innovation: the R&D ecosystem exploded in the last years, thanks to internet. Innovation is no longer brought by universities and R&D centres alone. Today it is brought also by insurance companies, business accelerator, start-ups and so on Industry 4.0 improves effi-
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ciency on the one side (inwards look) but more importantly, it creates new business models (sharing data and API) if we look outwards. The theme of the second speaker - Jacob von Wolff (Kiefel Packaging) - was “Industry 4.0; work digital for smart Thermoforming solutions”. He gave an insight into his company view on how industry 4.0 ideas and concepts could be translated into tangible benefits and solutions for the packaging industry. Digital controlled thermoforming systems making production of packaging, easier, faster and smarter. The presentation from Willemijn Willemen (Avantium) focused on the opportunity of sustainable materials. EU policies target drastic 80% reduction of carbon footprint in the next 30 years. The question is: how do we get there? The speaker pointed out that building C-H-based monomers from bio-based resources is very inefficient as we would throw away O2, about half of the biomass weight. Her company’s research is therefore focused at developing new monomers that fit best the biomass source. She discussed the large cost barrier for bio-based plastic, arguing that this type of product could not be cost effective against current oil-based plastic for a period of time. However, the pressure from industrial leaders such as Lego, Ford etc. will ensure the investigation and solution will not be delayed due to lack of effort. This driving force will surely produce results in the not too distant future. The subsequent lecture was made by Fabian Schmitt (Street Scooter), a subsidiary company of Deutsche Post DHL Group. They develop, manufacture and sell electric vehicles for short journey use. Their current range include pedelecs and light electric utility vehicles. The presentation entitled “A Thermoforming Success Story” showed the advantages of using thermoformed plastic parts for vehicle body and the savings in weight which manifested into the saving of fuel and extending the length of time
Participants pay attention to one of the several lectures held during the three-day conference
the vehicle could continue before the batteries need recharging. Claudio Menini (Polytype) gave a presentation on digital printing: “A B2C concept for custom made decorated cups”. The case study, based on two actual projects carried out in the US and Taiwan, showed how digital printing allows the customer to order online its own custom-printed cup. A user-friendly system, capable of handling even very small batches on production. He discussed the issues with printing on to conical objects and the need to ensure correct images to compensate for the shape of the cup. The printing theme continued with a presentation of HP (Spain) on the benefits of 3D printing in thermoforming, which focused on the benefits of 3D printing moulds. This innovation is still not perfect but it is used for initial trials on moulds and also to give the final customer a finished thermoformed part to review before expensive tools are manufactured.
THIN GAUGE THERMOFORMED PARTS In the afternoon of March 15 the delegates split into two sections. One was reserved for
presentations on thin gauge thermoformed subjects, whereas the second was devoted to commercial presentations by eight heavy gauge plastic thermoforming suppliers. The theme in the thin gauge session were based on the status of recycling of plastic waste from the thermoformed products The first speaker was Paolo Glerean (Aliplast, Italy) and discussed the status of PET thermoform recycling in Europe. He explained that a group called Petcore Europe is compiling information in regard to this issue and they have accumulated information on the actual volumes involved, the possible solutions and the progress they are making to offering solutions to this waste. This is not an overnight solutions as it is obvious that it will take many years before the problem is overcome. Ton Emans (Plastics Recycling Europe) discussed some of the issues such as picking out black plastic trays and containers. They cannot be easily picked out by IR scanners, so the question is why still produce black plastic containers. It is known that these black containers would be expected to be a combination of recycled items. However until the identifying of the different colours this will cause major problems in the recycling chain. The speaker went on to explain how, in his experience, barrier-layered material cannot be separated in its virgin components. The final take-away from a recycler to converters was “we cannot recycle what is non-recyclable”. “Reduction in food waste by plastic packaging without wasting the plastic” was presented by Christina Busk (Danish Plastics Federation). She reported some interesting facts,
SPE European Thermoforming Division Board at the Rome conference
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A pleasant moment of the conference
such as that 1.3 billion ton of food are junked every year, according to the UN Food and Agricultural Organisation. She talked about the Forum for Circular Plastic Packaging which is focused on reducing and improving the use of plastic packaging. Another interesting fact was mentioned that close to 1% of the total environmental impact came from packing and 70% came from the production. It is quite obvious that plastic packaging ensures the product lasts longer and allows the customer to buy products over a period of time, not on the day it is put into the food chain. This benefit seems to be overlooked in the media today and all they see is the plastic waste, not the benefits of plastic packaging. This therefore needs effort to educate the public and this is one of the main aims of the Forum for Circular Plastic Packaging. Thomas Tang (Faerch) continued on the same theme that there is a need to educate the public to recognise that plastic packaging is a force for good and that the savings in food waste would be many times higher if plastic packaging was not used. Therefore there is a need for education but also to develop and use more sustainable plastic packaging. The ability to use it more that one time by recycling used packaging is vital and needs to be accelerated if we are to ensure the public understands the benefits of having plastic packaging on their products. While the thin-gauge presentations were being held, in another part of the Marriott Park Hotel a number of heavy-gauge sponsors gave ten-minute overviews of the companies and the latest developments in their companies. The first was CMS, who discussed the process and automation aspects of thermoforming and trimming of low stability material. They were followed by Frimo with economical and profitable production on high quality - trends MACPLAS INTERNATIONAL AT PLAST 2018
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for production solutions. Geiss then spoke about their range of single-station thermoforming machines and highlights of their servo motor driven T10. Paul Alongi (MAAC Machinery) then presented the rotary thermoforming machinery, highlighting the advantages gained by continuous production. Sekisui spoke about collaborative developments for lightweight thermoplastic solutions. Self then presented the advantages of aluminium casting moulds in product design and tool engineering for top surface quality components. The last presentation from Senoplast spoke about the partnership and services offered by the company on three continents.
THE THERMOFORMING FROM DIFFERENT PERSPECTIVES March 16 opened with “Thermoforming-art-science: material testing”, a presentation by Amit Dharia (Transmit Technology Group) in regard to the unique way thermoforming stretches and then forms the part; this can add stresses as well as strengths. Transmit Technology Group were stating that the material properties cannot be tested using normal methods. To model thermoforming, high speed stress strain data in extensional flow below the peak melt point are required. The sag test has been existing for many years. Several indirect rheological tests have been developed and used to predict thermoformability, but no one test is standard. The speaker then presented various experimental
The cover for this premature baby incubator was awarded for its perfect transparency and material distribution
results using a new analytical test method and showed that in their opinion this new method is the path to take in the future. A practical presentation was then made by Roncato (Italy), discussing the reason why thermoforming is used in the manufacture of suitcases. They compared the use of thermoforming versus injection moulding. They acknowledged that more and more thermoformed cases are appearing in the market as the technology responded well to the need to produce lightweight products. With some of the new materials on the market it is easier to form either in the normal way or by special thermoforming techniques for products such as Curv. Thierry D’Allard (Styl’monde) then spoke on the subject “How safe is your process? Perceptions versus reality”. He elaborated on the misconception that as long as orders are following and products are being made and sold, all in the company, is fine. He used an example of his own company, where one day there was a fire that destroyed machinery and factory building. How could they cope and how to satisfy their customer orders? His description of the actions they had to take and the methods they now have in place to ensure they never go through that major issue again was of interest to the whole audience. They initially survived by subcontracting work out to other companies to ensure they could meet their customer deadlines. Safety issues such as fire procedures were investigated and improved. Separation of parts of the factory to ensure not everything is damaged if it happens in same place again, and as they grew they set up factory units around France that could duplicate the work if ever needed in the future. Thomas Hoefels (Senco Europe) presented “Inline coating material-curing with temperature during the thermoforming process”. This subject deals with the manufacture of film applications in the automotive industry. Senco can now produce a thermoformable hard coat on their film that is applied during the extrusion process and will withstand damage and scratching and even has higher chemical resistance. This means during the thermoforming process the coating stays in place and after assemble of the final product it can be removed. Then Karen Brock Amoah and Dennis Kelso (Sekisui SPI) spoke about “Bonded build-ups: improving strength to weight ratios of thermoplastic components”. The use of these type of products in places such as aircraft seats in business and first class gives the producer the ability to not only make great designs, but ensures a lighter product that reflects in lighter load that reduces fuel consumption and therefore less
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emissions. Forming could be produced by various methods, bonding, twin sheet thermoforming, glass fibre reinforcement etc.
COMMERCIAL PRESENTATIONS BY THIN GAUGE THERMOFORMER SUPPLIERS The delegates then split into two groups, one of which continued to discuss heavy gauge type activities, while the other group went into a session of commercial presentations by thin gauge thermoformer suppliers. In the first group, the first presentation was by Fabian Kayatz (Fraunhofer 1VV Dresden), who spoke about production of material efficient mould parts using moulding air. His presentation specified the use of forming (FIT) blow air into sheet to push into mould. They can change the temperature and pressure depending on which areas are identified as possible problem areas. Material is then cooled while in the mould. Temperature and pressures are determined via computer modelling. This will help in having fewer rejects during the process as the process itself is more precise. Marco Lanulfi (Lanulfi) then spoke about inmould cutting and the testing program they had developed until they now have reached a mould with cutting ability that, although more expensive than a normal forming tool, can ensure both the forming and cutting can take place while the part is on the mould. Tests have been carried out on ABS, PMMA, PC, PE and the results show a 15 kg/mm is needed for cutting parts. The hotter that part the easier it is to cut. The test has even been carried out in a twin sheet application and, although there were some initial issues, they have been resolved and the twin sheet part could be cut in-mould. The final presentation in this session was by Paolo Ronca (Safeman Thermoforming/Cannon) and focused on the Plastic Modular Shelter which is a non-profit partnership to provide Keeping the transparency of the original PET tray, this one in PP can be now used in microwave
shelter for refugees. It is essentially a flat pack tent made up of thermoformed panels and tubular steel construction. It can last up to three years and can be assembled and put into use in a few hours. It is much more weather resistant and durable than normal tents. Which means they do not need to be replaced as often as normal tents. While this session was going on, the thin gauge thermoformers watch commercial presentations from the following companies: - Amut Comi: Tuned in with Easy 4.0 the smart HMI; - CGP Europe: syntactic plug assist thermoplastics versus epoxy, what’s the future?; - GN Thermoforming: GN Tooling overview; - HP: 3D printed thermoforming moulds; - Illig: perforated packs made easy; - Kiefel: turnkey thermoforming solution for single-serve capsules from material to final product; - Kilde Automation: modular octopus-flexible end of line solutions; - Marbach: advanced thermoform tooling for functional thermoformed packaging; - Milliken: NX UltraClear PP, a viable alternative to PET and PS in thermoformed packaging; - OMV Polytype: smart solutions to thermoformed coffee capsules; - Scholbertechnologies: automatisation and robotisation in combination with rotary die cutting technology for the production of thin gauge labels; - Spartech: selecting the right product to meet your medical and industrial application; - Starlinger: bottle to tray, the successful way of rPET thermoforming; - Termostampi: mould maker since 1970.
AND THE WINNER IS… At the end of the presentations, on the last day, the winners in the various field of the competition for best thermoformed parts were announced. All parts submitted were of an out-
High optical quality and very complex shapes of this application were particularly appreciated by the judges
standing quality and the judges had difficulty in choosing the winners. Medical applications - VDLWientjes Roden The judges particularly appreciated the perfect transparency and material distribution of a premature baby incubator cover. The cover dismounts the superb quality that can be obtained on important parts in thermoforming in front of an injected part. Automotive thin gauge - RPC Promens The judges appreciated the high optical quality visible from both sides - and the very complex shapes - high preblow (600 mm). This part must hold the glued glass - high security part according to ISO 27956. Thin gauge - Miliken The weight reduction of the 14-to-2-g tray, or16%, was appreciated. The PP tray has kept the transparency of the original PET tray and now can be used in microwave ovens, or for hot filling, with the same stiffness and impact strength. Automotive heavy gauge - Walter Pack The judges particularly appreciated the innovation for stone thermoforming. This original application by its translucent or opaque declination in the automobile cladding makes the part a unique product, enhancing the innovative spirit of the industry. www.thermoformingdivision.com
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WM THERMOFORMING MACHINES IS LOOKING TO THE FUTURE
MULTIPLE ACTIVITIES IN STEP WITH THE TIMES. IN A WORD: RATIONALISATION DESPITE ITS YOUNG AGE – IT IS NOT YET FORTY – WM THERMOFORMING MACHINES IS ALREADY ABLE TO COUNT ON CONSOLIDATED GLOBAL MARKET SHARES OFFERING GOOD GROWTH MARGINS, EVEN IN THE FACE OF COMPETITION FROM LARGE MULTINATIONAL GROUPS. ALL THIS STEMS FROM CONSTANT RESEARCH AND DEVELOPMENT NOW SUPPORTED BY THE RATIONALISATION OF PRODUCTION, SALES AND MARKETING ACTIVITIES BY LUCA MEI
E
stablished in 1981 (it is not even 40 years old), WM Thermoforming Machines is a company that already enjoys a solid international reputation. It has its headquarters in the town of Stabio, a few kilometres from Lugano in the Swiss canton of Ticino, where it has always designed and built thermoforming machines and, since 1992, complete solutions equipped with in-line extrusion plants. This manufacturer has always regarded quality and reliability as the true trademarks of its products, which are constantly put through process tests and improved technologically in order to provide cutting-edge solutions capable of satisfying the requests from the most demanding processors. After all, it is by meeting the needs of customers like these that the company has managed to become a recognised name worldwide. This task is not an easy one, not least because of the fierce competition from large multinational groups, however the Swiss company has proved able to stand up to them, thanks in part to ongoing
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collaboration with suppliers and customers, which it indeed sees as the cornerstone not only of the results and market position it has already achieved, but also of the simple and clearly defined vision of the future that will ensure its constant growth. But to give these remarks more substance, and prevent them from sounding clichéd, we turn
to Luca Oliverio, global sales manager at WM Thermoforming Machines, whom we met to ask about how the company is currently faring.
COULD YOU BEGIN BY COMMENTING BRIEFLY ON THE COMPANY’S CURRENT STATE OF HEALTH? “The company’s current situation is flourish-
An example of a Twist 700 machine with MSv7 Multistacker device
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Then, of course, there is the development of automation, which, if you like, is part of the DNA of any company that produces high-output machines. In short, we develop specific automation solutions for the lines requested by our customers”.
An FC 780 thermoforming vacuum and pressure thermoforming machine
IN THE LIGHT OF WHAT YOU HAVE SAID SO FAR, CAN YOU PICK OUT SOME TOP PRODUCTS THAT ARE CONCRETE TARGETS OF THIS RATIONALISATION DRIVE?
ing to say the least, meaning that in the last two years we have increased our turnover by 30-35%. But even during the crisis we didn’t see a real decline in production, given that our machines are destined for the food packaging market. In general, those who have done a good job in a technical sense over the past decade – and we believe that this applies to us – are today having a better response from the market. Furthermore, we have implemented some internal rationalisation measures, both on the production side and on the sales and marketing front, with the aim of making our customers better able to appreciate the qualities that have always characterised us, given that these are aspects that aren’t always properly conveyed”.
COULD YOU TELL US A LITTLE MORE ABOUT THE RATIONALISATION YOU MENTIONED? “Well, to start with the sales side, in 2015 I took over as sales manager. Previously there wasn’t anyone in the company in this particular role, which entails working full-time on the organisation of sales and on linking sales with the company’s technological development. This is my role, and thanks to the work I’m doing with the sales department, and also to the current expansion of our range of products, we have been able to step up our market penetration potential. Our sales network was recently expanded with the recruitment of two people, while a third should be joining us in the second half of 2018. We have also reorganised our marketing activities; whereas we used to develop these on a day-to-day basis, we have now started to re-examine our communication skills and strategy, with a view to ensuring more continuous communication. For example, in the second half of this year, we will be launching a new website with a blog, so as to ensure MACPLAS INTERNATIONAL AT PLAST 2018
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that information about our business activity is conveyed to the outside world more clearly and in a more timely manner. We are also improving our newsletter, our advertising campaigns, and the image we present at trade fairs around the world, and so on”.
IN MORE STRICTLY TECHNOLOGICAL TERMS, WHAT HAS THIS RATIONALISATION ENTAILED? “A very important technological issue for us right now is interchangeability of moulds, i.e. developing machines that can use the moulds our customers already have at their facilities, so that they aren’t obliged to get new moulds should they decide to purchase our lines. In itself, this is not an impossible challenge, but once you find yourself having to find a technical solution suitable for application on two or three types of machine, then you realise that it is not going to be easy to do. Nevertheless, such a solution means a very important competitive advantage. One of the new developments that we are unveiling at Plast 2018 represents a move in this very direction: extension of our machine range to allow adaptability to different moulds.
“That would be too limiting. The concept applies to our entire production range, albeit more markedly in the case of tilting machines with punching/forming/die-cutting features, which are designed for medium-large production runs, and which use moulds that cost 3-4 times more than those used on die-cutting machines. The first of these two families incudes the FT and Twist series, which allow processors to use the moulds they already possess, thereby avoiding a further investment of between 100 and 200 thousand euros. With the FC series we have already reached a 60-70% level of compatibility, but in the course of 2018, we should manage to take this to 100%, which should attract some new customers”.
WHO DO YOU USE FOR MACHINE AUTOMATION? “Our engineering philosophy dictates that any valid “technological” choices we make should be extended to our entire range of machines. For around ten years now we have been using what we might call standard PLCs and power systems produced by B&R. This decision was carefully weighed up. Our machines are not the world’s top-selling ones of their kind, therefore using standard products rather than customised ones for each individual series, or even model, is less expensive and
In-line Intec FT 900 production plant: a true production cell, complete with extruder and thermoforming machine
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WM at Plast 2018
King Midas’ golden touch Gold is the foremost symbol of wealth and power, of success and achievement, while being optimistic and positive, a colour that illuminates and enhances other things around it. Gold adds richness and warmth to anything, it makes everything precious, and to meet visitors at Plast 2018 (stand C31/D32, hall 13) WM Thermoforming Machines makes its thermoformer FC 780 E IM2 Plus produce plates in this shiny colour. Foods, perfumes, cosmetics, fine wines and spirits, coffee and so on, when “dressed up” in gold are perceived as more desirable and precious. It is known that in business and marketing the usage of golden colour has the psychological power of conveying a higher perceived value, and it’s used by many brands for their packaging, suggesting that a product or service is outstanding, exclusive and expensive. For the 2018 edition of Plast, the international exhibition for plastics and rubber industries, WM Thermoforming Machines use its King Midas golden touch and dress up in the shiny material, to present its thermoforming machine model FC 780 E IM2 Plus in function, with an extra touch of elegance and glamour. The wide range of WM Thermoforming Machines models also includes versions with forming and cutting in the same station, in line punching etc.
The WM machine on display at Plast 2018 is the model FC 780 E IM2 Plus, with a forming area of 780 x 570 mm to allow the forming and cutting of the product in the same forming station and/or allow the cutting in a second inline station with subsequent stacking and discharging of the piles of counted products on a conveyor belt
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makes it easier to ensure after-sale service over time. Furthermore, a supplier could well lose interest in developing certain systems once the machines on which they are used go out of production. Developing special systems would not only bump up the costs, but also make spare parts hard to come by, not so much now as in the future. Therefore, standard products are, generally speaking, cheaper overall, even though admittedly they are less appealing”.
WHAT ARE YOUR MOST IMPORTANT MARKETS, BOTH IN TERMS OF APPLICATION SECTORS AND GEOGRAPHICALLY SPEAKING? “Our machines are developed mainly to be used in the packaging industry. Within this sector, food packaging accounts for 90% of the applications, while the remaining 10% can be divided between medical and industrial products. Technological development in this field is driven mainly by applications in the food packaging sector, but also, to an extent, by medical applications, which require dedicated machines, suitable for use in aseptic environments and clean rooms, and which therefore have to be developed in accordance with precise criteria and specific standards. Conversely, in the case of other applications (and this applies in particular to industrial packaging), the objectives pursued are greater flexibility and lower equipment costs, but they represent directions we are less keen to follow. In terms of market areas, 2016 was a particularly successful year for us in the Middle East, which accounted for around 40% of that year’s turnover and is an area where we enjoy a strong position among the market leaders. Our most important market, however, is Italy, which each year gives us around 30-35% of our turnover. Our brand is well known throughout Europe, but less so in Asia, where we are nevertheless hoping to grow, given that in the last three years our turnover from the markets in that part of the world has
Luca Oliverio, sales manager at WM Thermoforming Machines since 2015
grown by an average of 50%. We are also getting some good results in the Americas, especially Mexico, which for us is the market that, in the last five years, has grown the most in percentage terms. Finally, considering its size, we are even doing quite well in the Australian market too. We are not present at all in Africa, but this is probably a result of our approach, and also of the fact that the African markets are not so interesting for us”.
IS THERE ANYTHING IN PARTICULAR YOU CAN TELL US AHEAD OF PLAST 2018? “At the fair (see box) we are exhibiting a machine from the FC range, which is therefore a medium-sized machine based on punch-die technology, as well as a number of innovations, some which also feature on one of the two machines that we are developing to be launched in the second half of 2018. These two machines are not being displayed at Plast 2018, even though we are starting to give some previews of them: one, as already mentioned, will develop the concept of mould interchangeability, while the other will combine the precision of forming and die-cutting technology with tilting platen (therefore with cutting in the mould) with the flexibility of secondary cutting technology”. www.wm-thermoforming.com MACPLAS INTERNATIONAL AT PLAST 2018
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ARTHA MILANO photo: Studdio 3GK - Andrea Corbellini
29 May 2018 - 1 June 2018 Fiera Milano RHO Hall. 09 - Booth C131 D132
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.
has been producing Masterbatches, BiomasterbatchesÂŽ and Additives to colour all types of thermoplastic resins for applications in a wide range of industries.
VANETTI S.p.A. - Italy - Tel: +39.0331.389077 - Fax: +39.0331.389078 - vanetti@vanettimaster.com - www.vanettimaster.com
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As well as the Italian operators, the approximately 120 visitors to the Bandera open house event came from the following countries: France, Belgium, Germany, Spain, Portugal, United Kingdom, Ireland, Poland, Slovenia, Sweden, Russia, Turkey, Mexico, Argentina, Canada, Malaysia and even Australia
FLEXIBILITY IN BLOWN FILM EXTRUSION
“TECHNOLOGY IN ACTION” THE OPEN HOUSE HELD AT BANDERA AT THE END OF 2017 PROVIDED THE OPPORTUNITY TO WATCH A LIVE DEMO OF THE TECHNOFLEX PO5 LINE FOR THE EXTRUSION OF 5-LAYER BUBBLE FILM, AS WELL AS TO MEET THE SALES MANAGERS FOR THE MIDDLE EAST AND ASIA PACIFIC REGIONS AND TO DISCUSS ABOUT THE NEW COURSE OF CUSTOMER CARE AND SPARE PARTS SERVICES. ALL THIS IN PREPARATION FOR THE MOST IMPORTANT EVENT IN THE SECTOR IN 2018: THE PLAST EXHIBITION IN MILAN BY RICCARDO AMPOLLINI
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Pietro Zanotto and Mattia Gambarotto, the sales managers for the Middle East and the AsiaPacific area, respectively, in front of the colossal TechnoFlex PO5 line for blown film, displayed at Bandera’s “House of Extrusion” from November 28 to December 1, 2017 MACPLAS INTERNATIONAL AT PLAST 2018
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here were about 120 participants in the open house event held by Costruzioni Meccaniche Luigi Bandera from last November 28 to December 1, 2017. The venue was the company’s own “House Of Extrusion”, in Busto Arsizio (near Varese), where the Lombard manufacturer presented TechnoFlex PO5, the innovative technology of which being specifically dedicated to high-productivity extrusion of 5-layer, polyolefin based bubble film. The main features of the system being as follows: - 26-component batch dosing system; - 1 extruder of 100 mm in diameter for the core layer, 2 extruders of 85 mm for the intermediate layers and 2 extruders of 65 mm for the external layers; - 5-layer co-extrusion head with 500 mm diameter die of special design to reduce the dwelling time of the polymer inside the head; - Internal Bubble Cooling system with 8 ultra-sound sensors for automatic width control; - highly efficient, triple flow cooling air ring; - automatic thickness profile control system; - cage system for the double bubble guiding;
- swinging haul off with a width of 2,800 mm, with flattening devices and lateral guides, sintered bars and high-torque drive; - ESR winder with a width of 2,800 mm, with torque motors and non-stick treatment for the rollers. The system also features a line control system using Internet of Extrusion (IoE) software, developed by Bandera itself, as well as an extruder for trim re-granulation. The line is characterized by a high degree of versatility; amongst the applications of the exhibited plant, the capacity of which can usually exceed 100kg/h with a 500 mm die, is the production of film for lamination or printing, as well as industrial or heat shrink stretch film, with formulations that can also include PIB (polyisobutylene). The lamination/bonding and printing stages generally occur during the subsequent processing stages off-line or – rather rarely – in-line. The polymer types that can processed on this line are: LDPE, EVA, LLDPE, LLDPE and their
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blends with MDPE, HDPE or PP copolymer. The maximum working width of the film produced is 2,600 mm, while the thickness may vary from between 20 and 200 micron. Mattia Gambarotto, sales manager for the Asia-Pacific area, interviewed during the open house together with Pietro Zanotto the Middle East sales manager, proudly states: “This plant is at the top of the Bandera range. Although the concept of a high productivity line for bubble film is nothing new for us, it is necessary to point out certain innovative features that concern the “flexibility” of the system. While it main target if that of producing over a ton an hour of polyolefin film, TechnoFlex PO5 has both the capacity, and therefore the flexibility, to produce more or less technical products whilst maintaining the high quality of the latter. Going into further detail, this is a line that can easily produce film for both the converting and lamination industry, with stretch films of even a high degree of stickiness, as well as films for packaging or for industrial wrapping, whilst these last are slightly “poorer” than the former, they are still technical. This flexibility is not merely a question of downstream equipment but, as in the case of the entire line, it has been designed and built The Middle East sales manager Pietro Zanotto states: “Bandera enjoys excellent, ongoing collaboration with leading polyolefin producers such as Borouge and ExxonMobil (amongst others), for the testing of special formulations and in order to follow up the client in terms of materials as well which, for a film producer, make up 80% of the actual production cost, especially in the case of plants such as TechnoFlex PO5, that are capable of reaching output levels of over a ton an hour”
The TechnoFlex line presented at the open house featured a 100 mm diameter extruder for the core layer of the film, two extruders of 85 mm for the intermediate layers and two extruders of 65 mm for the external layers
to be flexible in all its parts, from the extruder to the runners of the head, right down to the cooling, haul-off and final film wrapping. So that improvement has been made not on one part of the system, but it has involved an overall optimization process”. Gambarotto goes on: “Bandera is renowned the world over for its tailor-made lines, which is something that can also be confirmed by our competitors. Flexibility is our winning card, which we can successfully play even against the German giants. To this we must add the fact that we are a long-standing and solid company and we have service points throughout the world capable of providing a fully comprehensive service, both in terms of technical support, after-sale assistance and spare part service. We currently have no less than seven service centres throughout the world”. However we shall consider this last aspect later on in the article, we now wish to focus on the several interesting devices installed on Bandera technical bubble film lines.
THICKNESS DISTRIBUTION ON THE FILM Thickness control on the TechnoFlex PO5 line is undertaken using a capacitive sensor for contactless measurement (see opening photograph to this article), which operates on an air “cushion” that rotates around the circumference of the bubble. In the presence of positive or negative peaks, or other thickness errors in relation to the pre-set parameters (that are also displayed on the line control panel monitor), the sensor will send a signal to the cooling air ring to which it is connected, as a result increasing or reducing the flow of air towards certain zones of the bubble, so as to
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compensate the thickness distribution along the circumference. This means that this system makes it possible to evenly distribute any micrometric errors over the entire reel, thereby increasing output capacity to the maximum possible levels (of over 1,000 kg/hours, as mentioned).
ENERGY EFFICIENCY FEATURES As well as focusing on the technological details described above, the company is committed to strongly increasing energy efficiency levels on its lines, and in particular to the optimization of the components... and not only the heads and extruders. “For example, we are seeking to optimize the design of our screws in order to reduce the torque by as much as possible, in order to reduce energy consumption”. Gambarotto goes on to say: “In fact during the course of recent years, when the so called ‘white certificates’ were in fashion, Bandera was amongst those companies that was practically certain of being given this certification for its new plants”. “Again as regards our bubble film plants, our “flattener” system is also particularly worthy of note. Launched at the K 2016, it improves film planarity, thereby making it possible to exploit the subsequent moulding or processing machine to its maximum capacity”.
INVESTMENTS IN INDUSTRY 4.0 AND 3D VISION Nowadays, all manufacturers and particularly the European ones, claim to have developed systems ready for Industry 4.0. We therefore asked Mattia Gambarotto to what extent this may truly prove a competitive factor over the medium term. “I believe that the systems for MACPLAS INTERNATIONAL AT PLAST 2018
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Bandera prepares for Plast 2018
The exhibition takes to the factory
View from above of the polyolefin film reel winding system
Industry 4.0 are the future for the extrusion plants”, Gambarotto replied. “All the last-generation lines produced by Bandera are ready for Industry 4.0 and we are continuing to invest in systems which permit even further improvement on the information exchange between the machinery and the factory systems, thanks also to the collaboration with a software house, which is currently involved in developing a special interface between the cyber-physical system (CPS: the 4.0 machine) and the smart factory”. Pietro Zanotto, the sales manager for the Middle East, goes on to add: “We intend to also integrate all the equipment upstream and downstream of the extruder within the plant control system, so as to assure improved line supervision. After which, it will up to the client to analyse all the big date relating to production trends, especially if it concerns the ‘centralization’ of the information coming from the different plants, in order to be able to evaluate the state of production, the energy consumption levels and to carry out any predictive analysis, so as to optimize the efficiency of its plants, or the so called OEEE (Overall Extrusion Equipment Effectiveness), that is the general and actual efficiency of the extrusion machinery, and the relative factory system.” Over the past year Bandera has also made considerable investment into the development of 3D design systems. The Oculus Rift project in particular, makes use of augmented reality to provide potential clients with a 3D view of the extrusion line before construction, making it possible to examine the components and make any necessary modifications in real time during the construction stage. The 3D view can also be used for the training of line operators and maintenance technicians, and can optimize the production process. It is also an excellent sales tool for the sales managers, because thanks to the Oculus Rift, they are now able to show potential clients a complete plant, allowing them to view the internal components, the different polyMACPLAS INTERNATIONAL AT PLAST 2018
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mers flows inside the extrusion head, and much more”. “It is in fact possible to “walk” inside a plant, thanks to the 3D visor, which has been developed by Bandera in collaboration with the Carlo Cattaneo - LIUC university of Castellanza, starting from the CAD drawings, which have considerably improved as compared to the past, thanks to collaboration with Dynamo 3D, a Marche-based company that leads the way in this field. If we then add the drawings of the complete factory to the three-dimensional animation, this means that the clients are even able to get an understanding of the logistics for the materials and end products. So that it is possible to term it a true 3D marketing service”, concludes Mattia Gambarotto.
Bandera head offices in Busto Arsizio (near Varese) are bustling with preparations for participation at Plast 2018, from May 29 to June 1 at FieraMilano exhibition centre. During the fair visitors to its stand can easily reach its research and development centre known as “The House of Extrusion”, thanks to its special shuttle service, in order to see the extrusion equipment on display: - a line for 5-layer bubble film, for the processing of polyolefins with a capacity of over 1,000 kg/hour, using POD technology and a table with working width of 2,600 mm; - a line for rigid PET, PP and PLA film, with gross output of over 1,200 kg/hour, working band of 1,450 mm and thickness of between 0.14 and 1.5 mm; - complete plant components for agricultural bubble film and for civil and industrial geo-membranes; - the new Pure system for food-grade rigid PET film, approved by the FDA. The Bandera packaging and processing solutions, currently under development, distinguish themselves by virtue of the attention given to reduced energy consumption, thickness and packaging weight. At Plast 2018 the company also highlights its commitment to the increasing use of recycled and/or biodegradable materials, making it a true flagship company in many applications, and it also highlights its software implementations in the sphere of Industry 4.0. The 1st of June will be entirely dedicated to the customer care service.
OTHER BANDERA OPERATIONS, FROM PET SHEET TO SPARE PARTS Bandera is currently operating in three sectors: bubble film, flat head extrusion (principally of PET sheets) and PVC granulation. The first two sectors account for over 90% of its turnover, equivalent to approximately 110 million euros in 2017, as compared to 85 million in 2016. Gambarotto underlines the fact that: “This turnover is principally the result of a marked growth in the PET market, together with rise in demand for bubble film extrusion lines. So that the growth is generalized and global, and does not just concern a single business area”.
During the Plast 2018 event, Bandera is exhibiting live some of its extrusion lines for flexible packaging, thermoformed rigid packaging and FFS (Form, Fill and Seal) applications at its premises in Busto Arsizio (near Varese)
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In the words of Mattia Gambarotto, the AsiaPacific sales manager: “Nowadays a customer care service needs to also focus on the big data. Thanks to remote connection, the Bandera assistance technicians are now able to monitor the installed lines and understand what the most frequent interventions and requests are, as well as the trends of a specific area of the plant”
The Lombard manufacturer is in fact the world leader, in both quantitative and qualitative terms, as concerns PET extrusion, thanks to its patented HVTSE (High Vacuum Twin Screw Extruder) system, for the processing of even post-consumer PET, without the use of a dryer or even a crystallizer. Furthermore, Bandera launched its “Pure” system onto the market in 2017, which offers a high-efficiency pre-treatment system for the production of material suitable for direct contact with food, combined with the patented HVTSE system: a co-rotary twin screw extruder with high-vacuum degassing system. The PET film obtained at the end of the process meets the EFSA and FDA requirements in relation to contact with food. Gambarotto goes on: “In 2017, the products (plates) of the Pure line , which are obtained from post-consumer PET flakes were approved as being suitable for contact with food by the US Food and Drug Administration (FDA). This was a ground breaking step in the PET sector and will make it possible to increase Bandera’s market share in this field. It is also important to point out that despite the fact that the construction of PVC plants is only a side business for Bandera, this sector has also
grown considerably over the past two years. A significant part of the company’s turnover comes from spare parts, which is also showing impressive growth (in the order of +35-40%, year over year), thanks to the new organization and the investment made into customer care and spare parts services (see the fact boxes on these pages), thereby bringing us ever closer to our clients”. www.luigibandera.com
With the Oculus Rift project, the extrusion lines comes to life thanks to augmented reality
Improved after-sales services
The importance of customer care The Italian company Bandera believes that customer loyalty nowadays cannot but take the form of customer satisfaction and ongoing care, which are today considered major aspects in industrial equipment construction and
Bandera has boosted its presence in China thanks to the new spares service centre in Beijing, to provide even faster and more efficient service in the entire Asia-Pacific area
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supply operations. This is why the Varese based manufacturer has recently been involved in enhancing its customer care service, which takes the form of strengthening the technical and sales staff, while at the same time providing it with the support of the latest digital tools for line and process testing and operation monitoring, from start to finish. A dedicated phone line has also been arranged together with a special e-mail for the handling of services reserved to the clients, and for the coordination of the service requests received from the seven assistance centres around the world. There have also been recent developments in foreign branches. Thanks to the agreement between Bandera and PTi (Processing Technologies International), for example, the company offers assistance service in the United States, a technical support service
centre in Dubai for the Middle East, a service centre in Jakarta to cover South-East Asia, and has an established collaboration with a company in Guatemala, which is involved in installing Bandera lines and providing exclusive assistance throughout Latin America. Thanks to the opening of a new spare parts centre in Beijing, Bandera has strengthened its technical and commercial collaboration with a leading Chinese processor in the field of bubble film extrusion for the production of industrial sacks. This new organization will assure the immediate availability of local assistance technicians (trained by Bandera), and spares availability to the whole of China, as it does for all the other Asiatic countries, thereby enhancing the Bandera brand name presence throughout the entire area.
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STAND 22-B141
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SOLUTIONS OFFERED FOR APPLICATION TO MARIS EXTRUSION LINES
INDUSTRY 4.0: WHAT’S NEW? INDUSTRY 4.0 IS A CONCEPT ABLE TO TURN THE PRODUCTION REALITY INTO A LEANER, DYNAMIC, FLEXIBLE, EFFICIENT AND SUSTAINABLE SYSTEM THANKS TO SPECIFIC PRINCIPLES. THIS PROCESS WILL LEAD USERS TO A FULLY AUTOMATED AND INTERCONNECTED INDUSTRIAL PRODUCTION. WITHIN THIS CONTEXT MARIS (HALL 13 - STAND C21/D22) HAS PROVIDED ITS EXTRUSION LINES WITH A NUMBER OF SOLUTIONS ENABLING CUSTOMERS TO BENEFIT FROM A SPECIFIC FISCAL ADVANTAGE
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he term Industry 4.0 has now become an expression of common knowledge, even though a widely shared definition or a specific relevant legislation still does not exist. The word was born in Germany in 2013 to be then interpreted in several and rather different ways according to the most diverse realities and specificities of the countries where it has been adopted. Industry 4.0 is a paradigm or - rather - a concept able to turn the production reality into a leaner, dynamic, flexible, efficient and sustainable system thanks to specific principles (e.g. interconnection and/or virtualization). In other words, it is the process that will lead users to a fully automated and interMACPLAS INTERNATIONAL AT PLAST 2018
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connected industrial production. Criteria for its application vary according to the country of reference. Common standards are particularly difficult to identify. As for the Italian legislation, the general guidelines applied to the extrusion lines are the following: - c ontrol by means of PLC (Programmable Logic Controllers); - interconnectivity with factory information systems and remote loading of instructions (recipes); - automated integration with factory logistics systems, supply network or other machinery of the production cycle; - simple and intuitive human-machine interface;
- remote maintenance, remote diagnostics or remote control systems; - c ontinuous monitoring of working conditions and process parameters through appropriate sets of sensors and the adaptability to process deviations. Maris has already provided lines enabling customers to benefit from a specific fiscal advantage. The following solutions have been selected.
CONTROL BY MEANS OF CNC (COMPUTER NUMERICAL CONTROL) OR PLC (PROGRAMMABLE LOGIC CONTROLLERS) Maris extruders are equipped with constantly evolving hardware and software
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Monitoring of working conditions and process parameters
PLCs. This allows the communication within different fieldbuses and to meet the interconnectivity requirement as well. Although all our software is in-house developed and is part of our know-how, no custom product and/or protocol is used for communication purposes.
INTERCONNECTIVITY WITH FACTORY INFORMATION SYSTEMS AND REMOTE LOADING OF INSTRUCTIONS - AUTOMATED INTEGRATION WITH FACTORY LOGISTICS SYSTEM, THE SUPPLY NETWORK OR OTHER MACHINERY OF THE PRODUCTION CYCLE
SIMPLE AND INTUITIVE HUMAN-MACHINE INTERFACE The human-machine interface (HMI) achieved by using colour touch-screen panels - has been studied and thought to be easily understood and employed by means of intuitive icons always placed in the same position on the various video pages, function buttons to start and stop several devices ordered and represented in logical sequence, soft colours to avoid eyestrain. Moreover, diagnostic pages have been inserted as well in the perspective of remote diagnostics purposes. Thus, the whole system status can be checked without opening the electrical panel or, better still remotely.
REMOTE MAINTENANCE AND REMOTE DIAGNOSTICS The market for machinery manufacturers has been using modem to modem connections to remotely access devices and systems for years. Nowadays, thanks to
Industry 4.0 means the possibility to intensively use, assess and analyse production data within the IT (Information Technology) systems of a company’s corporate level
the Internet and the broadband - through industrial VPN routers that easily guarantee excellent levels of connectivity and reliability - opportunities to connect any type of system or device in plants and installation sites worldwide are constantly increasing. An available remote connection for the systems allows to meet both the requirements of remote maintenance and of remote diagnostics.
Industry 4.0 means the possibility to intensively use, assess and analyze production data within the IT (Information Technology) systems of a company’s corporate level. Nowadays, PLC programs are already collecting large amounts of data on production and process levels (pressure values, temperatures, totalizers). Thanks to Industry 4.0, the exchange of data between production and corporate levels of a company, or with other systems of the line, must be guaranteed and made available to IT systems in order to - for instance - improve product quality. Taking into account the fact that historicizing data and handling the communication with the logistics department are a customer’s task (or of a company on its behalf), one of the essential requirements for the success of Industry 4.0 is therefore the existence of a uniform standard to exchange data. As for Maris lines, the use of worldwide recognized and employed protocols such as Profinet or open protocols as the OPC Unified Architecture (UA) makes reading and writing data available and easier to manage with no need to resort to a more specific purpose-oriented add-on software.
CONTINUOUS MONITORING OF WORKING CONDITIONS AND PROCESS PARAMETERS THROUGH APPROPRIATE SETS OF SENSORS AND THE ADAPTABILITY TO PROCESS DEVIATIONS This requirement is naturally fulfilled by Maris lines as it is vital to meet the basic process and safety needs of customers. www.mariscorp.com
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ADVANCED MACHINES FOR HI-TECH APPLICATIONS
BLOW MOULDING FOR THE MEDICAL FIELD THE EXTRUSION-BLOW MOULDING TECHNOLOGY IS SUITABLE FOR THE PRODUCTION OF A NUMBER OF ARTICLES FOR THE MEDICAL FIELD USING A WIDE VARIETY OF POLYMERIC MATERIALS. IN THIS CONTEXT PLASTIBLOW HAS DESIGNED AND SUPPLIED SEVERAL MACHINES WHICH OFFER MANY ADVANTAGES TO THE PROCESSORS. ADVANCED VERSIONS WITH ELECTRICAL DRIVES HAVE BEEN DEVELOPED TO PREVENT ANY CONTAMINATION OF PRODUCTS AND ENVIRONMENT AND CAN BE USED IN STERILE ROOMS OR CONTROLLED ATMOSPHERE
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n the medical field many articles are produced by extrusion-blow moulding using different polymeric materials: HDPE, LDPE, PVC, PET, PP, PC, EVA but also engineering polymers such as PTFE, polyeterimide and many others. The selection of the most suitable material holds a predominant importance, in particular when the application concerns the manufacture of a device in contact with human tissue, or that has to withstand continuous sterilization in autoclave. In recent years Plastiblow (hall 22, stand A01/ B02) has supplied several blow moulding machines for the production of medical articles such as test-tubes and pipes for laboratory analysis, small pumps for ECG suction cups made of thermoplastic rubber, soft PVC bags and PTFE or PEI articles for hospital use, polycarbonate inhalers and feeding bottles, polypropylene bottles for physiologic solutions, PVC dialysis tubes, as
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well as small bottles for pills, eye-wash or nasal drops made in of PVC or PETG. Each of these projects involved specific problems of planning, design and setup, sometimes requiring the use of special metal alloys suit-
Single-station PB2E/S machine for production of pipettes
able for very high working temperatures necessary for processing unusual plastic materials or specific automatisms for finishing, moving and packaging products of different shapes. With the introduction of electrical drives Plastiblow blow moulding machines have further established in the field of medical articles as the total absence of hydraulic devices prevents any contamination of the products or of the environment and permits the use of the machine in sterile rooms or in controlled atmosphere.
MANY ADVANTAGES FROM THE NEW GENERATION The new generation of blow moulding machines offer many advantages such as: consistency of movements, because without oil there are no differences in movement when the working temperatures changes; higher output thanks to MACPLAS INTERNATIONAL AT PLAST 2018
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PB26ED-800 E100/28 machine for production of PP intravenous vials
faster cycling and the reduction of production scrap due to more consistent movements; lower running costs due to less energy consumption; reduced maintenance costs due to the lack of hydraulic components; less contamination for the environment thanks to the absence of oil and reduced noise levels. Examining, for instance, a specific article, Plastiblow has accumulated a remarkable experience in the manufacture of machines for production of Pasteur pipettes, which are basically droppers for laboratory use so called in memory of their inventor Louis Pasteur. The pipette is made of a thin capillary and a wider top that acts as a pump. The capillary part is engraved with a graduated scale, usually 1 to 3 ml. Pipette working consists essentially in crashing the dropper in order to make the air on the small pipe going out, and dipping it on the fluid. Releasing the pump there will be a lack of pressure balance so that the fluid rises in the tube and cannot get out until the pump is once again crushed. Owing to this function it is important that the material is sufficiently elastic and soft. However, the production of the pipette by extrusion-blow moulding involves the presence of sprue around the perimeter, and the sprue must
be removed automatically inside the machine. So it is appropriate that the material is also stiff enough to allow the operation of scrap cutting. In order to satisfy all these requirements, the pipette must be made of a suitable blend of LDPE and EVA. Already at K95 in DĂźsseldorf, Plastiblow presented a PB250/S machine with 3-cavity mould producing 2,000 parts per hour, and subsequent models increased such output up to 16,000 parts per hour. For intermediate productions the most interesting electric blow moulding machine is a single station PB2E/S model with 60-mm extruder and 3-outlet head for a production exceeding 6,500 pipettes with a compact and easy-to-manage machine.
OTHER INTERESTING APPLICATIONS One of these is represented by the packaging for parenteral solutions, where plastic bottles are quickly replacing the conventional glass ones, both for economic and practical reasons, resulting lightweight, unbreakable and easily transportable. The study of new shapes with limited thickness led to the production of collapsible bottles, such as flexible bags, but with more affordable costs.
For the production of bottles intended for infusion of intravenous liquid substances, various plastics can be used, mainly PP, LDPE or HDPE. These materials meet the requirements of the European and North American pharmacopoeia, having been approved and certified for use in parenteral liquid packaging. The material is selected according to the cost, availability, sterilization temperature and compatibility with the fluid to be packaged. The latest developments of Plastiblow in the field of parenteral packaging include the following blow moulding machines: - a PB26ED-800 E100/28 model with a 10-outlet head for production of approximately 6,000 500-cc vials made of random PP - a double-station PB6ED-380 model (3+3 cavities) for the production of LDPE bottles of 100 and 250 ml with welded cannula and supplied flattened to reduce the volume during transport. www.plastiblow.it
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PLAST
HALL 9 / BOOTH A-02 May 29 - June 01, 2018
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PLASTIC & RUBBER INFRARED AND UV SOLUTIONS FOR EVERY APPLICATION
WELDING OF PLASTIC PARTS Heating of prepreg composite materials LAMINATING Shrinking of plastic foil STRETCHING OF PLASTIC FILMS IR HEATING FOR PET PREFORMS Thermoforming of plastic parts Deburring of stamped part
EMBOSSING PROCESS DRYING OF PLASTIC PELLETS Crystallization and drying of PET, PPS, PLA Curing of paints on plastic Softening process Forming process Bending process Vulcanization processed in rubber industry Drawing of plastic tubes SEALING
www.heliosquartz.com Helios Quartz Group SA Via Roncaglia 20 6883 Novazzano - Switzerland Tel. +41 (0) 919233555/6 Fax +41 (0) 919233557 swiss@heliosquartz.com
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PROCESS GLUING PROCESS Hall 13, Stand C169 29 May - 01 June Milano, Italy Helios Italquartz S.r.l. Via delle Industrie 103/A 20040 Cambiago - Milano - Italy Tel. +39 02 95 34 93 18 Fax +39 02 95 34 50 85 italy@heliosquartz.com
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PROCESSING MACHINERY
As a central building block of Industry 4.0, the Arburg host computer system (ALS) ensures end-to-end IT networking of moulded part production
ARBURG AT PLAST 2018
INDUSTRY 4.0, INNOVATIVE PROCESSES AND AN IMPORTANT ANNIVERSARY DURING PLAST 2018 (STAND C81/D82, HALL 22) AND FOR THE 25TH ANNIVERSARY OF THE ITALIAN SUBSIDIARY, ARBURG INTRODUCES THE HYBRID INJECTION MACHINE ALLROUNDER 820 H IN A NEW DESIGN AND WITH A VISIONARY GESTICA CONTROL SYSTEM. WHEN IT COMES TO INDUSTRY 4.0, A PRACTICAL EXAMPLE OF MULTI-VARIANT INJECTION MOULDING IS ON SHOW, INVOLVING “ON DEMAND” MANUFACTURE OF ELASTIC TENSION STRAPS, AS WELL AS THE ARBURG HOST COMPUTER SYSTEM (ALS). STAND C25 IS ALSO FEATURING INDUSTRIAL ADDITIVE MANUFACTURING WITH THE FREEFORMER
“T
his year’s Plast in Milan is a very special trade fair for us. We have now been represented by our own subsidiary in the Italian market for 25 years. The trade fair launch of the hybrid Allrounder 820 H in a new design and with the visionary Gestica control system shows that we continue to set trends in the market and that we will be a reliable and innovative partner for our customers in Italy for the decades to come”, emphasises Björn Noren, managing director of Arburg Italy. “We look forward to being there for our customers, providing
“The trade fair premiere of the hybrid Allrounder 820 H in a new design and with the visionary Gestica control system shows that we continue to set trends in the market and that we will be a reliable and innovative partner for our customers in Italy for the decades to come”, commented managing director Björn Noren MACPLAS INTERNATIONAL AT PLAST 2018
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them with comprehensive support and continuing to grow with them. At present, this particularly applies to digital transformation and the topic of Industry 4.0, which has gained a lot of momentum thanks to state subsidy programmes in Italy. In addition to the practical example of elastic tension straps, we also have many features to offer in terms of information technology-linked plastic parts production and the individualisation of high-volume parts. In addition, of course, we are showing innovative solutions for industrial additive manufacturing with the Freeformer and numerous functional components”. At the Plast 2018 a hybrid Allrounder 820 H with a clamping force of 4,000 kN, is celebrating its trade fair premiere in a “new look”. The exhibit is the highlight on the exhibition stand and uses PP to produce a 300-gram bucket with a capacity of nine litres in just 11 seconds.
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Handling is by means of a Multilift V40 linear robotic system with a load capacity of 40 kilos.
PRACTICAL EXAMPLE OF INDUSTRY 4.0: ELASTIC TENSION STRAPS “ON DEMAND” As a practical example of Industry 4.0, a turnkey system built around a vertical Allrounder 375 V injection moulding machine will show how customers’ requirements can be incorporated online into the ongoing injection moulding process. Elastic tension straps will be produced in different variants “on demand” and yet cost effectively in a flexible process from shot to shot without any need to change the machine set-up, thanks to a clever product and mould design. In industrial practice, such an application would be ideal for cable assembly in the automotive industry, for example. In the application demonstrated at the trade fair, visitors can choose between straps of different lengths, colours and end piece combinations and can enter the variant of their choice directly at the terminal. The requirements are transmitted to the central Selogica control system via the OPC UA communication protocol. The strap is cut to the selected length from the roll and handling is by means of a six-axis robot, which is compactly arranged within the machine installation area. The mould has two cavities each for hook and eyelet. The strap ends are placed in the cavities and overmoulded according to the order. This allows hook/hook, hook/eyelet or
eyelet/eyelet combinations to be produced in a cycle time of about 40 seconds. The finished elastic tension strap is finally removed by the robot and removed from the system.
NETWORKED AND FLEXIBLY AUTOMATED PRODUCTION Visitors to the Arburg stand can also get an idea of all aspects of digital transformation: they will see solutions for the smart factory, combinable Industry 4.0 components or for the individualisation of high volume parts in batches of a single unit thanks to the combination of injection moulding and additive manufacturing. At the Plast 2018, all exhibits on the Arburg trade fair stand and on the Sverital partner stand are networked via the Arburg host computer system (ALS). As an important component of Industry 4.0, the ALS, enables the comprehensive traceability of orders and batches. Machines can be networked in a simple, standardised manner by means of interfaces based on the OPC UA communication protocol. The Arburg experts provide detailed information on the connection of this MES system to ERP systems.
COST-EFFECTIVE AUTOMATED MOULDED PART PRODUCTION With two other injection moulding exhibits, Arburg will be demonstrating the cost-effective automated production of plastic parts at the Plast 2018. An Allrounder 470 E Golden Electric that produces four 5.75 g switch housings from PA6 (GF 30) for the automotive industry in a cycle time of around 20 seconds, demonstrates that the electric entry-level series is ideally suited to technical injection moulding. A servo-electrical Integralpicker is used for sprue removal. A specially equipped hydraulic Allrounder 370 S is configured for the processing of liquid silicone (LSR). The LSR machine uses a 4-cavity mould to produce a four-gram valve diaphragm (hardness 60 Shore A) in a cycle time of 30 seconds.
INDUSTRIAL ADDITIVE MANUFACTURING
In addition to the Freeformer for industrial additive manufacturing, numerous example parts, as well as an interactive station where visitors will be able to experience their functionality for themselves, are on view at Plast 2018
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A Freeformer and numerous functional components are used at Plast 2018 to demonstrate that Arburg Plastic Freeforming (APF) is not only suitable for prototyping but also for the industrial additive manufacturing of functional components in particular. Visitors can handle parts at an interactive station and convince themselves of their functionality and quality. The exhibit uses the components PP and elastic high-performance TPE to produce retaining clips in a hard/soft combination. The Freeformer is an open system that allows users to qualify their own original materials in
High-volume production “on demand”: a turnkey system at Plast 2018 produces elastic tension straps according to customer requirements in a flexible process from shot to shot
the APF process and optimise the freely programmable process parameters specifically to their particular application. One huge advantage in this context is that original materials certified e.g. for medical technology or aerospace applications can be used. In addition to amorphous standard granulates such as ABS, PA and PC, the ever-expanding range of materials qualified by Arburg includes, for example, elastic TPE, semi-crystalline PP, medical grade PLLA and PC approved for the aerospace industry.
25 YEARS OF ARBURG IN ITALY 2018 is not only the year of the Plast trade fair in Milan, but also the 25th anniversary of Arburg Italy. The subsidiary was established in 1993 under the management of Björn Noren, who is still managing director, and has developed very successfully. The subsidiary in Peschiera Borromeo near Milan has 38 employees. Arburg’s “Wir sind da” brand promise formulates the company’s high standards of quality, reliability and personal proximity to customers and partners. In addition to the efficiency of the machine technology, these groups particularly value Arburg’s comprehensive expertise in service and consulting. The extensive range of services includes the hotline staffed by experts, experienced service and application technicians, a well-equipped spare parts warehouse, a 300 square metre showroom for trials with Allrounders and a training programme in either Italian, English or German. www.arburg.com MACPLAS INTERNATIONAL AT PLAST 2018
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www.ipm-italy.it
The detail makes the difference...
HALL 13 / STAND 13D-62
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pubblicitàBELOTTI - www.pubblicitabelotti.it
40 YEARS TOGETHER 40 ANS ENSEMBLE 19 7 8-2 0 1 8 40 AŇOS JUNTOS SEIT 40 JAHREN ZUSAMMEN
DEGA S.p.A. Largo del Lavoro 4 - 25049 Iseo, Fraz. Clusane (Bs) ITALY Tel. +39 030 989595 - Fax +39 030 989596 info@dega-plastics.com
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PROCESSING MACHINERY
AT THE PLAST SHOW, IN MILAN, THE ITALIAN MANUFACTURER IMG IS EXHIBITING ITS ELASTOMERS MOULDING SOLUTIONS, AS WELL AS THE THERMOPLASTICS PROCESSING SOLUTIONS BY HAITIAN AND ZHAFIR, FOR WHICH IT IS THE EXCLUSIVE DISTRIBUTOR FOR ITALY. THEREBY DOUBLING THE PRODUCT RANGE OFFERED TO FULLY MEET THE PROCESSORS’ NEEDS
DOUBLE DISPLAY FOR IMG AT PLAST 2018
PRESSES FOR ELASTOMERS FROM ITALY, MACHINES FOR THERMOPLASTICS FROM CHINA A
t Plast 2018, IMG is present with two separate stands: in one (hall 11, A/B 41/42) it is exhibiting its elastomer moulding presses, while in the other (hall 24, C/D 41/42) is presenting Haitian and Zhafir machines for thermoplastics moulding. Both the machine ranges are specifically geared to the production of high-tech applications.
THERMOPLASTICS INJECTION MOULDING Four Haitian and Zhafir injection moulding machines for thermoplastics, equipped with auxiliary equipment and advanced software for production data collection and processing, provide a demonstration of the various stages of the process in accordance with the Industry 4.0 principles.
The Zeres range has been on the market for three years, and over 400 units have already been installed in Italy MACPLAS INTERNATIONAL AT PLAST 2018
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Jupiter II, with a clamping force of 550 tons, is a two-platen hydraulic servo-assisted machines, equipped with a mould for the production of a pet carrier, starting from a polypropylene shot of 1,100 grams. The press is also equipped with a Cartesian robot Success 22 Haitian by Sepro with three electric axes, which is being presented in Italy for the first time, since the start of collaboration between the Chinese manufacturer Haitian and the French automation system supplier Sepro. Then there is the Mars II, which is again hydraulic and servo-assisted, with 90-ton toggle joint clamping system. This press is part of a range, of which 150 thousand units have been installed throughout the world. The machine will produce a technical moulding made of fiberglass reinforced PA 6, handled by a robot in the Hilectro range by Haitan. The other two machines on display are electric presses of the Zeres range. This machine, which was originally launched three years ago
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and since then over 400 models have been installed in Italy, highlights the advantages to processors of the hybrid electric/hydraulic solution. Movement overlap, increase in the demoulding force, impeccable precision and reduced energy consumption all go to make the Zeres series extremely flexible in all kinds of applications.
The 450 and 120 ton models are exhibited at the fair. The former, fitted with a robot supplied by the Italian manufacturer Tecnomatic, will mould a motorbike component made of polypropylene. The latter will be equipped with a Haitian robot by Sepro and produce a gadget to be distributed to visitors.
ed during the exhibition. The loading of the 12 inserts and the unloading of the two finished items occurs in a totally automatic manner thanks to a humanoid robot supplied by Kawasaki. The entire working area is monitored by two laser scanners. The icing on the cake is an electric, horizontal toggle joint clamping unit, which the company is now presenting following two years of trials and tests. This solution has been developed in order to increase the repeatability, accuracy and speed of the movements and to assure an overall improvement in machine performance. All the exhibited presses, both electric and hydraulic, are linked to a data collection and processing system in accordance with Industry 4.0 principles, in order to meet the legislative requirements for participating in the hyper-amortization incentive programme of the Italian government. So that IMG intends to present and highlight the full potential of its products to the visitors of the international show in Milan, starting from a standard press, proceeding on to an automated production cell complete with robot and conveyor belt, and finally looking to the near future with a high-tech prototype. www.imgmacchine.it
ELASTOMERS PROCESSING
Example of a press in the NEK range, featuring a gap frame without tiebars
There are IMG three presses on display for elastomers moulding, starting from the model in the GUM range with hydroblock horizontal clamping unit and reciprocating screw horizontal injection unit. The machine, which features a clamping force of 3,000 kN and an injection capacity of 500 cm3, produces O-rings in a totally automatic cycle, thanks to the use of a double brush for the removal and release of the manufactured items into a compartment on the machine. The model of the NEK range, featuring a gap frame without tiebars, with a vertical two-piston clamping unit and vertical reciprocating screw injection unit, distinguishes itself by virtue of its clamping force and injection capacity of 500 kN and 200 cm3 respectively. It is fitted with a two-cavity mould which has been designed to produce a “spinner” made of EPDM, to distribut-
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Our latest products at
PLAST 2018
STAND 21 - HALL 11
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PROCESSING MACHINERY
AMONGST THE FIRST COMPANIES TO BE INVOLVED IN THE DEVELOPMENT OF BAGMAKING MACHINES, MOBERT NOW OFFERS AN EXHAUSTIVE RANGE OF MODELS FOR PRODUCTION OF ANY KIND OF PLASTIC BAGS. INNOVATION IS THE KEY WORD THAT HELPED THE COMPANY TO GAIN SIGNIFICANT SHARES IN A COMPETITIVE MARKET, FOCUSING ON THE USE OF ADVANCED ELECTRONICS IN ORDER TO OPTIMIZE THE PERFORMANCE OF ITS MACHINES
110E SHP 2M line for production of shopper bags and bottom sealed bags in roll
EXHAUSTIVE RANGE OF WELDING MACHINES FOR PLASTIC FILMS
BAGMAKING AT THE TOP C
lose to the finish line of 60 years of activity, Mobert is displaying at Plast 2018 (hall 15, stand C101) its latest novelties of welding machines for plastic films. The company was one of the first in its sector to develop bagmaking machines able to produce bags in rolls. Thanks to the success and increasing diffusion of this line - identified as Roller - it decided to continue in investing resources to develop further this winning technology. Still today the company is writing the story, in a competitive market that has been partly revolutionized with the mandatory adoption of “biomaterials” of vegetal origin. Today the new Roller machines provide rolls with and without cardboard core perfectly packaged, thanks to the automatic application of adhesive paper bands (that can also be printed) with logo and product brands. Various models are available for different needs, all with a capacity up to 250 strokes per minute and equipped with automatic winders that provide for wrapping, closing and unloading of rolls on a conveyor belt that will lead them to the packaging section. MACPLAS INTERNATIONAL AT PLAST 2018
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AMONGST THE MOST COMPETITIVE BAGMAKING MACHINES Thanks to their high performance, together with production efficiency and low running costs, Roller are today among the most competitive bagmaking machines as for price/productivity ratio. The proof is the great increase in orders of these models obtained by Mobert in recent years, which led to consider Roller the top line of the company. All the last generation machines are managed by an industrial PC. Remote assistance is managed by Internet connection and allows Mobert’s engineers to be connected with the machine control system, monitoring the process, highlighting any drawback that may arise during production and solving any problem related to technical assistance. This new approach represents a remarkable achievement, above all because it considerably reduces machine downtime, allowing accurate remote diagnostics of all drivers and electronic components of the machine, from the reel holder to the roll collection device. The operator is also assisted by a graphic layout of the
line, displayed on the command monitor, which permits an immediate detection of the device to be controlled. In this way 90% of problems can be solved directly by the customer, without the need for external intervention. Innovation is the key word that helped Mobert to gain significant market shares for the supply of heat-sealing machines in the packaging industry. For almost 60 years the company has been focusing its activity on the use of advanced electronics, optimizing the production of automatic welding machines, both for bags collected in bundles and for bags in rolls. Another section in which the company has successfully developed its long experience, is that of machines for production of pre-made bags. The MPP machines have been designed for various applications in the flexible packaging sector in the food, non-food, pet-food, medical and pharmaceutical fields. Different types of bags therefore can be produced - vacuum bags (2-3 welds), side gussetted bags (pet.food and cofffe), stand-up pouches (Doypack), medical bags - with various accessories in accordance
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with specific customer requests. These new machines are available in four different widths: 600-800-1000 and 1200 mm. Starting from 1 or 2 reels all types of envelopes can be produced. Different varieties of laminated or coextruded film materials can be used, with or without printing, with PP or PE sealing base. Each group is driven by brushless motors with independent regulation.
LINES EXHIBITED IN OPERATION AT PLAST 2018 Roller 110 SHP is a line for production of shopper bags and bottom sealed bags in roll with knurling for tearing, wrapped with and without cardboard core. This model, like almost all Mobert welding machines, allows the production of both shopper bags (the classic one with double welding and die-cutting of handles) and open-mouth bags (such as, for example, garbage bags). The operator, acting only through the control monitor, can select the production of shopping bags or open-mouth bags. The immediate change of production, without mechanical intervention, is made possible by the patented cold cutting system which, simply by switching off a resis-
MPP 800 SUP line for production of stand-up pouches and side-welded bags
tance, allows changing from simple to double welding. Starting from a motorized and self-centering 1700-mm roll holder, four independent tracks are produced with the slit sealer and gusseting units. The tracks are guided in the welding section, with a useful welding width of 1100 mm, which ensures the welding of bags and pre cutting for the subsequent tearing. An automatic winder station, equipped with a device for inserting cardboard cores, provides for the formation, closure and unloading of four rolls at each change. The innovation on this line is represented by the proprietary system for tension control of each single track in operation as well as by the patented punching system with passing cut. These devices make the line especially suitable for processing biodegradable films also for fruit and vegetables.
Roller 115 E/2M mono is a line for production of bottom sealed bags with “drop-resistant� side welding, in roll on 1 track with pre-cutting and taping of the roll. The machine is composed of: motorized 1150-mm reel holder (automatic lift), thermo-welding unit Roller 115-X 250, group of single-folders for bending the previously welded film, reel unit for the formation of the final roll with a paper taping device. Last but not least, MPP 600 SUP-Z is a line for production of Doypak/stand-up and 3 side-welded bags with and without zipper. The machine includes the following units: motorized reel holder with continuous drilling system for Doypack, folding group, longitudinal sealing/cooling group, cross welding and cooling units, accessories for production of stand-up/Doypack pouch with zipper, round corners and easy open punches. www.mobert.it
The WRD system ensures remote assistance to all installed plants
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Milano, Italy | 29 May - 1 June ‘18 VISIT US: Hall 24, Stand nr C/D 81/82
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PROCESSING MACHINERY NEWS DEDICATED LINES FOR SPECIAL APPLICATIONS
Flexoprinting and bagmaking Operating in the plastics machinery market since 1975, today BFM is one of the main Italian players in the production of takeoffs & winders for blown film lines (as partner of Luigi Bandera), flexographic printing units with central drum (up to 10 colours) and stack-type (2-4-6-8 colours) and automatic bagmaking machines. The company is attending Plast 2018 (hall 15, stand A131) with some accessories of its top printing machine - the 8-colour Marte central drum gearless model - designed exploiting the proven application experience from Bosch Rexroth, the industry leader in automation of printing and converting machines. This model is available in different printing widths; the standard repeat length ranges from 350 up to 800 mm (or 1200 mm for Plus Model) and the highest output speed is 400 m/min. During the exhibition one of the latest innovations in flexoprinting is on display: a line for printing, gusseting and embossing of FFS (Form-Fill-Seal) tubular film. The heavy duty sack is obtained from a gusseted or flat tubular film with an embossed area. It is normally used for polymer granules, fertilizers, salts, bulk goods, composts. This line is composed of a motorized unwinder suitable for reels up to a 1500-mm diameter, a flexoprinter with 2-4-6-colours (according to customer needs) and 800mm width, gusseting and embossing units and finally a W400 single-station automatic winder with 800-mm width. It can be also equipped with corona treatment (refreshing or total), automatic web guiding units and micro-perforators. As for the bagmaking machines, the special line on display is suitable for the production of “sac-a-poche” collected in rolls. It is a pastry-bag with triangular shape, made of a special, very elastic coextruded material (3 layers, 90-100-micron thick). The production process starts from a reel of tubular film; a double nip-roll (needed for tension control of such material) is followed by a station for inclined pre-cut and sealing, placed on the accessory section of the machine. A further station in the main machine provides for transversal cold pre-cutting. www.bfm.it
Flexoprinting, gusseting and embossing line for FFS tubular film
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New demonstration plant launch
From PET bottles to food packaging From May 28 to 31, Amut and Erema invite guests to experience the closed material loop of PET firsthand. Washed post-consumer PET bottle flakes are recycled live at the Amut headquarters in Novara, Italy, to make food contact grade thermoforming sheet in a direct process. This rPET sheet is used at the Plast 2018 in Milan - which is being held at the same time - to make thermoformed trays for the food sector. Interested producers are able to process their own input material on the demonstration system in future to make plastic rolls. They can then test the samples later in their own thermoforming production to check the quality. Amut and Erema are holding an open house to present a sophisticated “bottle to packaging” process and show that the desired closed material loop in the PET sector is already reality. The post-consumer flakes are processed in the new demonstration facility - a direct combination of Vacurema technology and the Amut Inline Sheet plant - in a single process to make food contact grade thermoforming sheet. Thanks to the direct combination of recycling and production technology there is no longer any excess process stage. This is because the melt goes straight from the Vacurema to the Amut plant without the detour of pelletising. A free shuttle service between the trade fair in Milan and the Amut headquarters in Novara is available for attendees. The 100% rPET sheet is used to make thermoformed trays for the food sector at the Amut stand 111/112, in hall 13, during the Plast show. The demonstration facility in Novara continues to be available for customer trials also after the Plast show. The post-consumer PET material is already decontaminated and pre-
“Energy savings, IV preservation, lower logistics and process costs lead to higher profitability and are unbeatable arguments which are driving the trend towards direct food grade PET processing”, says Amut president Piergianni Milani
dried prior to extrusion in the vacuum reactor of the Vacurema Basic, with a throughput of up to 1,000 kg per hour. The newly developed Erema PET Laserfilter processes input material with a degree of contamination of over 1% without any difficulty and discharges the filtered particles continuously. Thanks to its unique pressure consistency this filter system is particularly suitable for inline production. Despite varying moisture, IV values and bulk densities in the input material, the melt has a constantly stable IV value and colour. The melt then goes directly into the Amut Inline Sheet plant where it is processed into thermoforming sheet. The hot lamination system represents an additional production benefit and is particularly suitable for sensitive barrier film thanks to the adjustable contact point. The wet coating at the end makes for an antistatic and anti-blocking solution. The clear advantage over other suppliers: the monolayer thermoforming sheet produced from pure rPET is not only 100% food contact compliant, it also fulfils the FDA regulations and Efsa guidelines. www.amutgroup.com www.erema-group.com
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For production of hoses and profiles
Tailored extrusion lines Established in 1977, Officina Meccanica Carlassara (hall 13, stand B162) has provided until the Nineties a mostly local market with contract manufacturing. A fundamental change occurred with the entry of the current owner Luigi Carlassara into the company. He integrated the existing business with the production of plastics extrusion lines, which now represent the core-business. What makes the lines produced unique is the ability of designers and engineers of the company to build machinery starting from the customer idea of how the final product should be. Starting from such request they make studies, drawings, projects and build the extrusion line, which thus results
different from all other machinery on the market. The peculiarity of the company is the particular harmony of the team, which works with great passion and has been trained mainly on the field. This is true especially for the technical staff, and this factor has allowed the company to adapt to the new 4.0 industrial revolution. All 4.0 machines are entirely studied, designed and produced inside the company and can be used in the most varied sectors, such as the medical and industrial ones, for the production for example of: PVC spiral hoses, soft PUR air ducts, PUR and PA6 single-layer pneumatic hoses, PVC and PUR braided hoses, garden hoses, small rigid and soft
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Carlassara brand machinery includes pieces which are unique on the market, as they are specifically designed and built according to customer needs
profiles, small PVC-PS-PP sheets, flat PVC and PUR soft hoses. Like all other parts of the line, the software also is created entirely inside the company according to customer needs. All functions requested for 4.0 certification are provided in addition to other adhoc demands from the user. The different functions, listed below, can be tailored according to customer needs. All the machines are equipped with PLC and drive controllers of the latest generation for high per-
formance and efficiency. Greater efficiency is ensured by innovative components, for a simple working and a safe commissioning and startup, with the diagnostics of system status that can be easily configured and interfaced. Each machinery is equipped with panels of simple use for the worker with advanced features to facilitate the job for operators. Particularly appreciated by the customers is the remote assistance service with smart access. www.carlassara.it
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PROCESSING MACHINERY NEWS Extrusion lines and equipment for pipes, profiles and sheets
Dedicated to irrigation and furniture Operating in plastics extrusion for more than 25 years, Profile Dies (hall 13, stand B61 at Plast 2018) is specialized in the design and production of special equipment and complete systems for drip irrigation pipes, films, flat sheets, hollow profiles and sheets, in addition to equipment tailored to specific customers requirements. These extrusion lines are addressed to the following application fields: production of furniture trim (PVC, PP or ABS) with thickness from 0,4 to 3 mm, PE/PP/PC/PMMA hollow sheets and profiles with thickness from 2 to 60 mm (up to 9 layers), and flat sheets with thickness from 0,2 to 15 mm.
Last year the company has developed new automated extrusion lines for the production of drip irrigation pipes with flat drippers, which can attain a maximum output speed of 250 m/min and insert up to 2000 drippers per minute by mechanical or laser drilling. Moreover extrusion lines were designed for the production of round drip irrigation pipes with an output speed between 80 and 100 m/min and inserting capacity up to 400 drippers per minute, to produce pipes with diameter from 16 up to 20 mm. Still with a view to develop solutions for the irrigation field, Profile Dies has recently intro-
A recent complete extrusion line from Profile Dies
duced onto the market a new extrusion line for production of drip-tape. This irrigation system is extremely cheap and is suitable for both crops in open fields and gardens. It is easy to install and to remove after use, thanks to the low pipe thickness.
Technical specifications for the new line technical specifications are: maximum output speed up to 200 m/min, spacing (distance between holes) between 10 and 15 cm, minimum wall thickness: 5-6 mils (127-152 micron). www.profiledies.it
Produced by co-rotating twin screw extruders
Foam pipes for insulation A wide range of solutions for foam pipe extrusion is introduced by Sara (hall 13, stand C88) at Plast 2018. The new RS80 co-rotating twin screw extruder (recently installed at an important Italian production site) ensures an output ranging from 30 up to 130 kg/h
RS80 co-rotating twin screw extruder for foam pipes
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according to density, thickness and diameter of the pipe extruded. The foam pipe produced with RS80 is an ideal solution for the following applications: - thermal insulation up to 95°C; insulation of piping for civic and industrial heating plants; it is suitable for cold piping, such as those for air conditioning, cold pipes near to hot pipes, freezing piping for applications down to -45°C; - anti-condensation, particularly useful on cold piping which need protection against the problem of condensation; - anti-vibration, the expanded polyethylene sleeve prevents vibration and resonance in the piping; - anti-corrosion, the properties of the expanded polyethylene sleeve are not
affected by detergents, greases, oils, fumes, paints etc.; it is ideal for protecting the piping from the corrosion by weathering agents and industrial environments. Co-rotating twin screw extruders manufactured by Sara develop minimal heat through mechanical work, far below the amount needed for the material to reach the temperature required for gas mixing; additional heat is applied in order to reach it. After mixing, no more heat is applied, and due to the low shear developed, the melt temperature will decrease. Thanks to the relatively slow movement down the barrel, with a reasonable low cooling, the required temperature for optimal foam extrusion will be reached easily. www.sarasrl.eu
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Meccanoplastica unveils JET 85
Injection blow moulding for perfect necks The latest development from Meccanoplastica (hall 22, stand B71 at Plast 2018) is JET 85, a fully electric injection blow moulding machine designed for the production of small containers with closures that must be manufactured to very tight tolerances, and thus demand extremely precise neck finishing. JET 85 is a three-station injection blow moulding machine with a trigger bar length of 665 mm, a rotation radius of 620 mm, and a total clamping force of 850 kN (i.e. 750 kN on the injection mould and 100 on the blowing mould). The machine is ideal for the pharmaceutical and cosmetics industries, where quality and tolerances are two key considerations. The critical mould opening/closing phases are based on a combination of electric drives, leverages and toggle joints that give these movements structure and reliability. This Tuscany-based company is among the few manufacturers worldwide that produce this reliable solution, in which all the movements are completely electric. At last NPE fair (Orlando, May 7-11), the machine was presented with a set of five-cavity moulds for producing, at a rate of about 1110 pieces per hour, 225 ml LDPE bottles weighing 23 g and featuring a rectangular base. Mould closing/opening and clamping force are obtained by means of a four-point toggle system controlled by an electric servo motor with adjustable speed absolute encoder feedback and satellite roller screw with high loading capacity. The clamping force of the injection mould reaches 750 kN and is automatically adjusted during the calibration of the mould itself according to the pressure needed for the type of bottle to be produced, while the clamping force of the blow mould reaches 100 kN. The 120° rotation of the head is obtained by means of an asynchro-
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The machine has a centralized automatic greasing system for lubricating the mechanical sliding parts. It consists of a 24 V electric pump managed by the machine PLC
nous electric motor driven by an inverter and a mechanical globoidal cam system, making it possible to reach the three positions required by the process (injection, blow moulding, unloading). The system for unloading the bottles from the male moulds is controlled by an electric brushless motor with absolute encoder feedback and a rack and pinion transmission. A pneumatic cylinder allows the rotation of the bottles and their positioning on an output conveyor belt (optional). The speed and position of the translation travel can be set from the control panel. The three-zone plasticizing screw, with diameter = 60 mm and L/D = 24, is connected to an electric brushless servomotor with incremental encoder feedback by means of a belt-pulley transmission. The barrel has four heating zones: three thermoventilated ones for the screw and one for the primary nozzle. The injection movement of the material is obtained by means of a synchronized electric servomotor with absolute encoder feedback, with the encoder acting on a recirculating ball screw with high load capacity. The material can be injected at five speeds and with five screw positions that can be set by the operator. A probe is mounted on the primary nozzle to detect injection pressure and manage the transition to the maintenance phase. www.meccanoplastica.com
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TECHNOLOGICAL SOLUTIONS FOR INDUSTRIAL FILTERS EXE Spazio pubblicitario 172x90 ing 4_2018.indd 1
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PROCESSING MACHINERY NEWS Complete equipment derived from woodworking
Machining of thermoformed plastics A complete range of technological solutions for every process used in machining of thermoformed plastics is presented by Biesse at Plast 2018 (hall 13, stand A101/B102). The visitors will be able to experience the advanced technological innovation that has characterised the company in the woodworking industry for almost 50 years, now applied to the new business of plastic and composite materials. Since its entry in the field of technological materials in 2015, Biesse has experienced growth that exceeded expectations, with a 300% increase in sales in three years. According to Matteo Nazionale, business manager for Biesse Plastic and Composite Materials, the company achieved this growth by investing in strategic assets such as sales intelligence, distribution, and marketing & communication. The
Processing detail of a machining unit
resources dedicated to this sector have increased by 30% over the past year and further significant growth is expected in 2018 as well, in the technical, service, and commercial fields. All of this is meant to increase the presence on the ground, at the service of and closer to Biesse.s true asset: the client. After having carefully studied the target market, Biesse completed its range of equipment for machining of thermoformed plastics by introducing thermoforming units for hot
moulding starting from sheets. This new technology is introduced for the first time at Plast 2018. Next to these will be the Selco Plast WN6 panel saw for sheet cutting, the Material CL for double edge form trimming, and the Rover Plast A FT to perform special machining operations. Moreover, visitors will be able to find information on Sophia, the platform which makes a wide range of services that simplify and rationalise the management of work available
to the customers. It is based on a connection to a cloud service and to special sensors applied to Biesse machines. The information and data on the technologies in use can be recorded and sent just in time to optimise performance, prevent malfunctions, and increase the productivity of machines and systems. In addition, the direct connection to Parts, the portal for spare parts, and the chance to upgrade software with just a few clicks, provides clients with everyday work tools that can simplify a host of tasks. “Plast 2018 is a key event for the international market of advanced materials and”, as stated by Prati Raphaël, director of marketing and communications for Biesse Group, “we strongly believe that this event is a great opportunity for us to display our products. It enables us to demonstrate to our visitors the ways in which our machines can increase the competitive value of our customers, helping them to stand out in the market”. www.biesse.com
Co-rotating twin screw extruders for special lines
Advanced multiskilled compounding A new order has been recently committed by an important European company to Comac (hall 13, stand B72) for the supply of a co-rotating twin-screw extruder model EBC 90HT-High Volume 52D for hot melt production (1500 kg/h). In the field of compounding, the company has supplied plants for a wide range of products, the main of which are: polyolefins with mineral fillers, PP or PA with glass fibres, different kinds of polymeric alloys, flame retardant products, hot-melt adhesive products, high temperature resistant materials (such as PEEK, PPS), elastomers and TPU. For compounds with mineral fillers on polyolefin bases, the most common production capacity of Comac lines are in the range of 2500-4500 kg/h; typically the following charge concentrations are reached: up to 75% with uncoated CaCO3, from 30 to 50% with talc. The lines manufactured for glass fi-
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bre compounds have a production capacity exceeding 1000 kg/h; typically reaching the following concentrations of glass fibres: up to 50% on PA base, up to 35-50% on PP base. Alongside the compounding lines, the company is increasingly involved in projects where the compounding section based on co-rotating twin-screw extruders is integrated with downstream equipment. Some examples are given below. Lines have been manufactured for sheets and foils in polyolefin matrix loaded with CaCO3 for different end uses. A line of this kind is under development for polyolefins with high percentages of self-extinguishing charges. In cooperation with Amut, lines for R-PET foils and sheets have designed in which Comac extruders in special versions process the material without any upstream crystallization-drying system. Usually these lines also include the coextrusion of virgin PET
Co-rotating twin screw extruder for advanced compounding
material for the surface layers (if destination is food packaging). Conversely in this type of lines, the co-rotating twin-screw extruder does not perform compounding but it is used to make PET dryerless extrusion. Lines of this kind with appropriate modifications and additions also permit the continuous production of PET or PP sheet physically expanded without the use of harmful gases. Finally a special mention deserve the lines for plates in PP matrix loaded with long glass fibres fed as roving from coils (the so-called D-LFT process) directly in the extruder. www.comacplast.it
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PROCESSING MACHINERY NEWS Bagmaking and flexoprinting machines
Fully-integrated film converting Since 1961 Saldoflex has been operating in the market of automatic bagmaking machines as well as of flexoprinting presses (with its own Filippini & Paganini brand). During Plast 2018 (hall 15, stand A41/ B42) the company is introducing some innovations including the new range of 1500-mm bagmaking machines for stacked bags and bags on roll, extending the already existing range having 800-11001350-mm sealing width. This not only permits an increase of productivity by taking full advantage of
At Plast 2018 Saldoflex is introducing some innovations including the new range of 1500-mm bagmaking machines for stacked bags and bags on roll
the multiple-lane production from wider jumbo rolls, but it also enriches the range of possible bag sizes, thus meeting the increasingly diversified production needs of modern converters. In addition to the possibility of providing a number of options including the company’s own 1-to-8-colour in-line flexoprinting units, the most appreciated features of Modula and Rollflex bagmaking machines is highlighted during the exhibition: full compatibility with all the last-generation biodegradable and
compostable materials; highest flexibility (some models can produce bloc-note bags, T-shirt bags and bottom-seal bags either with or without stacking pins, all in one machine); fast set-up when changing bag sizes and when shifting from double seal (for T-shirt bags) to single (for bottom-seal bags) and back; very simple changeover of the PTFE tape on the sealing head; electronic servo-driven precut system; draw-tape unwinders with automatic change; rewinders with fully independent 4-station
Friul Filiere at Plast 2018 with Futura40
Technological innovation and corporate history in a name The Italian manufacturer Friul Filiere has always set great store by its participation at the Plast fair, but this year’s event is a particularly special one for the company: having recently turned 40, it could not have wished for a better stage on which to celebrate this significant milestone. The Friuli-based manufacturer is therefore participating in the event with a large stand that allows it to offer its most recent technological innovations, unveil new partnerships and greet visitors. Specifically, the following are exhibited at the stand: - an Omega60 single-screw extruder offering high energy savings; - equipment for the extrusion of polyurethane profiles; - the new Futura40 line that, together with a R63 twin-screw extruder, dedicated die and dedicated calibration system, is used to provide, each day, live extrusion demonstrations during which profiles in Resysta, a composite material made from rice husk and a very small proportion of polymer, will be produced. Futura40, a name that hints at Friul Filiere’s 40 years in the business, reflects a modern industrial philosophy that, for the company, is summed up in the following three key concepts: energy saving,
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safety and Industry 4.0. Friul Filiere is currently one of the few companies in Europe able to provide complete process know-how for the production of Resysta composite profiles: extruders, equipment and auxiliary equipment for finishing. At Plast 2018 (hall 13, stand C11/D12), Friul Filiere is also organising a series of conferences to be held by experts in the field. These deal with the most innovative technologies and topical subjects such as: - Industry 4.0; - Tubeasy: less waste, greater productivity; - ultra-high-speed production of PA pipes; - PU can be extruded; - Resysta: all the opportunities offered by a “green” composite material. www.friulfiliere.it
tracks and servo-driven spindles; reliable and fully adjustable system for application of the gummed paper tape onto the finished rolls. Back again to new developments, Saldoflex has recently launched an innovative range of embossing stations with table width up to 2000 mm, expressively conceived to work in-line with flexoprinting presses and blown-film extruders. Main features of such units, thanks to a careful engineering and to their very sturdy structure with adjustable-pressure hydraulic closing system, are the high production speed (over 200 m/min) and the possibility to emboss not only a background texture but also trademarks and logos thus giving a highly customized appearance to the film, and then to the final product. Moreover, a special system by interchangeable blocks makes it possible to use different logos without needing to replace the embossing roll. As regards Filippini & Paganini flexopresses, the company is investing a lot towards product innovation and manufacturing rationalization: interesting new solutions are being developed and will be applied soon to the roll-to-roll Superflexol range and to the in-line Flexol units, both already available in three versions: mechanical, servo-driven and gearless. www.saldoflex.it
With Futura40, Friul Filiere offers technological innovation and forty years of company history
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Injection moulding of elastomers
Electrical machinery for producing demanding parts Today, Ecotronic is not just an injection moulding machine with unparalleled performance, it can also mould items - effortlessly and at low cost - that are difficult to process with conventional machines. According to the manufacturer, RPM (hall 11, stand C61, at Plast 2018), the Ecotronic injection press can achieve the following results: power consumption: -76%; cycle time: -30%; productivity: +22%; waste: -14%; dead times: -100%; part, water and noise contamination: -100%. This is made possible thanks in particular to the use of electro-mechanical cylinders in place of hydraulic cylinders, with positioning accuracy of 0.005 mm and speed of 600 mm/s. For some years now, electro-mechanical cylinders have replaced most pneumatic and hydraulic actuators available on the market, in many applications. Being similar in size and appearance to hydraulic cylinders and equipped with the same fixturing devices, electro-mechanical cylinders also have the same protection degree from weather agents, developing the same forces, and they meet ISO standards. Compared to hydraulic cylinders, however, they deliver impressive advantages: no maintenance, no oil loss, absolute precision, tripled speed and overlapping movements, no complications. In addition, they are extremely simple, spare parts are standard and available all over the world and are interchangeable with all brands present on the market. The motors connected to the electro-mechanical cylinders are brushless, have powerful and precise electrical drives, they are already used and tested in hundreds of applications and, therefore, offer the guarantee of working for very long periods continually. Thanks to these motors, coupled with Ecotronic electro-mechanical cylinders, just 1.5 kW is needed to generate a force of 2000 kg/cm2, making it possible to move really heavy weights up to a maximum speed of 600 mm a second. This force can also be generated at low speed. The encoder ensures maximum positioning accuracy, up to 10 mm/1 million points, equal therefore to 0.00001 mm, even at top speed. Reaching the precision and speed of these motors would be impossible with traditional systems. Here are the other Ecotronic figures: injection capacity 1,500 cm3, clamping force of 340 t, total length 5 m, injection pressure up to 3,200 kg/cm2 and speed up to 600 mm/s. Prismatic linear guides - replacing bushes and bushings - eliminate mechanical friction and the need for lubrication. www.rpm-srl.it Ecotronic: 340 tons of clamping force for a total length of 5 metres
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PE pipe coating with PP
Shift able cross head for two extrusion lines The company Conextru managed a project and designed the equipment a cross head which can be moved in between two extrusion line for PE pipe coating with PP. The special request for that cross-head was to cover the big diameter range from 63 to 500 mm on two different extrusion lines. Line one covers the range from 63 to 250 mm and line two from 250 to 500 mm. This was managed by add on system for the die sets. One die set is foreseen to cover three outer diameters. To make this possible the extruder for the PP layer is placed in between the two extrusion lines. To be able to feed the Crosshead just with one extruder, a special turntable and changeable adapter was designed to reach always the same feed point of the head which is on top of the cross head. The system for coating includes a preheating station at backside of the crosshead. This heating system is based on IR emitters and on four temperature zones, which are adjustable in temperatures. This unit can cover the same range of diameters as the head: 63 to 250 and 250-500 mm pipe. Preheating increases flexibility of the process because a certain surface temperature of the PE pipe is needed in order to get the required adhesion. On the other hand, the pipe itself should be cold for the coating to get nearly same shrinkage of both materials PP and PE. Both units are mounted on
The head itself is based on helical spiral distributor: a well-known proven system for best melt distribution
one frame and the frame runs on wheels to shift easy from line one to line two. The head itself is based on helical spiral distributor: a well-known proven system for best melt distribution. The head has low volume and small channels for the lower output range suitable for PP as well for PE. The head is heated from outside as well from inside. For smaller pipe sizes there will be a pipe support to make sure the pipe is kept straight in the head for best uniform coating. On the frame, an unwinder is mounted for a wire which is guided though the head until the die set. The wire is later on foreseen for location detection. The coating process is a sort of tubing which works with under pressure. The under pressure is generated via a small side channel compressor (called blower) and the pressure is controlled via measurement and speed adjustment of blower motor. www.conextru.eu
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NEWS Leistritz Elongational Rheometer
Everything under control German Leistritz Extrusionstechnik presents the new Elongational Rheometer at the Plast 2018 in hall 13, stand A51. It is a stateof-the-art-measuring system that provides solid data to prove even the slightest variations in the compounding process. The range of applications extends to all plastics and supports the process reliability when working with both highly viscous pipe compounds as well as low viscous products for fiber and injection moulding. During the extrusion process, a small amount of the melt flow is channeled off via a bypass system and pushed through the rheometer’s slot die. This die is based on a new, patented design with a hyperbolic narrowing. After the measurement, the material is transferred back into the process without losing any material. The rheometer facilitates online measuring of the shear viscosity with shear rates in the range of 10 to 10,000 s-1 and the elongational viscosity with elongation rates in the range of 5 to 75 s-1. The novel die generates a constant elongational flow. So far, this has not been possible with current online measurement devices. During a continuous measuring process, the operator can query two measured values of shear viscosity and one value of extensional viscosity
in the according, precisely defined shear and expansion ranges at the same time. An intelligent automation in the online rheometer’s control unit allows the user to obtain viscosity curves of the material being currently processed within a very short time. This is accomplished through targeted variation of the shear and elongational rates. Moreover, the Leistritz Elongational Rheometer can also indicate the melt flow index as well as the IV value. The wide range of online analysis options is complemented by the determination of the melt density. The online elongational rheometer can be mechanically integrated onto any given extrusion process, without having to undergo major retrofits. The software and visualization of the measured results is either part of the Leistritz extruder control unit of a separate standalone version. The development of service features goes hand in hand with the development of modern extrusion lines. This is why Leistritz extended its portfolio by adding some attractive after sales products. In addition to the standard program the Leistritz service team will therefore also present Industry 4.0 solutions and “smart services” at Plast. www.leistritz.com
The Leistritz Elongational Rheometer with patented die geometry, closed and open
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The E-60 extruder for the hot recovery of scrap material, specially designed for trim waste feeding without the use of air
Recycling systems
Targeting waste reduction Our modern day society is increasingly aware of separate collection and the need to reduce waste. For over 40 years now, Exact has been committed to the optimization of plastics processing, with the aim of reducing edge trim waste to zero in the extrusion process of thermoplastic films of all types. The Italian company distinguishes itself by virtue of its capacity to adapt its operations to every kind of material and thanks to its consolidated experience alongside the leading plant manufacturers in the various sectors, which in 1974 gave rise to the development of the first cold recovery system based on compacting. A development conceived as the realization of a genuine market need which today has become an essential aspect for the company, assuring its growth and competitiveness. In order to offer even greater flexibility to its customers, Exact has in recent years also developed the E-60 extruder for the hot recovery of scrap material, specially designed for trim waste feeding without the use of air. As a result the E-60 makes it possible to exceed the potential offered by cold recovery systems and to cover the needs of an increasingly demanding market. In only a very short time Exact has delivered many “E60” systems that fully meet the demands of customers all over the world, and which have also driven the sales of traditional cold recovery systems. Exact is exhibiting both technologies at Plast 2018 (hall 15, stand A111): from the latest “E-60” extruder using hot technology, to the highly popular granulators (R6/Gold, Evolution, Cyklop 20 e Cyklop 30) featuring cold
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system technology for basic compacting in order to provide a complete response to all customer needs. An open house event is planned to take place during the fair at Bandera, where it will be possible to see both the hot and cold systems in operation, directly combined with the film production lines. An important novelty of Plast is the new sharpening systems of the cutting unit of the cold granulators, which are now manually controlled by a lever. The mechanical modification consists in the application of a wheel-controlled gear unit for the micrometric regulation of the cut. The modification can be applied to all granulators of any type or age, and is very significant as it simplifies and provides added safety during the cutting blade approach phase and, when combined with the “Long Life” treatment recommended for abrasive materials, it also optimizes the cutting of even the toughest materials. The manufacturer has always maintained direct contact with the users and highly values all information and advice coming from them in order to develop a programme of ongoing improvement of its systems. In this respect other interesting innovations are exhibited at the Plast: - the enlargement and improved positioning of the HMI control panel of the machines in order to aid the operator during the various regulation stages of the recovery system; - software and page view rationalization to facilitate granulator use. www.exact.it
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ULTRA PLAST
THE PURGING COMPOUND.
Ultra System S.A.
Rue de l’Ancienne Pointe 30 1920 Martigny - Switzerland Tel +41 27 7226271 email: info@ultrasystem.ch www.ultrasystem.ch
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Gianfranco Cattapan, president of Plastic Systems (left), and Valter Vio, sales director for the Blauwer division, in front of a ChillWer industrial refrigeration system
ANCILLARIES AND COMPONENTS
PLASTIC SYSTEMS: ITALIAN-MADE GOODS APPRECIATED ON A GLOBAL SCALE
“BEHIND THE SCENES” OF A MAJOR SUCCESS AS A RESULT OF A PRODUCTION AND ORGANIZATIONAL POLICY ORIENTED TO SUCCESSFULLY OPERATE INTERNATIONALLY, IN 2017 THE ITALIAN GROUP PLASTIC SYSTEMS GENERATED AN IMPRESSIVE 90% OF ITS REVENUES FROM EXPORTS OF AUXILIARY EQUIPMENT, AUTOMATION SYSTEMS AND CUSTOM LINES FOR PROCESSING PLASTICS. INVESTMENTS IN THE COMPANY VALUE CHAIN ARE PROCEEDING FULL STEAM AHEAD BY ANGELO GRASSI AND RICCARDO AMPOLLINI
B
ecause of the high degree of fragmentation within the Italian industrial system, it is often said that exporters tend to be smaller in size. On the other hand, national Istat data leaves no room for doubt in this regard: micro enterprises (from 1 to 9 employees) and SMEs (from 10 to 49 employees) represent 65% and 29% respectively of the total of Italian exporters. This was a source of pride in the Seventies and even into the Eighties, but is this still the case?
“SMALL IS BEAUTIFUL” IS NO LONGER ENOUGH... And the verdict is unanimous - In one of his first speeches to the assembly of Italian entrepreneurs, Confindustria president Vincenzo Boccia declared: “The company of the future will have to be of a suitable size”; while, even more directly, the governor of Banca d’Italia, Ignazio Visco said: “The high incidence of small enterprises in Italy remains a point of weakness, because on average they are smaller than MACPLAS INTERNATIONAL AT PLAST 2018
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companies in competing countries, and have greater difficulty expanding”. Lastly, economic literature suggests that at least two strategic aspects are needed to implement effective internationalization of enterprises: the individuation, in every sector, of minimal conditions in terms of size and productivity necessary for exports; and the position of companies in each sector in regard to these conditions. And so the editors of MacPlas visited an Italian company based in Borgoricco, near Padua, who had a lot to say about competition on an international scale, and related conditions in terms of size and productivity: Plastic Systems (stand C32, hall 24, at Plast 2018).
PET and Blauwer Division
The new APS division building
A BRIEF BUT CONCISE INTRODUCTION TO THE GROUP “Let’s say first of all that since we were established in 1994, we have been working with automation products for plastic processing”, Gianfranco Cattapan, pres-
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ANCILLARIES AND COMPONENTS The ancillary equipment delivered in Georgia (USA)
ident of Plastics Systems, said, “and we do it comprehensively, starting from storage of raw materials, then continuing through all polymer processing stages, then integrating with the moulding and extrusion machinery manufacturing departments. In these 24 years, we have changed many things, but everything has been done with passion for our work; on the one hand, at a group level, we have 320 employees, 230 of them in Italy (who together helped to generate 70 million euros in 2017 alone, accounting for 90% of exports). On the other, again in the 24 years since the company was established, we have been able to provide our customers with after sales assistance for every machine produced and sold since our first year in business”. Plastic Systems is one of the leading manufacturers globally of auxiliary machinery for polymer processing, also covering Asian and American markets through its branches. Specifically, for 12 years, PS China has been in operation, with a 16,000 sq.m facility near Shanghai, producing machinery for the local market and for other countries in the vicinity. Having Italian management, the company follows the parent company’s philosophy, delivering products that meet the same quality and production standards as Italy. PS Brazil, on the other hand, is headquartered in São Paulo, while PS India is located in Mumbai: two branches, each with ten or so employees, that not only stock finished materials, but which can customize products according to the orders received. An after sales service with expert technicians ensures top level assistance. In addition to these three branches, in 2017 an office was opened in Columbus, Ohio (USA), where a small pool of special-
The Plastic Systems China headquarters
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ist staff take care of sales and the after-sales service. To date, on the American market, Plastic Systems has worked in particular on tailor made systems for major industrial groups, who have invested in new production facilities and who have elected to purchase Plastic Systems engineering expertise. With its participation at the NPE fair in Orlando (7-11 May 2018, booth W4674), the group based in Padua has enhanced its presence on the American market, also presenting its range of products in line with current standards.
The plant in Indiana (USA)
FOCUS ON 4 RIGOROUSLY ITALIAN TECHNOLOGICAL AREAS Advanced Plastic Solutions Operating in three different business areas, the three partners (Rinaldo Piva, Gianfranco Cattapan and Michele Zanon) decided to divide the company into three different business units, each with its own facilities. The PET division, located at the group’s historic headquarters, handles all machinery and systems linked to PET processing for the production of preforms; the APS division, or Advanced Plastic Solutions, handles standard machines and tailor-made systems for all sectors. The standard machinery department features six production lines and handles assembly of: pneumatic feeders (single-phase and three-phase), dryers, blenders (volumetric and gravimetric) and, lastly, granulators. The department dedicated to systems has four production bays, to process four work orders at the same time. Here, in fact, the main system units are preassembled then, once delivered, they are installed and tested at the client’s facilities. The APS division generally produces about a hundred tailor made systems each year. “In recent years, we have built a number of turnkey systems, where the engineering component has been the winning card for entering specialist sectors such as fibre production, compounding and recycling”, Gianfran-
co Cattapan explained in more detail. “One of these, recently installed in Georgia (United States) for a German multinational, is a system to serve a line for the production of PET non-wovens. A second system is located in the state of Indiana, and features some systems for storing raw materials and finished products and devices for pneumatic conveyance of powder and granules in diluted phase and compounds in dense phase. For these, like for all our turnkey plants, the engineering side of things is the fundamental aspect of our work”. Without forgetting the philosophy of “making”, we could add, which marries very well with the engineering know-how mentioned by the group president. During a brief visit to the production department at Plastic Systems, the same MacPlas editors got to see some manufacturing stages of larger hoppers with an impressive capacity of 20,000 litres. And this, too, is a fact! Equally worthy of note are the conveyor and blending lines, often including a silo, capable not only of handling granules, but also fibres and powders, which are notoriously critical. Also continuing on our “random investigation” of the APS Division, it is worth noting the particular attention recently dedicated MACPLAS INTERNATIONAL AT PLAST 2018
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to high precision batch gravimetric blenders in the DGB series, and the latest generation loss-in-weight gravimetric blenders of the DG series, for optimal masterbatch and additive blending. Lastly, there are the DVM loss-in-weight blenders, with vibrating channels, that can be integrated according to a modular logic, a bit like Lego bricks, to give rise to an extrusion blending stations handling 1-4 tons/ hour, for very, very, large systems. In drying, in addition to the new DWC (recently patented on a European level), the high efficiency DWS multi-hopper system (equipped with devices designed for excellent dehumidification quality and to control productivity and energy consumption for each material individually) and the DAC series mini compressed air dryers with molecular sieves, ideal for precision high quality moulding of small parts are being launched. The manufacturer’s new products also include filterless receivers or receivers with integrated dust extraction system for the medical sector, as well as receivers for powder conveying: talcum, calcium carbonate and other additives. For all the equipment, moreover, important R&D work is being directed at developing a standard (OPC US or its evolution) suitable for communicating between machines with Industry 4.0 in mind. “Such commu-
Dryer of the DWC series
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nication standard”, Cattapan pointed out, “must more than anything be independent from the producer and platform, thus permitting not only communication between Plastic Systems solutions and MES and ERP systems on a higher level, but also the transmission of data between the machine and its peripherals”. The PET division “The very first plastic we committed to as a machinery manufacturer was PET and, in this context, we began by tackling issues associated with conveying raw materials for packaging production: especially preforms for the production of bottles. I like to then emphasize the fact that we have never stopped investing in that field, to the point that today, the PET market recognizes us as the leading world producer of large drying systems for polyethylene terephthalate”, Gianfranco Cattapan explained. There is plenty to say about the products of this division, but not to spend too much time on it, we will just list the main systems, which certainly include feeding, blending, drying, mould conditioning equipment, as well as robots and octabin fill management systems. Heat pumps from the Blauwer division The PET division now works “side by side” in the same production facility (at least for now) - with the “Thermal Division”, Blauwer (stand B31, hall 24, at Plast 2018), created in 2015. Indeed, there are three industrial buildings at the Plastic Systems site in Borgoricco, but a fourth building, already in an advanced stage, is being added, that will give each technological area - how can we say it? - “a primary autonomous location”. Buildings aside, Blauwer was established in 2015 to provide refrigeration systems, heat pumps for industrial applications, high efficiency drying systems, and heating and refrigeration control units, and it focuses, in particular, on producing large systems. “Recently in the United States, for example”, sales director Valter Vio said, “we worked on a 5,400kW refrigeration system for injection moulding, for water process temperature of 10°C in a first circuit, and a 8,500kW system for process temperature of 30°C in a second circuit. In this case, we also delivered all the piping and we took care of installation”. “Less waste and more future” is the inspiration behind every project. The name itself - Blauwer (meaning “more blue”) - is intended to be auspicious, so employees in
The sales director for the Blauwer division, Valter Vio, near a WTC thermorefrigerator of the ConWer series
this division work with the conviction that respect for the environment is a non-negotiable ethical priority. As Valter Vio explained in greater detail: “Here we handle two fluids - air and water - through the respective internal units and, in both cases, we are able to generate both hot and cold thanks to our special heat pumps. Having said this, in terms of range, we make different types of industrial refrigerators, adiabatic coolers (fluid coolers and/or free coolers), but also very high efficiency dryers and, in particular, heat pumps that can heat or cool not only moulds, machinery or material, but also company or office interiors”. In particular, at the Mecspe fair in March, Blauwer showcased: a ConWer series line system thermorefrigerator, which controls two different temperatures (between 5°C and 90°C) on the mould and is equipped with a free cooling device to recover energy during the cold seasons, and with a new microprocessor for innovative process conditioning; a system in the RecuWer series, with low energy consumption and cross-flow energy recovery system which, thanks to the diffusion of dried air, prevents condensation in the mould from ambient air; and a high efficiency air cool-
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ANCILLARIES AND COMPONENTS
ing condensate refrigerator in the ChillWer series. Special Blauwer patents relate, however, to high temperature heat pumps for preheating plastic, recovering residual process energy (already mentioned), and a single compact box that integrates both a water refrigerator (chiller) and a dehumidifier for the mould, using the same refrigeration circuit. “Then we have our original ‘modus operandi’ that I want to mention”, Vio added. “The source for producing new heat comes in particular from residual heat released by a production process. Let me explain: if, for example, we send cooling fluid into a mould, it comes back hotter. Well, that heat “contained” in the return fluid is - to all intents and purposes - “waste energy” that goes normally lost; however, the Blauwer systems are not only able to store that energy, but they return it to the cycle!” “But what is the purpose of all this?”, Vio asked himself rhetorically, then continued: “To answer this question, we would have to outline all the paths that our technology has opened these years, but, for brevity, I will mention just a few. A path, already well tested, regards the application of Blauwer technology to hot waste (synthetic fibres) processing, where, thanks to a CO2 heat pump for high temperature, we have been able first to recover the waste heat, and then to use it to raise the temperature of the waste to over 100°C. In this regard, the operators are well aware that, until now, heat pumps have normally reached only 65-70°C in operation, while with this application we have gone over 100°C!
Production of water-condensed ChillWer systems
Another path we have already successfully taken regards preheating polypropylene granule which, before entering the extruder, we have been able to take to 80°C. This is all a result of the clever - and patented reuse of waste heat which, as such, lowers the global energy cost”. The Steel division Last on the list, but certainly not in importance, is the Steel Division, located in a large production department specialising in processing stainless steel, that provides the metalwork needed for all the company departments thanks to a large machine fleet including, for example: fibre-type laser systems for cutting sheets with 20 mm thick-
Rendering of the new production site with the fourth building, that will increase space dedicated to the production department
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ness and tubes with 150 mm diameter, CNC bending machines, automatic calenders and welding robots. This embodies the often cited “philosophy of making” which, in this specific case, operates in the service of all the group divisions. It should be remembered that the “making” option offers Plastic Systems the major advantage of having direct control over all production activity, as well as over the supply and product quality, while also ensuring the maximum confidentiality of any industrial secrets it may have. “In conclusion, I have to point out that at Plastic Systems, we work according to the principles of lean production: the wellknown philosophy that originated with the Japanese car maker, Toyota, to minimise production waste, to the point of eliminating it. We, however, apply this philosophy ad hoc, given that naturally, we do not have such high production volumes as the car industry. To whatever extent we do it, working according to Toyota’s approach has given us objective advantages and sometimes metaphorically speaking, of course - we think we are earning a round of applause from Womack and Jones”, Gianfranco Cattapan said, with irony. Womack and Jones are two academics who first coined the term “lean production” in their book “The Machine That Changed the World”, which analysed the production systems of the leading car makers in the world, and then compared them with the Japanese Toyota, revealing all the scientific reasons for the latter’s superiority over its competitors. www.plasticsystems.it - www.blauwer.com MACPLAS INTERNATIONAL AT PLAST 2018
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INNO VA TION
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ANCILLARIES AND COMPONENTS
MORETTO AT PLAST 2018
ENERGY SAVING, SUSTAINABILITY AND SMART MACHINES S
trong of the positive trend consolidated in 2017 in Italy and in the world, Moretto faces this new Plast appointment with great optimism and motivation, proposing specific solutions for plastics processors based on three guiding concepts. Energy saving is achieved through unique systems and automation like Moisture Meter Box, Guard and Manager, the only system able to measure in-line with absolute precision the exact residual moisture content of the polymer in ppm and even to automatically manage the drying process, and Eureka Plus, one of the most advanced low consumption drying system available on the market. Eureka Plus has already become a standard in mature markets who demands more performance and which are looking for a truly 4.0 efficiency. Plastics and future also mean sustainability for Moretto, which presents Be Tomorrow, the new project of eco-sustainable activities and the crystallizer MPK, a solution for PET recycling. In terms of smart machinery, automatic systems, smart and adaptive machines like, Moisture Meter Manager for drying, One Wire for feeding, Mowis supervision systems are presented.
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AT PLAST 2018, MORETTO EXHIBITED IN A 4,000-SMQ BOOTH (A81/B82, IN HALL 22) ITS MOST REPRESENTATIVE MACHINES FOR INJECTION MOULDING AND PET PROCESSING FURTHERMORE, AN EXHIBITION DEDICATED TO MACHINERY AND SPECIFIC SOLUTIONS FOR THE EXTRUSION OF BLOWN FILM IS PRESENT AT THE CONTREX BOOTH (C91, IN HALL 13), A MORETTO COMPANY
THE CONTEXT Record performance achieved by Moretto in 2017, economic data recorded double-digit growth, equal to 22% compared to the previous year. The Italian market is in excellent health, it constantly grows and consolidates since 2009. Even the export is in clear progression and represents 75% of the business, the result of the excellent work done by the headquarters Moretto present in 8 countries (Germany, Eastern Europe, Turkey, Brazil, United States, Russia, India and China) and from the distribution network, which now covers 74 countries. The company proceeds on a precise business strategy aimed at the future and continuous investment in technology, automation, research and specialized staff. The goal is
Moisture Meter Manager Touch Box MACPLAS INTERNATIONAL AT PLAST 2018
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An installation of Kruise Kontrol, one of the most sophisticated automation machines proposed by Moretto
the world technological leadership, continuing to realize intelligent automations to support excellent and cutting-edge processes, adapted to the needs of an increasingly sophisticated clientele. The strategic plan includes an impressive project of expansion and production reengineering in view of the Smart Factory and Industry 4.0 criteria. On 2017 Moretto has made important acquisitions of production spaces: today the company has 5 factories and over 75,000 sqm of production space in the Padua area. Work is underway to start a new production area of 20,000 sqm, which in 2019 will host Moretto of the future: a new 4.0 business dimension, an example of production efficiency, digital and logistics as well as an innovation hub, a training center and a permanent showroom. A 4.0 approach is required mainly by sectors such as automotive, medical and packaging, areas that require major technological standards and where Moretto records his better performance.
“EMPOWERING PLASTICS”, THE NEW MORETTO PAY OFF For over 35 years Moretto has been committed to providing intelligent, innovative and energy-efficient machinery that aims to sublimate and strengthen the value of plastic as an indispensable and irreplaceable “raw material” in the life of each of us. In Moretto know-how, research and technological innovation enhance the materials characteristics, quality, importance and multiple uses. The company has always recognized itself in this concept of “proactive” work aimed to improve polymer transformation processes and to give plastic a role of strength and power, and in this year of strategic reorganization, it adopts “Empowering Plastics” as new pay off. Empowering Plastics means giving more power to plastic, helping the supply chain from the beginning, responding with competitive and high-tech solutions to the problems of plastic moulding and environmental.
ENERGY SAVING The goal of the Italian manufacturer has always been to provide innovative and customized systems, able to maximize process efficiency, guarantee final quality and energy savings for their worldwide injection molding, extrusion and PET processing customers. MACPLAS INTERNATIONAL AT PLAST 2018
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successful because it meets the needs of plastics transformers, offering the certainty of the result, production certification and the overcoming quality audits. At Moretto research never stops, and the certification of quality is combined with the maximum energy efficiency for the development of Moisture Meter Manager, an absolutely brilliant and unique device that marks a real revolution in drying. Moisture Meter Manager closes the loop of Moretto drying system by measuring In line each granule residual moisture (in ppm) and applying this data to the adaptive drying system as provided by the 4.0 Smart Factory. It is composed by MM Box and MM Crown devices and Manager control. The double control of the granule’s moisture content at the hoppers input (through MM Box) and output (through MM Crown), allows the system to manage the dryers work conditions by maximizing process performances. The device is equipped with an extraordinary measurement capability thanks to the Power-Peak technology, which measures the dielectric characteristics of the granule. Moisture Meter Manager creates a real “on demand drying”, focusing the process on the real drying needs of the polymer at any given time and managing the drying functions in response to the variables, internal and environmental, which interfere with the moisture level of the polymer. This Moretto device is able to guarantee production certification with maximum energy efficiency. Moisture Meter Manager is one of the four technologies that creates Eureka Plus, the revolutionary drying A Gravix dosing unit installed on a processing machine system realized by Moretto to conAt Plast 2018, the company presents its full range products fully compliant with Industry 4.0 criteria, interconnected machines and software that allow the acquisition of new and important data to be processed and shared to achieve ever and ever higher levels of efficiency. Particular attention is given to drying, one of the most energizing processes in the transformation cycle of plastic materials, and where Moretto has always been strongly involved in the search for original solutions, able to make the difference in terms of quality and energy efficiency. The company exhibits at Plast 2018 the drying system Eureka that evolves in Eureka Plus version thanks to the Moisture Meter Manager. Moisture Meter Box is the only device in the world able to analyze the polymer in-line and to “read”, with an accuracy of ±3 ppm, the real residual moisture leaving the drying hopper. A product that has already been very
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sistently reduce energy consumption and to improve performance in drying systems. Eureka Plus is known to be one of the most advanced low consumption drying system available on the market. It has already become a standard in mature markets, such as the United States, which are not satisfied with the performance of traditional systems but aim at true efficiency 4.0. Eureka Plus combines four of Moretto patented technologies: - Moisture Meter Manager, a revolutionary inline polymer moisture measuring system and automatic management of the drying process based on the real need of the polymer; - X Max, a high performance, multi-bed dryer with consistant dewpoint; - Flowmatik, a dynamic airflow management device; - OTX, drying hoppers with superior mass flow drying characteristics. For the treatment of small quantities of technical polymers the OTX hopper can be combined with the compact X-Comb mini-dryer, for a customized drying totally adaptable to the various needs. At Plast, Moretto will also showcase the mini dryers (Dry Air e X Dry Air) and the DS Mould Dryer, designed to prevent the formation of condensation in the molding area. Cooling is also a very energetic process for which Moretto developed new solutions that can respond adequately to the needs of the sector: maximum performance, constant service, minimum consumption. X Cooler is the innovative modular refrigeration system, capable of connecting up to 6 units, creating
Plant for PET
highly efficient systems with cooling capacity up to 900 kW. Particularly attention is also focusing on dosing, another essential phase which guarantees stability in both injection and extrusion processes. Gramixo the continuous loss-inweight batch blender specifically developed for blown film is, with Gravix a real solution for Dosing 4.0: these machines are designed not only to dosing with an extreme precision (0,01%), but to exchange data in a networked environment, manage machine parameters remotely, run production, consumption, and costs statistics. Moretto proposes a complete range of Te-Ko thermoregulators (water, oil or pressurized) that ensures absolute efficiency and precision in the automatic temperature control both in
A Flowmatik Multi system
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the moulds of the injection presses and in the cylinders and rollers of the extruders.
PLASTIC AND FUTURE FOR MORETTO ALSO MEANS SUSTAINABILITY Sustainability is a principle on which Moretto policy is based since 1980, when the company took his first steps. A principle that today the company perpetuates with more emphasis than ever by taking ever larger and transversal initiatives, to ensure a reduced environmental impact. Be Tomorrow is a new eco-sustainable project launched by Moretto, which has always been committed to creating “energy-saving� machines and sponsoring projects to protect the environment. With Be Tomorrow Moretto think of safeguarding the world of tomorrow, that of our children. With this new project the company wants to involve and sensitize the entire supply chain towards eco-responsible attitudes. There are several planned activities: investments in sustainable production processes, the provision of company electric cars, incentives for innovation with the R&D department, involved in the front line in the search for low consumption technologies and new solutions dedicated to bioplastics and recycling. The PET recycling is possible through crystallization a technique developed to reuse the re-granulated granules obtained from bottles, containers and fibers without any problems. Through the crystallization process, PET passes from the amorphous to the crystalline state, regaining its basic characteristics before being subjected to a new transformation process. A proper crystallization also allows to achieve significant energy savings in the drying phase. MACPLAS INTERNATIONAL AT PLAST 2018
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Mowis, a system for supervising all the machines of a processing facility
At Plast 2018 Moretto also presents MPK crystallizer, designed to guarantee maximum reliability in the PET crystallization process. The MPK main characteristics are robustness, efficiency, ease and speed of maintenance and inspection of parts. The device is equipped with an exclusive mixing system with adjustable blades, the process is controlled by a series of sensors that manage the processing phase through the PLC logic. The MPK main characteristic is surely the cone that can be opened in just two minutes, which allows access to the mixing chamber in absolute safety.
the entire automation chain in plastics processing plants. Mowis overcomes the barriers of traditional supervision by adapting to the needs and quality, production and management objectives of each client. A modular software with unique, auto-configurable and user friendly interface which allows immediate display of the system status. With Mowis the integrated process control is easily managed from any location, on-site or remote. Built on Scada system Mowis makes safe and immediate the exchange of data between standard modules, taylor-made modules and the customer management system. Kruise Kontrol is certainly one of the most so-
phisticated automation machines proposed by Moretto. A fundamental tool for feeding systems, able to automatically control and manage the speed of each material profile by guiding the granule to the destination at the most suitable speed, eliminating speed peaks, thus avoiding the phenomena of angel hair creation, dust and pipe wear. The exclusive patented Moretto technology defines, in fact, what are the best transport conditions for each material and guides it in the pipes up to the transformer machine. Kruise Kontrol is completely automatic, the operator must only set the type of material and the machine to be fed. The system automatically establishes the perfect transport condition for each individual cycle and, through self-learning, manages the speed of the granule smoothing the peaks and ensuring the best performance. In 2017 Kruise Kontrol has been officially recognized from the European Patent Office (EPO) like “the only automatic and intelligent plastic material conveying system in the world”. One Wire is the intelligent transport system developed by Moretto. “Intelligent” because it is able to automatically handle the demands of the individual receivers, to adapt to changes and manage the entire process with maximum efficiency, without resorting to manual settings. A single server could manage up to 80 receivers, 8 indipendent vacuum units, 4 Kruise Kontrol, 4 Dolphin manifolds, 4 manual manifolds and 10 info screens. All the equipment of the transport system can be programmed and controlled, from any point of the network, through the Touch View interface and handheld with the palmtop touch Master 600, One Wire is prepared for Mowis. The range of Kasko receivers and containers and the automatic manifold Dolphin complete the exhibition. www.moretto.com
SMART MACHINES The Moretto 4.0 project is a concept of smart industry where machines and software are interconnected, allowing constantly-refreshed data to always be available for achieving the highest possible levels of efficiency. The 4.0 factory is able to automatically adapt the output to the needs of the market, predict in advance possible breakages or downtime and have a real time remote support. Today’s challenge is to move from fragmented services to an interconnected supply chain model. The 4.0 impression is evident on all Moretto product lines. At the show in Milan Moretto presents Mowis 3, the new update of the supervision and integrated management system for the connection of the machines and the control of MACPLAS INTERNATIONAL AT PLAST 2018
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The range of Te-Ko thermoregulators (water, oil or pressurized), that ensures efficiency and precision in the automatic temperature control
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IML labels ready for pick-up
CAMPETELLA ROBOTIC CENTER AT PLAST 2018
FULL AUTOMATION IN ACTION MANUFACTURER BASED IN THE MARCHE REGION OF ITALY, CAMPETELLA IS ATTENDING THE INTERNATIONAL EVENT IN MILAN WITH A COMPLETE LINE-UP. THE FAIR PROVIDES AN IMPORTANT OPPORTUNITY TO DEMONSTRATE ALL ITS EXPERIENCE IN THE INDUSTRIAL FIELD, THE RESULT OF OVER 120 YEARS OF HISTORY AND ONGOING COMMITMENT TO TECHNOLOGICAL RESEARCH AND DEVELOPMENT
A
t the Plast 2018 exhibition Campetella Robotic Center is exhibiting its most recent developments to meet the needs of the modern manufacturing industry in all its varied aspects, from energy saving to digitalization, from Industry 4.0 to the Internet of Things. At the exhibition, the manufacturer will be showing 14 robots in six separate stands in order to demonstrate the best of their varied application potential. Three genuine novelties are of particular note: the latest robots in the Prime range, showcased at the Campetella stand (A41/B42, hall 22) and the stands of Aquila Service and Tederic Italia, consisting of an automated IML system in operation at the BMB stand, and the total integration of the robot and the press controller, both at the Campetella and BMB stands, in line with the principles of Industry 4.0.
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PRIME SERIES As regards the Prime series, the optimized choice of quality components – and above all the new touch controller – enables programming strategies capable of meeting all the common product handling and movement needs. Prime robots ensure excellent value for money, at quality levels never before reached by Campetella. This range includes seven Cartesian robots as well as the sprue extractors, in which the difference between the MC and CO versions consists in the position of the vertical axis as compared to the horizontal one (fixed or floating): the Reha robot distinguishes itself by virtue of the stroke of the Z, Y and X axes of respectively 1,500, 800 and 300 mm with 2 kg loading capacity; MC1 and CO1 feature Z axis of 1,500/2,000 mm, Y of 1200 mm, X of 600 mm and load-
The automated IML system installed at the BMB stand
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ing capacity of up to 6 kg; MC2 and CO2 incorporates a Z axis of 2,000/3,000 mm, Y of 1,800 mm X of 1000 mm and loading capacity of up to 18 kg; MC3 and CO3 are characterized by Z axis of 2,500/3,500 mm, Y of 1,800 mm, X of 1,200 mm and loading capacity of up to 30 kg.
A Campetella robot displayed in function at Plast 2018
AUTOMATED IML SYSTEM The BMB stand is not displaying an automation system with classic IML feature (in-mould labelling), in which the moulding of thin sided containers is almost the only function, but rather a flexible IML system designed in line with Industry 4.0 principles. This system makes it possible to position the label magazine alongside the stationary platen or the floating platen in order to allow the production of containers and lids with label positioning on either the fixed or mobile half of the mould itself. This is no mean feat, and has been specially conceived to the advantage of those processors dealing with limited production runs and frequent mould changes. This IML system also stands out by virtue of its servo-motorized label magazine as well as greatest precision and easy label change. The labels are fed from above in complete safety whilst ensuring total visibility for the operator. The system is installed on a single plate on the ground and its flexibility is further enhanced by three Cartesian axes of the SM2 robot, thanks to the possibility of selecting the entry position, the stack height and direct unloading or manual transfer. The label change is undertaken with the substitution of the gripper and the label magazine, which are replaced and wired in less than 15 minutes. The robot recipe is memorized together with the press mould program, with automatic recall on the change of the mould itself, and thanks to the program selection feature on control board of the press.
INDUSTRY 4.0 SOLUTIONS In relation to Industry 4.0, the moulding cell on display at the Campetella stand enables the analysis of all production data and online parameter tuning for the best possible results. To provide an accurate insight into what really happens in the production department in relation to Industry 4.0 requirements, all the moulding parameters appear on a giant monitor, together with all the processing and productivity data of both the moulding cell at the company stand MACPLAS INTERNATIONAL AT PLAST 2018
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consisting of an BMB and eKW16Pi press with Gunshot robot - and the moulding cell equipped with IML automation system in operation at the BMB stand, which consists of a BMB eKW28Pi Hybrid press with SM2 robot. The data provided by this production cell is transmitted via Wi-Fi, and can be processed in remote mode online, should it be decided, for example to produce articles without labels for 300 shots, or to slow down a press as the result of a piece-loss alarm, or for the depositing of a sample moulding every 100 shots, with operator recall.
AT THE OTHER 4 STANDS As well as the products displayed at its own stand and at that of BMB, the company is also showing other products in the display areas of a further four companies. At the Aquila Service stand visitors can see a moulding cell for the production of icecream spoons in transparent PS, packed in 300-piece bags. The cell includes a MC22HS robot on a JSW J280 ADS 280-ton press equipped with a 64-cavity mould, cycle time of 6.5 seconds; an automated moulding cell with pick-up and delivery of thick flower pots on a conveyor belt based on a MC3-2H robot, a ChenHsong JM650 650-ton press, a single-cavity mould, cycle time of 35 seconds; an automated production with pick-up and delivery of thick drinking cups on a conveyor belt, based on Reha robot, Chen Hsong JM168 168-ton press and a single-cavity mould, 25-second cycle time. At the Toyo Europe stand visitors can see a moulding cell for the production and packaging of disposable PS trays for 12 serv-
The moulded folding box manufactured at the Toyo Europe stand
ings, based on GunShot robot, Si280 280-ton electric press, 2-cavity mould, 4.5 second cycle time; as well as a moulding cell for the in-line production and assembly of folding boxes based on MC4-1H robot, Si1300 1300-ton press, a single-cavity mould and 45-second cycle time. Moreover at the Engel stand it is possible to see a moulding cell with compact, highspeed automated IML system for the production of 500 cc food containers featuring the Mini Modula 3+1 robot, e-motion 440/160 160-ton press, 2-cavity mould and cycle time of 2.8 seconds. Finally the Tederic stand is presenting an automated moulding cell for the pickup and delivery on conveyor belt of portable ashtrays with incorporated base and lid, based on ME-2A robot, DE180 180-ton electric press, 4-cavity mould and 15-second cycle time; an automated production cell with pick-up and delivery on conveyor belt of seaside buckets and spades featuring a CO2-1S robot, DE160 160-ton press, 2-cavity mould and 20-second cycle time. www.campetella.it
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SINCE 1962
Co-Rotating Twin-Screw Extruders.
Technology and competence, to lead compounding formulations to new standards in: • Organic pigment Masterbatch • Inorganic pigment Masterbatch and mineral fillers • Additives Masterbatch • White Masterbatch • Black Masterbatch • Polymeric Alloys • Technopolymers reinforced with glass fiber and natural fiber • Polyphasic compounds of thermoplastic elastomer with SEBS base • Polyphasic compounds with polyolefinic base • Reactive Extrusion • Elastomeric compounds complete with vulcanizing agents • Monomers and/or solvent content reduction • Technopolymers qualified recycling • Compounds for cables halogen free • Compounds of Rubber, EPDM, NBR, NR, SBR • Rubber recycling by devulcanizing process • Hot-Melt adhesives • Solvent base adhesives • Extruders for bioriented film lines (BOPP, BOPS, BOPET, BOPA, BOPE, Lithium Battery Film)
C.so Moncenisio, 22 10090 Rosta (TO) Italy 092_Maris_ADV.indd 92
Tel. +39 011 9567925 Fax +39 011 9567987
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ANCILLARIES AND COMPONENTS
THE TALE OF A “POCKET MULTINATIONAL” THAT EMBRACED CUSTOMIZATION
“BEHIND EVERY SUCCESSFUL ENTERPRISE THERE IS ALWAYS SOMEONE WHO MADE A BRAVE DECISION”… …AUSTRIAN ECONOMIST PETER FERDINAND DRUCKER USED TO SAY. TO ILLUSTRATE THIS, MACPLAS WENT TO VISIT THE COMPANY DEGA - FOR 40 YEARS A PRODUCER OF SPECIAL AUXILIARY MACHINES FOR INJECTION MOULDING PRESSES AND EXTRUDERS, SUPPLIED THE WORLD OVER - TO TALK TO THE PROTAGONISTS OF A GREAT ENTREPRENEURIAL STORY THAT DESERVES TO BE TOLD BY ANGELO GRASSI
I
t was 1978 when two enterprising young men founded a company which they decided to call De.Ga (stand D32, hall 24, at Plast 2018). In that time it was common practice to derive company names from the first letters of their founders surnames, in this case “De” stands for Delledonne and “Ga” for Gatti. “In the late 1970s, here in the Brescia area, the plastics processing industry was undoubtedly playing a major role in a very lively phase of industrial development, even though there can clearly be no comparison with the ways in which we are today approaching Industry 4.0”, begins Angelo Delledonne, before explaining further: “I am referring to an era that most people today would struggle to understand: a time in which a farmer who had a good harvest might decide to buy a plastic moulding machine and try using it, simply because the year before another local farmer had done the same, or a truck driver who had earned more than usual might decide to invest his extra earnings in one or two small inMACPLAS INTERNATIONAL AT PLAST 2018
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jection moulding machines, installing them in his garage at home, and perhaps getting his wife, a housewife, to use them for him. Actually, these are all things that really happened! But what did they do with these machines? In most cases, these ‘budding’ entrepreneurs used them to mould clothes hangers. At that time, there were numerous clothing manufacturers in this area, and for a while they created a huge demand for hangers. And so, by setting up moulding machines on their premises, ordering in the moulds and materials they needed, and drawing on their growing experience, plastic moulding became a new line of business for these people. But, of course, hangers also need metal hooks. So how on earth did they deal with that? In many cases, subcontractors would be called in to help. These operators would use gas burners, setting the metal hooks close to the flames to heat them up, after which, with the aid of pliers, they would force the hot hooks into the plastic at room temperature - the idea, technically sound,
can be likened to pushing a hot knife into butter. The trouble was that sometimes the hook was either too hot or not hot enough, or it didn’t stay put because the plastic gave way. In the end - I remember this clearly - a subcontractor from Palazzolo came to me and said: “Angelo, you know all about plastic processing machines
Automation systems assembling area
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and you’re pretty creative, why don’t you try and come up with one that can fix hooks in place?”. After that - and I remember this episode clearly too - I happened to see a car body shop worker using a portable electric welder. In itself, that was no big deal, of course, but it gave me the idea that led to our first ever machine, which we called Rapidinsert. And that machine, obviously updated and improved over the years, is still in our catalogue today”. This anecdote makes a pretty good opening chapter, not least because it gives you an idea of the qualities that, 40 years since it was established, still characterise Dega today; first of all, there is its ability to listen to customers, which is encapsulated by Delledonne in his story of how he was invited to “invent a machine that can fix hooks in place”. It also reflects the company’s ability to move with the times - after all, if the insert heater is still in the catalogue today, that means it must have “evolved”, to the point that it can be used both manually, very safely, and in combination with a robot in automatic or semi-automatic mode. All in all, a pretty good start then! But what were Delledonne and Gatti like as young men? And how did they come to be so attached to plastic materials of all things?
FIRST MAINTENANCE WORKERS AND THEN ENTREPRENEURS, BUT ALWAYS FRIENDS It is a well-known fact that the history of plastics began in the nineteenth century when, between 1861 and 1862, Englishman Alexander Parkes created and patented a semi-synthetic material that he called Parkesine (better known as Xylonite). It was an early type of celluloid used for the production of handles, boxes and flexible articles such as shirt cuffs and collars. Italy, too, features in the history of plastics thanks to Gi-
Thermoregulator packed and ready to be shipped
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Conveyor belts assembling area
ulio Natta, whose studies on ethylene polymerisation catalysts were crowned, in 1945, by his creation of a thermoplastic material called isotactic polypropylene; these studies - conducted with Karl Ziegler, who had discovered polypropylene in 1944 - earned the pair the Nobel Prize in Chemistry. Since 1957 polypropylene has been industrially produced under the Moplen brand, revolutionising homes all over the world and becoming associated, in Italy, with the legendary “economic boom” years. The following decades brought major technological developments in the field of plastic materials and, with the advent of engineering plastics saw them becoming well established in increasingly sophisticated and surprising fields of application. This was the period in which Angelo Delledonne and Serafino Gatti embarked on an increasingly close working partnership that has always been absolutely solid. “In 1970 I was in charge of moulding at a toy manufacturer’s, a company owned by a cousin of mine”, explains Delledonne, “and our fleet of machines included some Sandretto presses used to mould ABS parts. I also remember that to learn more, I went to the Sandretto factory in Turin on several occasions. There, my enthusiasm was clearly noted, as a Sandretto commercial agent asked me, as an extra evening assignment, to help him instruct processors from the Brescia and Bergamo areas that had purchased these Turin-built presses. I didn’t need to be asked twice! I had such a passion for technology that, far from content with the commitments I already had on, I also embarked on correspondence studies in electrical engineering with the then famous Radio Elettra School of Turin. Subsequently, the company I worked for was sold to a larger concern, and I was given the task of developing technical assistance for the internal processing lines. It was a great job that I continued to do
until 1976 as an employee of the firm, and then, between 1976 an 1978, as an external consultant. This is the point at which Serafino entered the scene. In that period, he was involved in servicing hydraulic and electrical systems in a local foundry, but he was also helping me, more and more, as an expert maintenance technician. From then on, partly because we have a similar outlook on work and partly because we had great respect for each other, one thing led to another and, 40 years ago, we founded Dega, with the idea of offering technical assistance to plastics processors”. “In the early 1980s, as well as presses, we also repaired auxiliary equipment: granulators, dryers, the first feeders”, says Serafino Gatti. “By repairing those machines we came to understand how they work, and to appreciate their construction features and their real economic value. And so, by combining our know-how (based on advanced knowledge in electrical technology and also on our understanding of the real needs expressed by customers) with that of a manufacturer of electrical resistors who had expertise in manufacturing critical parts, like drums, we designed, built and then started marketing our first Dega feeders, which certainly had the edge on those of our competitors. We previewed them at the Plast fair in 1988, where we were proud to be the first company to be producing a stainless steel feeder. But that was not all. Back then, feeders worked according to a fixed operating cycle, but we, wisely wanting to innovate, managed to come up with tools that as well as being more versatile, also allowed unprecedented performance levels. We were the first to incorporate alarm sensors to signal inadequate or absent suction, and also the first to adopt brush wear monitoring systems. And the market loved these features! I remember that we subsequently produced a small portable dryer, in this instance, too, managing to meet our users MACPLAS INTERNATIONAL AT PLAST 2018
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A Dega dosing system
of breaking down and packaging working processes into individual actions/manufacturing operations. The era of tailor-made solutions was dawning, and both Delledonne and Gatti could see this. The tailor-made philosophy, as espoused by Dega, literally means adopting a methodology aimed at creating solutions that are made to measure, rather than relying, as in the past, on standardised and universal processes and/or machinery. On an operational level, this meant that Dega was able to provide its customers in the vast plastics processing sector with a personalised service, designed and implemented for each single case, and able to meet the needs thrown up by the latest requirements and demands. “Along the same lines as what my father said when he was talking about Rapidinsert, today, THE “FEELING” OF A COMPANY THAT WAS 40 years on, almost all our solutions are born GETTING GOING JUST AS TAYLORISM WAS of our customers requests for improvements, and we intend to keep it that way”, says MauRUNNING OUT OF STEAM By the 1970s in Italy, and even earlier than that ro Delledonne, Angelo’s second son, who is rein other parts of the world, the once legend- sponsible for business development at Dega. ary scientific approach to work organisation “Accordingly, when Dega was founded in 1978, developed by American engineer F.W. Taylor it was already well established that it would be was running out of steam. Since there was no organised according to the principles of the longer much call for large quantities of prod- new tailor-made approach. In short, if you want ucts with uniform characteristics, it no longer to make special products, it’s best to set yourmade sense to rationalise the production cy- self up more as an engineering than a produccles according to the Taylorite approach - that tion concern. Thus, as Serafino Gatti recalls, the feeder presented at Plast 1988 was, in fact, produced with the Semi-finished products help of a subcontractor that, uswarehouse ing its machinery, produced, to Dega’s specifications, a critical and strategic subunit. Basically, faced with the choice “make or buy”, this company has always opted to “buy”. Indeed, just as it does today, Dega chose to focus on R&D; on the technical offices that - divided by area of expertise - work out designs and specifications to guide the production of ad hoc pieces and/ or the purchase of commercially available parts; and, finally, on the assembly departments. Today, perhaps, this strategic choice to buy rather than make - does not sound particularly revolutionary, but it must be remembered that it was taken by two young men who, rather bravely, had weighed up and compared the unit production costs of internally produced items with those of items made by subcontracnew demand for flexibility. After this, one thing led to another, and we eventually started focusing on the production of temperature controllers, masterbatch blenders, dryers, onboard granulators, and so on. Indeed, every year our range of ad hoc solutions for the new needs of plastics processors was extended with the addition of at least one or two new models”. When Gatti talks of “ad hoc solutions for new needs” he is referring to the phenomenon whereby Taylorism, the old model of manufacturing based on repetitive, separately packaged and standardised production criteria, was being consigned to the past. These were years of great change in which Italian manufacturing was starting to embrace a new approach, where the aim was to provide customised, or tailor-made, solutions.
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tors. The fact that the two partners managed to find numerous subcontractors specialising in complementary technologies, moreover led by other young entrepreneurs who “spoke their language”, perhaps explains why that decision proved to be a winning choice, and still is today”. But there are other factors, too, justifying Mauro Delledonne’s positive take on things; first and foremost Dega is present worldwide. Indeed, something of a pocket multinational, it has its own operating sites and offices in Europe, India, Mexico and China.
A POCKET MULTINATIONAL OR A GLOBAL “SMALL BUSINESS”? Towards the mid-1990s, Italian economics journalist Giuseppe Turani, having seen that medium-sized companies were emerging as the protagonists of a new form of capitalism, coined the term “pocket multinational”. This is certainly an apt and catchy label, but we really need to look at exactly what is meant by the term. The Mediobanca-Unioncamere research centre defines pocket multinationals as: 1) manufacturing corporations that 2) have a workforce of between 50 and 499 people, and 3) a turnover of between 15 and 330 million euros. And Dega therefore qualifies for the description! But referring back to the above heading, how does the company see itself: as a pocket multinational or a global “small business”? One person with very clear ideas in this regard is Nicolò Moreno, CEO of Dega, who explains that “the advent of the euro and the negative repercussions it had on exports was a major upheaval in the various plastics sectors, as elsewhere. If you also consider that the turnover recorded by
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ANCILLARIES AND COMPONENTS
Dega has always been very dependent on exports - I am talking about levels of 70-80% - it is easy to appreciate that quick and clear choices had to be made in order to cope with the effects of the euro. The first of these choices was to strengthen an existing partnership with Japanese manufacturer Harmo, an automation systems producer. Thus, in 2005, we founded the company Harmo Dega, based in Iseo, which serves as the logistic base for the distribution, on the European market, of Harmo devices created for use with plastics. The same site also provides Harmo with logistic support for its distribution to the European automotive sector. And if that were not enough, Iseo is also the site where we assemble customised automation systems for some European manufacturing industries. Another important move concerned the China project, launched in 2006. And I am very pleased to point out that this choice was prompted by a request we received from an important company, already a customer of ours at the time, which, needing to open a site in China but not wanting to forego the support we were already providing, wanted us to be able to provide the same kind of assistance to them in China too. So far we are hugely satisfied with the performance of our production unit in China, working for the Asian market. Pretty much in parallel with this operation, we also opened our Mexican subsidiary Dega America S.A., having chosen this country partly for logistic/strategic reasons, as it is a very convenient location for reaching the North American market. Finally, in 2009, we opened Dega Plastic Machinery in India, as a sales and services company. Throughout all this, the parent company Dega Italia has remained a fixed point of reference, always being located here at the historic Iseo site”. This talk of parent company, foreign subsidiaries and partnerships obviously lead us on to another important issue: that fact that, given its adherence to the Mediobanca-Unioncamere criteria mentioned earlier, the company is a capital corporation.
A stage of the mechanical designing
“We became a joint stock company in the period spanning the late 1990s and the start of the 2000s, prompted by a series of factors, namely the exponential growth in our turnover, the orders received in Europe first and then increasingly further afield, and even pressure from the banks” says Moreno. “With hindsight, I would say that the corporate structure chosen has proven to be consistent both with the evolution of the market and with the “rules” on which it is based. Let me put it like this: to be able to participate in certain “weighty” contracts or enter a global corporate “club” you have to cross an all-important threshold. You may well have the necessary technical expertise, but if you fail to respect the “dress code”, this can prove impossible to do”. That’s perfectly clear and entirely logical. Yet Dega also has something of the global small business about it. “Referring back to those Mediobanca-Unioncamere parameters, I feel it’s worth saying a couple of things about the workforce”, says Gianantonio Giorgi, Dega sales director. “What I mean is, these past 40 years may be taken as confirmation of the fact that, to offer customised solutions, you need to be streamlined and flexible like an SME. This is why, in setting up the for-
Commercial division
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eign branches mentioned a moment ago by Niccolò Moreno, we strove to replicate - obviously taking into account the realities of each single country - this winning formula”.
WHEN GENERATIONAL CHANGE IS A “WINNING CARD” “Girogi’s comments make me realise that we have talked extensively about our 40 years, but not enough about the new protagonists”, concludes Angelo Delledonne. “Left to ourselves, my partner Serafino and I would probably have confined ourselves to the Italian and European markets, likely recording very good performances on them. The fact that we have, instead, gone up a gear is thanks to my sons Andrea, Mauro and Matteo. Serafino’s daughters have instead chosen completely different professions, but I can quite honestly say that has in no way undermined the friendship between myself and Serafino, and this is something I am keen to underline. When my sons completed their education and entered the company they all were all fortunate enough to have Serafino as a “tutor” on an internal training programme dealing with the production aspects, which are my partner’s particular forte. This support was “crucial” for my sons, giving them a solid basis, because here at Dega technical preparation is always the priority. After their respective initial periods of specialisation training alongside Serafino, Andrea began focusing on the English language markets and the launch of the American facility, Mauro specialised in quality management and production, and then led the China project through to the start of production, while Matteo specialised in automation, and is now managing Dega Automation business unit across all fields”. Having heard this fantastic story, all we can say is “hats off” to everyone at Dega! www.dega-plastics.com MACPLAS INTERNATIONAL AT PLAST 2018
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7-11 Maggio Orlando, Florida USA
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29 Maggio - 1 Giugno Milano, Italia
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ANCILLARIES AND COMPONENTS
THE MANUFACTURER OF ROBOT AND AUTOMATION SYSTEMS TAKES PLACE AT THE INTERNATIONAL TRADE FAIR IN MILAN WITH A NUMBER OF SOLUTIONS ALL READY FOR INDUSTRY 4.0 AND CELEBRATING AN ANNIVERSARY
STAR AUTOMATION EUROPE AT PLAST 2018
FOUR ROBOTS ON DISPLAY, AMONGST NOVELTIES AND CONFIRMATIONS P
last 2018 (stand C81/D82, hall 24) has been chosen by Star Automation Europe, as they often did in the past, to launch several novelties, and in particular, the new ZXW-VI robots series. The two ZXW-1000VI and ZXW-1600VI models receive the baton of Fx series, introducing numerous enhancements, aiming above all to operation speed. Being loyal to its 2018 motto, “Speed & Precision”, Star succeeded in boosting the already high level of performance of Fx series, with a speed increase higher than 10% for both the machines, when compared to their predecessors. The technical new features include strengthened guides, modified belts and stronger motors, though maintaining a special attention to design, aligning the new models’ appearance to that of XW-VI series. Design is obviously not the only thing asso-
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ciating XW-VI and ZXW-VI series: the new high-speed robots are as well as a standard supplied with STEC-520 controller, which possesses extraordinary potentiality regarding Industry 4.0, such as remote monitoring, production control, and inte-
gration inside the IMM display. Alongside its new models, the company is also exhibiting two models from its XW-VI series, which has now been well-known for almost three years. The two machines are a XW-1000VI, the best-selling model in the
The ZXW-1600VI, one of the novelties displayed by Star Automation Europe at Plast 20118
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ANCILLARIES AND COMPONENTS
Eins OX tool changer systems for the automatic EOAT changes of the four robots exhibited at Plast 2018
rope technical service staff by customers (installations or maintenance activities) are organised through a new application: GOL. This allows the customer service to digitally organise all information, and also enables the customers to log in on a personal web page, where they are able not only to check their service history, but also to directly ask for help or to be guided towards the autonomous individuation of the cause of the problem and its solution.
TEN YEARS OF EINS
whole product range, and a XW-1800MVI, the giant of this series, for the first time shown in an international exhibition and particularly suited for big size moulded products in the automotive and electrical appliances sectors. Visitors of recent exhibitions have surely noticed the attention Star is paying in order to offer to its users a product which is absolutely respondent to most modern standards of industry digitalisation, and Plast is the perfect occasion to move a further step towards the targets which the most demanding users intend to reach as far as technology is concerned.
ratio, robot status, or alarm history. When this kind of information gets refreshed inside the controller, or after a time defined by the user, data get written in dedicated CSV files. Subsequently, these CSV files are loaded through FTP to the directory selected in the server. The viewing of this information is possible on a dedicated web page, thus making the correct functioning of the software independent from the operative system or the browser the user chooses to use. A further innovation is introduced at Plast 2018 also regarding the so-called Smart Service: from the beginning of 2018, in fact, all interventions of the Star Automation Eu-
Starting from the end of 2017, Star has been celebrating the tenth anniversary of Eins, its components for the realisation of EOATs for both cartesian and anthropomorphic robots. The four robots shown at Plast 2018 performs automatic EOAT changes thanks to OX series tool changer system: all its models are on show, thus allowing visitors to verify the incredible lightness which characterises them, and how these devices put only a minimum weight on the robots wrist. Thanks to the cooperation with the Japanese group Vessel, several nippers and mini-nippers for EOAT are also shown. Finally, another highlight is represented by the new version of the Eins portal, configured like a true e-commerce website, where it is possible to purchase Eins products. www.star-europe.com
SOLUTIONS FOR INDUSTRY 4.0 At Plast 2018, Star Automation Europe moves a further step towards the digitalisation requirements of the industrial production, which its most recent products are already designed to meet. Smart Production is embodied in a new software: SF-NET, regarding which demonstrations is held at the fair. This system allows viewing all the information related to production which are contained inside the robot’s controller, thanks to their upload to a server connected to the company network. Viewable production-related information kinds are for example production
The WRD system ensures remote assistance to all installed plants
Render of the company stand at Plast 2018, where large space is reserved for new products and applications and the tools from Eins - the brand that celebrated ten years in 2017 - are displayed
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HALL 15 BOOTH A131
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ANCILLARIES AND COMPONENTS
WIDENING OF RANGE FOR THERMOPLAY
SPECIAL SOLUTIONS FOR INJECTION MOULDING THE ITALIAN COMPANY THERMOPLAY HAS RECENTLY WIDENED SOME RANGES OF PRODUCT. BELOW A NEW VALVE GATE MINI NOZZLE AND A NEW TEMPERATURE CONTROLLER ARE PRESENTED. THEY ARE PROPOSED AT PLAST 2018 TOGETHER WITH OTHER FLAGSHIP PRODUCTS
T
THM controllers with 3, 6 and 12 control zones
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he new valve gate F mini nozzle, with diameter of 11 mm has expanded the small nozzles range of Thermoplay (hall 24, stand D102 at Plast 2018). Designed to meet the increasing requirements of special applications in cosmetic, medical and food packaging markets, the nozzle features a small pitch and is now available for valve gate applications. The new F valve gate nozzle has a minimum pitch of 17 mm. Thanks to its compact profile, this nozzle is ideal for use in restricted spaces and allows the injection on an “inside� surface of the part. The nozzle and tip design allows low thermal dispersion giving the maximum flexibility to the mould maker to design the cooling system. The patented Thermoplay heaters uniformly distribute heat along the whole nozzle surface, providing low energy consumption (150 W maximum per nozzle). The tip can be easily replaced for the maintenance with the mould installed into the injection machine.
The valve gate actuation can be pneumatic or hydraulic, individual or plate actuated, making them ideal for high cavitation applications requiring increased precision. The pin, available in a cylindrical or conical option, is designed to minimize the witness mark on the part (gate diameter from 0,8 to 1,2 mm) providing the highest quality finish. This valve gate nozzle range combines flexibility and quality, and is available in lengths from 56 to 146 mm as standard. This nozzle is suitable for injection of all thermoplastics, excluding abrasive materials.
THREE-ZONE TEMPERATURE CONTROLLERS Thermoplay recently enriched its range of THM6 temperature controllers by offering a new 3-zone model, ideal for hot runners moulding applications with one and two points or single-nozzle injection systems. The new temperature controller is a compact and low-cost product which presents the same characteristics of the 6- and 12-zone models. A wide graphic display of 240 x 64 pixels allows the simultaneous visualisation of all information relevant to each single controlled zone and visualises the scrolling messages that can help the operator in case of alarm. The temperature controller continuously regulates the absorption of each zone and allows a prompt intervention in case plastic material leaks from an injector. MACPLAS INTERNATIONAL AT PLAST 2018
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The temperature controller identifies and signals thermocouple failures (breakage and inverted connection), fuse and heater interruption, solid state relay faults, and interruption of one of the supply phases. On the front panel, 6-LED indicators are present for each zone, which signal any kind of malfunction of the control loop in a univocal way. In case the thermocouple fails, the operator can submit a zone to another with the same thermal behaviour (“slave” function). This is a valid alternative to the manual operation. The synchronous increase of temperatures function avoids heating differences in the various zones, due to the different characteristics of each heater during the machine start-up. Therefore, it is not necessary to resort to a delayed start-up of the zones relevant to nozzles anymore. All regulation parameters and those referring to alarms can be collectively modified in all zones. The function is turned on through a button on the panel. www.thermoplay.it
Online configurator
Reducing project and manufacture times The online configurator Webcreator allows automatic configuration and manufacturing process of Thermoplay injection systems and generates 2D and 3D CAD models, reducing the design and production times. The design parameters can be inserted by web interface and the software generates the configuration and final assembly CAD drawings in the file format chosen by the user. The files are sent automatically to the user in real time. The standard injection systems with 1, 2, 4, 6, 8 and 16 injection points with or without shut off groups, and the related accessories, have been transformed in a highly customizable product to follow the project settings. The manifold can be configured in relation to the distance between nozzle axes, the injected material and the transformation temperatures. Flow channels size according to the type and diameter
of the nozzle chosen. Nozzles, injection bushing and accessories can be chosen throughout the standard range Thermoplay. The Webcreator allows to extend the standard product range and to reduce the production times, the costs and delivery time of injection systems.
A screen of the Webcreator online configurator
Design by:
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TURN A NEW LEAF, DON’ T MAKE THE CONVENTIONAL CHOICE
www.filtec.it
Hall 15 Stand A21
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ANCILLARIES AND COMPONENTS
COMPOUNDING EQUIPMENT FOR A GROWING MARKET
GIANT MIXER FOR THERMOPLASTIC ELASTOMERS RECENTLY DELIVERED TO A GLOBAL PLAYER OPERATING IN THE THERMOPLASTIC ELASTOMERS FIELD, PLAS MEC PRESENTS ITS BIGGEST MIXER FOR TPE EVER REALIZED. A CONCENTRATE OF TECHNOLOGY AND INNOVATIONS THAT SUMS THE EXPERIENCE OF THE ITALIAN MANUFACTURER
T
he biggest mixer for TPE compounds ever manufactured by Plas Mec (hall 13, stand C41/D42) has been recently delivered to a global player in thermoplastic elastomers. These compounds are made of a hard thermoplastic material in combination with soft rubber often incorporating additives such as plasticizer oils and fillers which make them soft and flexible. Although they can have a rubbery feel and are sometimes called thermoplastic rubber, they are not made out of rubber. Unlike thermoset rubbers, TPE compounds can be recycled; that’s why their market is growing remarkably.
A COMPLETELY HOMEMADE PROJECT Completely designed, manufactured and assembled inside the Plas Mec factory, the TRG mixer is composed of a vertical vessel in high-hardness stainless steel, designed to mix homogeneously the different ingredients. The mixing tool is definitely the mixer core, with a
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design geometry which has been optimized to ensure a very homogeneous mixing of polymers with plasticizer oils. The mixing tool is also made of stainless steel, but with special tungsten carbide coating on the surface most subjected to wearing. The inner surface of the vessel, as well as the mixing tool, are finely polished to allow a quick and easy cleaning when it is necessary to change the recipe and avoid contamination. The mixing tool is actuated by an electric motor driven by a frequency converter to set different speeds for the different steps of the mixing process. The transmission from the motor to the mixing tool is performed through pulleys and high capacity V-belts. The mixing tool shaft is supported by two high-load roller bearings and a sealing system ensuring no powder leakage from the vessel. The mixing process for TPE compounds often requires external heating, therefore the vessel is built with a double jacket for heating oil circula-
The mixing tool is also made of stainless steel, but with special tungsten carbide coating on the surface, most subjected to wearing MACPLAS INTERNATIONAL AT PLAST 2018
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tion, to be connected to a thermoregulation unit. The vessel is thermally insulated to prevent heat dispersion. The cover includes a silicone foam seal and three manual locking clamps in order to close perfectly avoiding any powder leakage.
EASIER CLEANING AND CONTROL
The TRG mixer includes all the features to make the cleaning operations easier between the processing of different recipes which could create contaminations
controls including the frequency converter to drive the motor. Design and software are developed to fully control the mixing process and all the safety features. The programme allows hundreds of different recipes to be stored with all the parameters required and it is possible to
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DU
have different protection levels to access the system. As for all the company equipment, also the TRG includes the device for remote connection to the control system by VPN, enabling system surveys or upgrades whenever needed. www.plasmec.it
S TRY 4
.0
IN
The TRG mixer includes all the features to make the cleaning operations easier between the processing of different recipes which could create contaminations. The swivel device, for instance, allows the cover to be easily turned 90°, and the discharge housing can be completely and easily opened frontally sliding out and turning the pneumatic piston with the plug. The mixer includes two valves for injection of plasticizers, to be connected to gear pumps. The valves are installed on the vessel wall, in order to inject the liquid in the vortex core during the mixing phase. In this way the plasticizers are better absorbed from the resin. The valves, a proprietary design of Plas Mec,are of plug type and spring actuated. The TRG mixer includes two temperature sensors, to get a precise value of material temperature during the mixing. It is completely controlled by an electrical dust-tight cabinet including a PLC, a touch screen panel and all the power
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THE CLEANING CREAM SPECIFICALLY DESIGNED TO CLEAN EVERY KIND OF EXTRUSION AND MOLDING LINES
BECAUSE SOMETIMES
SIZE DOESN’T MATTERS.
INSTANTANEOUS
Deeply cleaning, residuals are taken out in one shot without going through color gradations thus reducing downtimes.
CONCENTRATED
Extracleaning power in a single dose sachet, easy to use, move and stock.
UNIVERSAL SAFE
One product to meet any purging scenario: works at any temperature (70°-420°), on any machine, (extrusion, injection, 3Dprinter) and material, (from caucciù to PEEK) Both for humans and environment. Purgingit obtained FDA’s GRAS Certificate and “Food Contact Certificate”.
106it can be used with all materials: abs, pa, pet, ps, pmma, pc, San,pvc, eva, pu, tr, pbt, ppo, pps, ppa, pp, pe, sbr, epdm, bms, fpm, siliconeV Purging MACPLAS n. 341 - Giugno/Luglio 2014
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ANCILLARIES AND COMPONENTS
PRINCIPE EVO: A WINNING COMBINATION OF SKILL, EXPERIENCE AND SIMPLICITY
AN INNOVATIVE PRODUCT BECOMES AN IMMEDIATE SUCCESS T
he RG Polietilene company in Salassa (near Turin, Italy), has been active in the plastic industry since 1980, and is involved in the recycling of low and high density polyethylene, that principally comes from post-consumer waste. An operation which is certainly virtuous but also complex as explained by Alejandro Gaeta, sales and marketing manager of CM Evolution Plast (stand D62, hall 15, at Plast 2018), based in Rescaldina, on the outskirts of Milan. “The materials that come from separate waste collection, account for the greatest proportion of the products treated by RG Polietilene, and contain a high percentage of contaminants such as sand, wood, glass etc. Once these materials have been washed, ground and dried, they are then transferred to the extruder by means of a forced feed system. The extruder grounds the material to a melt, and this is where our Principe EVO automatic continuous filtration system comes into play - which is used to filter the melt through a metallic screen which separates the contaminants which are still present in the melt. At the end of this process, the material which has become a secondary raw material is then granulated and stored in silos, and then transferred into big bags”. Alejandro Gaeta explains that RG Polietilene was the first company (and there have been several since) that has looked to the future and
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THIS INNOVATIVE AUTOMATIC CONTINUOUS FILTRATION SYSTEM WAS UNVEILED AT THE K 2016 EXHIBITION BY CM EVOLUTION PLAST. DURING THE COURSE OF 2017, THE PRINCIPE EVO SYSTEM PROVED TO THE FIRST AND ENTERPRISING RECYCLERS WHO HAVE CHOSEN IT THAT, IN ADDITION TO MAKE ANY PROBLEMATIC ASPECTS OF PLASTIC MATERIAL FILTRATION MORE MANAGEABLE, IT IS ALSO ABLE TO ENSURE NEW PRODUCTIVITY MARGINS BY ANGELO GRASSI AND LUCA MEI
decided to install a Principe EVO filtration system. In this specific case, the continuous automatic filtration system developed by CM Evolution Plast delivers regenerated LDPE with a fineness of 80 micron.
WHEN FILTRATION USED TO BE THE MOST “PROBLEMATIC” PART OF THE LINE Alessio Prinzo the sole director of CM Evolution Plast states: “It has always been no secret that by its very nature the filtration zone positioned between the extruder and the cutting system has always been problematic. This is because it is no easy task to manage the melt in the filtration stage whilst avoiding any pressure peaks or leakage, or even the breakage of the filtration elements, and at the same time assuring the consistency of the filtration grade. Despite this RG
Polietilene, after installing the Principe EVO, stated that the need for apprehensive and constant supervision by the operators disappeared, and that there was a noticeable increase in the extrusion line output. This last aspect being mainly due to the uniformity of output rates during the course of the 24 hours. It is in fact unfortunately not unusual to hear recyclers state that output rates during day-time shifts exceed that of the night shifts; sometimes due to staffing limitations, or for other reasons. It must also be pointed out that the line’s output with Principe EVO is not conditioned by the contamination degree of the material. Furthermore, RG Polietilene has also recorded an amazing saving of over 50% on the only consumable element of Principe EVO, that is the metallic screen, as compared to the previous system which also used metallic screens”.
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To the advantages described by Alessio Prinzo it can also be added that the filtration grade required by RG Polietilene for the LDPE treated with Principe EVO is very high, as the secondary raw material that they produce is destined to be used in the production of very thin film. Alejandro Gaeta goes on to state: “Obviously Principe EVO has allowed RG Polietilene to undertake much more intense filtration operations, whilst at the same time making it possible to undertake processing at fairly balanced pressure rates, which goes to the benefit of the quality of the secondary raw material produced. On the basis of these results, I feel confident in speculating that thanks to the special features of the Principe EVO, it may be possible for a recycler to feed more contaminated production waste into its production line, which translates into cost savings as this material is less costly, with the assurance that they can always rely on an impeccable end product on the one hand, whilst being sure of an enhanced final profit margin”. The phrase “formally impeccable”, formulated by Gaeta, also in view of the fact that it is supported by the report on the application of Principe EVO in RG Polietilene, which has demonstrated how this automatic continuous filtration system is capable of turning a “problem” into an “opportunity”, thereby allowing the user whose job it is to produce secondary raw material to concentrate on its own vital parameters, such as: the type of plastic it is better to filter; the optimum hourly output rate required of the extruder; and the grade of filtration that is required; what type and amount of contamination needs to be removed in order to assure 100% optimum quality. To each his role! The Principe EVO CM230 filtration system with safety enclosures
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THE FEATURES OF PRINCIPE EVO If we are talking about “professional goals” CM Evolution Plast has no doubts about its own: precision mechanics and factory installations, suitably applied to plastics. Because although it is true that Principe EVO was unveiled at the K 2016 fair in Düsseldorf, it is also true that 2017 was the year of the launch of the first successful work orders, and it is also true as we learnt for ourselves during the interview that 2018 has been the year in which the product has been consecrated, and it is also true that as early as 1970 Alessio Prinzo’s father, Carmine, began a mechanical sub-contracting business closely interconnected with the numerous local machinery manufacturers working for a variety of end sectors: especially plastics. Anyone with a slight familiarity with the business culture linked to the intricate world of Italian sub-contracting, is well aware that the dream of every factory owner is to be able to combine its sub-contractor production with a product of its own, that is the result of its own technological experience; and so it was that in Rescaldina this innovative automatic continuous filtration system was conceived. A machine which embodies a concentration of different features which had never before been seen together, such as: continuous flow, screen filtration, totally automatic operation, simplicity and sturdiness. The machine comes in three sizes to meet market needs: - EVO 160: 580 cm2 of filtering surface and output rates between 550 and 1,700 kg/h; - EVO 230: 1,200 cm2 of filtering surface and output rates between 800 and 3,000 kg/h;
Alessio Prinzo (standing), sole director, and Alejandro Gaeta, sales and marketing manager of CM Evolution Plast
- EVO 300: 2,000 cm2 of filtering surface and output rates of up to 3,500 kg/h. The machine reflects the original specialized mechanical know-how of its manufacturer, and features sturdiness and engineering accuracy, the complete machine being produced inhouse by the Lombard company, with the exception of the heat treatment, and the skilled use of the tempered steel specifically employed in the manufacture of each component. We have already mentioned that the operator’s intervention on the Principe EVO is limited to one single task: the change of the screen reel. An operation that absolutely does not require welding or any special manoeuvres, and which does not require the use of any specific tools, and which most importantly, can be undertaken while the machine is in operation carrying out its normal production cycle. Here is a synthetic summary of the end advantages of Principe EVO: - excellent management of the filtering surface, in order to assure efficient control of pressure variations, which are so slight that they never actually alter the melt; - automatic control of the screen changer’s mechanisms that undertake the replacement of the screen, to the benefit of processing stability; - ease in the handling of the scrap material, as the filtration system envisages the separation of the scrap from the exhausted screen on the delivery side of the machine, the shredding of the screen and its conveyance to an easy to empty container; - any material seepage and/or leakage is kept under control thanks to the innovative PLC controller systems: EvoBlock and EvoPulling (both systems being protected by a registered patent application.) www.cmevolutionplast.com MACPLAS INTERNATIONAL AT PLAST 2018
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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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serie
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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 109_Mobert_ADV.indd 109
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ANCILLARIES AND COMPONENTS
“X SERIES” BY PROMIXON
LATEST GENERATION OF PVC DRY BLEND MIXERS THE WORLDWIDE POPULARITY OF THE PROMIXON RANGE OF XM TURBOMIXERS AND XC HORIZONTAL COOLERS, DEVELOPED AND COMBINED BY THIS MANUFACTURER, IS A DEMONSTRATION OF THEIR VALIDITY. HERE FOLLOWS AN EXAMPLE OF JUST SOME OF THOSE THAT FULLY MEET CUSTOMER NEEDS
T
he combination of the XM turbomixer and the XC horizontal cooler has led to the development of the XBlend-MC plant for the mixing of plastics, powder, additives and dyes by Promixon (attending Plast 2018 in hall 13, stand C151/D152), that features some of the latest products supplied by the manufacturer.
the XC cooler water circuit, as well as with the mirror polishing of the mixing containers which makes for fast cleaning and fast material dis-
charging into the turbomixer. Polifilm, a company in Venezuela specializing in the production of PVC dry-blend, has ordered a XBlend-MC/200/1200 mixing system, consisting of an XM-200 turbomixer and an XC-1200 horizontal cooler. The client is particularly appreciating the respect of the production and delivery times, the remote technical assistance offered and the after-sales service. Finally, the tube production company Gulf Manufacturers ordered the XBlend-MC/1500/5600 model, consisting of a XM-1500 turbomixer and an XC-5600 horizontal cooler. Thanks to the support provided by the intuitive operator interface, the plant start-up stage was particularly fast, whilst once again meeting the performance specifications agreed between Promixon and this customer.
All Promixon machines feature mirror polished interior surfaces; the advantages include processing accuracy, product quality and easy cleaning
TECHNICAL FEATURES
RECENT CASE HISTORIES An example of the XBlend-MC/500/1800 has been recently ordered by the Colombian industrial company Plasticos Imec, a PVC tube manufacturer. The processor ordered a XM-500 turbomixer and a CX-1800 horizontal cooler; this mixing plant fully meets the performance requirements of the client, thanks also to the remote assistance provided by Promixon engineers who make it possible to follow up the initial start-up period, allowing the operators to complete the necessary training sessions. The customer is extremely pleased with the efficiency of
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From a technological point of view, this solution is also meant to meet all production requireMACPLAS INTERNATIONAL AT PLAST 2018
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ments in the preparation of PVC dry-blends, both rigid and plasticized grades. The plant ensures low running costs, high output rates, whilst, at the same time, providing highest mixing quality and excellent cleaning potential, thanks to the easy accessibility of the cooler itself. The winning features of the X series are the innovative design and geometry of the mixing tools, making for a greater mixing intensity using any kind of plasticized, rigid, transparent material etc. while special anti-wear coating helps to drastically reduce their rate of wear. The coolers incorporate an innovative cooling water circulation jacket with a high efficiency circuit. The cooling tanks geometry is also novel and specifically conceived to intensify the contact between the material and the heat exchange surface. The engineering features of the entire system have been specifically designed with the aim of enhancing the practical efficiency of all mechanical components.
CONTROL AND SUPERVISION The fully automatic control panels are fitted with all the most modern technology intended to assure the safe management of the mixing plant. The choice of components
supplied by internationally well-known manufacturers means that they can be easily sourced, therefore facilitating the after-sales and assistance services all over the world, and minimising machine downtimes. All panels are fitted with frequency changers to control the speed of the turbomixer, which translates into flexibility and energy savings in running the plant. The manufacturer also provides tailor-made solutions to meet the specific needs of the user, so that the operator panels can be fully customized to meet even the most demanding requirements. The management software has been developed for the most basic to the most sophisticated mixing system, specifically conceived and implemented in order to ensure a series of advantages such as: ease of use; fast troubleshooting operations by providing the operator with instructions; manuals available on the operator panels; reports on the operating conditions of the system in terms of productivity, hourly batch output and alarms; graphs; possibility of setting the mixing recipe according to specific time, speed, temperature and safety requirements. www.promixon.com
Quality, reliability, emergencies, energy savings and much more are all managed by the software that has been specifically developed and adopted by Promixon on all its mixing plants, from the most basic to the most sophisticated
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. MARFRANÂŽ... a world of possibilities !
Beware of imitations.
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FUTURE IS WHERE TECHNOLOGY MEETS PERFORMANCE.
BESTONTECH S-TECH 6500
Beston is the perfect balance between customized solutions and machinery performance. Special IMM for optical plastic products adopting top alloy optical grade screw plasticizing technology, for optical materials like PMMA, PC using precise and high pressure injection, and ultra-low speed stable ďŹ lling, aided by synchronous and asynchronous compression sequence thermal technology, and with long time table pressure holding, machine can produce thick complex irregular optical products.
www.beston-italy.com BESTON SRL | VIA DON BERGOMI, 30/34 | I-25030 CASTEL MELLA (BS) | T. +39 030 877 5149
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ANCILLARIES AND COMPONENTS
ANNIVERSARY NEXT TO COMO
FIFTY YEARS OF QUALITY SCREWS AND BARRELS SPECIALISING IN THE CONSTRUCTION OF SCREWS AND BARRELS FOR PLASTICS AND RUBBER PROCESSING, THE ITALIAN COMPANY MAST, WITH OFFICES IN CAGNO (COMO), IN 2017 CELEBRATED ITS FIRST FIFTY YEARS, DELIVERING POSITIVE FINANCIAL RESULTS AND MODERN PRODUCTION TECHNOLOGY BY RICCARDO AMPOLLINI
O
pen house and gala evening for Mast’s MacPlas at the gala evening. “Because, today, TECHNOLOGY ON SHOW 50 years (stand B66, hall 13, at Plast we certainly have the people who had the idea IN THE PRODUCTION AREA 2018). The manufacturer of screws and and will to create the company to thank for this The open house featured a display of some of barrels celebrated its fiftieth anniversary at its 50th anniversary celebration, but also the people the most important and representative machine facility in Cagno, near Como, on July 7, 2017. who have sustained it: namely our clients and, tools that Mast uses to manufacture high quality The date of the event was no coincidence: July 7 equally important, our suppliers. Mast is in ‘ex- screws and barrels for plastic extrusion and also was, in fact, the birthday of the late Marino Arioli, cellent shape’ and is working towards its future though to a much lesser extent - for processcompany founder and the father of the current because of this combination of strength and will”. ing elastomers and raw materials for food uses. directors, Carlo and Marco, who “In more detail”, Carlo Arioli explained, spoke about him during the eve“we started up the two milling maning. What’s more, July 6 of 1967 chines we use to make screws. These was the date when Marino Arioli are machining centres made by the founded the company Mast, short Austrian Weingärtner, who we befor “Macchine Attrezzature Speciali lieve represents the state of the art per Termoplastici” (i.e. special mafor this technology. We also ran some chinery and equipment for thermogear-cutting machines to demonstrate plastics). how Mast makes the splined shafts of co-rotating twin screws, on which it The open house was attended by then assembles the individual screw the company’s 22 employees and elements: a very different technology many industry operators. “We wantfrom that of standard screw profiles. ed to invite our key suppliers and Lastly, the edgewheel grinding malong-standing clients to this event”, Owners and employees celebrate the fiftieth anniversary of Mast in front chine - the latest Mast investment up Carlo Arioli said in an interview with of a cake worthy of the occasion MACPLAS INTERNATIONAL AT PLAST 2018
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ANCILLARIES AND COMPONENTS
to September 2017 - and the boring machine put on a good show, which we use to make barrels for extruders”. “We work almost exclusively on extrusion technology for plastic and elastomers”, Carlo Arioli continued. “In fact, we have also made augers and processing compartments to blend the rubber, but not barrel-type mixers. In addition, although it’s a secondary operation, Mast has also made equipment for the food industry: extrusion technology very similar to plastic technology, where only the type of steel used and some accessories are changed”.
SCARCITY OF QUALIFIED PERSONNEL “Research and training for us is a big problem”, Carlo Arioli underscored, his only negative comment of the day. “In Cagno, in fact, we have always faced two problems when it comes to staff. The first is geographical: being very close to Switzerland, we face stiff competition when it comes to salaries, which are notoriously higher than in Italy, because of Switzerland’s higher cost of living. In the second place - and particularly in recent years - we have seen a lack of people who are truly interested and want to work in metalworking, even though today working in a workshop is an entirely different story than in the past. It appears, in fact, that the idea has come about that working on machine tools is not gratifying,
and that it’s almost a second-rate job. Unfortunately, in our minds, this perception is mistaken, because the machine tools of 50 years ago were very different from today, now they are fully programmable on a control panel”. “We participate in school work programmes and we have always had an interest in investing in new generations”, Marco Arioli added. “The fact that we need to train workers almost from scratch (because the equipment used in schools is very different from ours) is not a hurdle for us, we expect it. However, to date, we have had a really hard time finding young people who want to do our work. And to think that at this event today, some of our former employees have come looking for us”. Employees who have fond memories of Mast, we, at MacPlas, would like to add.
POSITIVE RESULTS AND EXPANSION PROJECTS “Despite problems in finding qualified and, more importantly, motivated workers”, Carlo Arioli continues, “in 2016, Mast recorded highly positive results. Naturally, we no longer see the same results we saw in the Sixties and the Eighties, but we can confirm that the company has been doing rather well - with numbers that continue to rise - for at least 5 or 6 years”. Also during the event on July 7, the two company directors announced that they will soon begin work to expand the production area at
1967-2017
Fifty years and a new logo In 2017, at its fiftieth anniversary, Mast also updated its corporate image. It in fact has changed its logo, choosing more sober graphics, intended to be In the picture, from the left, Marco Arioli, Carlo Arioli and, by his side, his wife, Fabiola Plebani, in front more effective. th “Reaching fifty years in business, we of the poster with the 50 anniversary Mast logo felt we needed to make our mark on this historic moment. The choice of a new logo marks a change in continuity, a sign of the past reflected in a modern key that expresses what Mast is today, a company projected towards the future but, at the same time, proud of its historic identity”, director Carlo Arioli said. The new brand, developed by the Brescia-based company Form, intends to evoke the idea of technology through a sober and minimalist design, but one capable of portraying dynamism and individualism. The choice of the colour blue gives it a more current and industrial look and delivers a more concise message, reflected also in the decisive and net cuts of the lettering chosen. In an age when overuse of messages confuses the point being communicated and the visual experience, Mast has now been condensed into a brand with fewer graphic marks than in the past, to increase recognisability and to be more memorable.
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Carlo Arioli, with some clients and suppliers, in front of a Weingärtner machining centre, which according to the owners of Mast, represents the state of the art in screw profile processing technology
The small barrel for twin screw extrusion, complete with screw profiles, made by employees for the 50th anniversary
the Cagno works. In the meantime, Mast has invested in a very modern machining centre, installed in September in the old site, the layout of which had to be adapted to accommodate the “new arrival”. “This was an old textile business, opened back in 1926, according to some documents that were found in the Municipality of Cagno”, Carlo Arioli points out. “So, despite the renovation projects already carried out over the years, we have to expand the warehouse used for manufacturing and also renovate the rest of the building (which, it should be remembered, is fully owned by the company, along with the surrounding land) to handle the work orders already received. We will stay at the same site, but increase in size to continue to expand our production capacity. The warehouse will be expanded to the rear, the same building where we held the gala reception”. “We invested, we are investing and we want to invest also in the future, because we intend to keep up with the times, and because we are looking at the next 50 years”, Carlo and Marco Arioli concluded almost in unison. www.mastsrl.it MACPLAS INTERNATIONAL AT PLAST 2018
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ELECTRIC DRIVE TECHNOLOGY FOR A SUSTAINABLE DEVELOPMENT
HALL 22 - A01/B02
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ANCILLARIES AND COMPONENTS NEWS TECHNOLOGY FOR BLOWN FILM EXTRUSION
Innovation comes from experience Established in 2006 as an idea to design and build equipment at the forefront of technology in blown film extrusion, Bmec (stand D32, hall 15, at Plast 2018) turned such idea into a brand. Finally, by cooperating with other manufacturers, the company became an icon of hi-tech and reliability, covering a wide range of products, from bubble cages to rotating haul offs up to conveying units and nips (up to large sizes, 5 to 8 metres). The know-how of three co-founders brought Bmec to success: the experience of Alessandro Santoro, who has been operating in this field since 2000, cooperating with leading Italian companies; the Sanplast company and Graziano Visintin, who played an unforgettable role. In 2014 the brand became an actual company owned by Santoro, who is also the technical manager. By using 3D technology to develop its projects, the dynamic company Bmec is able to satisfy the requests of clients in order to totally customize the machines. Optimal solutions are provided even in the most critical situations, where standard solutions available on the market cannot fit. Despite its young age, the company has wide experience and knowledge. As proof of this, two innovative patents were applied, which permit an improvement of machinery efficiency. The first patent is concerned with a rotating platform based on an innovative toothed rotation. This involves money savings due to costs comparable to common belts, but ensuring as high performances as those of conventional toothed rotations and silent chains. The second patent is the result of a deep study, which led to the development of a special oscillating haul off, with a new-generation nip laying inside a double randomizer, horizontal and vertical. This solution allows to fit two randomizers taking up the space of one: the double-stretching action thus considerably increases the yield of plastic materials. Bmec cooperates in full tuning with Sanplast, the company that was its starting point. Its products are sold and distributed only by the two companies: directly by Bmec or through Sanplast, who is the sole and unique licensee of the brand. www.bmec.eu
The special oscillating haul off developed and patented by Bmec
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Extrusion equipment
Small: the advantage to be nimble and flexible The advantage of being “small”, 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, without having to redefine structural equilibrium or production, and doing so relatively quickly. A company that knows this well is the Italian Eprotech (hall 13, stand A146), which has more than fifty years’ experience working with tools for extrusion using the know-how handed down by Pio Oleotti. Today the company offers an alternative to major groups, particularly those based in Germany or Austria, which normally turn down work orders that fall short of certain quantities, and which do not often stray from their standard, consolidated production lines. 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, an added value in its sales approach. 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. A reflection of Eprotech’s agility manoeuvring in fields that are relatively different, one of its projects involves com-
bining reclaimed and virgin materials through a co-extrusion process. 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 use of reclaimed material in combination with virgin materials is strategic and practical in today’s world, where it is imperative to cut costs and find new niche markets. The plastics processing segment, for some time now, has 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, including care for the environment, sustainability, environmentally friendly practices, all synonyms for a business approach that boosts a company’s image. 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. www.eprotechsrl.com
Die and calibrators by Eprotech MACPLAS INTERNATIONAL AT PLAST 2018
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Comerio Ercole’s calenders at Plast 2018
L configuration and 7-metre long rolls At Plast 2018, Comerio Ercole (hall 11, stand A61) presents, together with its subsidiary CKA, some important technological innovations recently developed for calendering machines and plants for plastics processing. In particular, the company unveils Flexi, a multi-purpose calender with high-precision hydraulic roll positioning, designed to work with 4 or 5 rolls according to the type of processed product (plasticised or rigid PVC sheets), thus obtaining 3 and 4 lamination banks, respectively, while keeping the same downstream stretching, embossing and cooling units. The new inverted L calender configuration, designed and patented by the two compa-
nies, enables the calender to grant high quality performances for a wide range of applications. During the show, a giant calender is also exhibited, featuring 7-meter long rolls and designed for the production of thermal/ acoustic insulation materials at process temperatures up to 260°C. The first giant calender has been commissioned and started up during 2017, and the customer, based on the results obtained in terms of process accuracy, has confirmed a new order for a second identical unit, to be delivered within the first quarter of 2018. It’s a great result for Comerio Ercole to have designed and built this calender, as well as the satisfaction of the customer and his
confirmation of the new order. These recent results were further strengthened on the basis of the service provided by the Comerio Ercole R&D team,
which allowed the development of new and innovative composite products on behalf of the final customer. www.comercole.it The comparison with operators and car gives an idea of the dimensions of the calenders produced by Comerio Ercole
THE EXTRUSION XXPERIENCE Nuovi standard produttivi con la tecnologia di estrusione Leistritz! all’avanguardia nell’ingegneria di processo e grande know how ottimizzazione dei processi produttivi e miglioramento della qualità
XXPERIENCE US! PLAST 2018 hall 13/booth A51 extruder@leistritz.com | www.leistritz.com MACPLAS INTERNATIONAL AT PLAST 2018
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ANCILLARIES AND COMPONENTS NEWS Hot runner solutions
Fast assembling and disassembling for a wide application range A number of additions and enhancements have been rolled out by Mold-Masters (hall 22, stand C141/D142 at Plast 2018) to Fusion-Series G2, the drop-in system favoured by the automotive industry for high-quality large part production. Maximized for uptime, the Fusion-Series G2 hot runner system is delivered completely pre-assembled and pre-plumbed, saving significant set-up time in order to get back into production right away. Incorporating popular features like field replaceable heater bands ensures that any maintenance is quick and easy. Capable of shot sizes from less than 15 g to over 3,500 g, Fusion G2 is favoured by automotive, appliance, logistic packaging, and similar industries focused on producing medium to
large high-quality parts. These systems also come fully supported by Mold-Masters global network. New are the F3000 and F8000 nozzles, which expand the capabilities and applications of this system. F3000 has a shot capacity of less than 15 g, which is ideal for smaller under hood components, technical automotive components and price sensitive packaging and consumer good applications. The F8000 increases shot capacity of the system further than ever before to 5,000 g by utilizing runner diameters up to 28 mm. Nozzle lengths are also available that exceed 1 m. F8000 has been developed to meet the processing requirements of common large automotive components like fascias, instrument panels, door panels and also large white goods.
Also new is the second generation of the Melt-Cube side gating hot runner that allows simultaneous direct side gating of up to 8 cavities per Cube for high cavitation moulds. Based on a successful advanced side gating technology, this version features a simplified design making it easier to maintain and service. Tips are clamped by a single bolt in sets of 2 (not entire assembly) which reduces assembly/ disassembly times by up to 85%. Manifolds can be accessed from the parting line and tips are located to gate. As with many Mold-Masters products this Melt-Cube also incorporates Brazed Heater Technology for precise thermal profile for enhanced processability and superior reliability that often outlasts
Doss strengthens its structures
New R&D centre and, soon, offices in North America and Asia An Italian company with more than twenty years of experience in visual inspection machines, Doss Visual Solution (DVS) is based in Erbusco, near Brescia, where a new R&D department of 600 square metres
has been added to the existing 1,220 square metres of offices and workshops, giving rise to a site employing about 60 people. At stand A21, hall 11, at Plast 2018, the company’s technical staff is presenting the latest developments in the world of artificial vision - in particular, key standard models such as the automatic dSort2 with piece self-recognition feature, and the dSort3T equipped with a 12 Mpx camera. The heart of DVS machines is a high-tech vision system ful-
A dSort3 inspection machine
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ly conceived and designed by in-house engineers and further optimized over the years based on the feedback from hundreds of applications around the world. The company lends its expertise to cover a wide range of manufactured goods (inspection of rubber and plastic items, but also glass, ceramic and metal products) in various sectors (automotive, pharmaceuticals, clothing, home appliances and so on). In the context of steady technological innovation, the new department dedicated to research and development will allow Doss to also face the hardest challenges in
Fusion G2 hot runner system has been improved to reduce assembling times and increase the productivity, above all in large dimensions applications
the life of the mould. Melt-Cube is known for its excellent vestige control, low-pressure drop and precise cavity-to-cavity rheological balance. Melt-Cube side gating eliminates wasteful sub-runners and offers higher pitch density than circular systems for greater production output. Perfect for deep draw medical parts such as pipette tips, syringe barrels, needle shields or parts where only side gating is permitted. www.milacron.com
the quality control and industrial automation sector. Aware of the importance today of being present and reactive even on markets on the other side of the ocean, Doss ensures an efficient after-sale assistance service to ensure timely intervention both remotely and on site. To this end, two new offices will soon be in operation in North America and Asia. A network of agents spanning the globe is among the strengths of the company, delivering direct and timely technical and sales support to the users of its products. The ability to meet even the most stringent requests, moreover, has enabled Doss to enter and consolidate various collaboration agreements with preferential suppliers to multinationals in the compound sector. www.doss.it
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Suitable solutions for improved reliability and higher performance
No compromise for pipe corrugators
The new no-compromise F200/50HP corrugator developed recently by Itib Machinery International is characterized by very high performance and primarily dedicated to the production of cable ducting pipes. The top-of-range version is displayed during Plast 2018 (hall 13, stand C142). The experience gained by the company in this application over the last 15 years brought to new technical solutions. A higher reliability of mechanical components of the machine, the optimization of some basic parameters for achieving much higher performance than the previous models and the development of new devices to allow high outputs in the whole range of tubes are the results of this R&D activity. In fact the F200/50HP corrugator features a new simple and solid system to move the moulds, which enables them to achieve a maximum mechanical running speed of 35 m/min. It includes also a new low-maintenance device for direct cooling of the inserts and a system to run the moulds in the closing and forming area bringing to a very short length of the die-set. This favourable condition involves lower values of melt pressure and the consequent increase of production speed even with small diameters, where speeds are often limited by this pa-
Mould running system of the F200HP pipe corrugator
rameter, rather than by the cooling capacity of the machine. The corrugator is thus very versatile and an optimal choice for the whole range of tubes from 40 to 200 mm. The direct cooling of aluminium moulds, the vacuum-assisted pipe forming and the possibility to open and close the forming channel are as in the previous models the main characteristics of the F200HP corrugator. In the same time, the optimization of the length of its cooling channel, the simplification of the system to move and cool the moulds result in a significant improvement in terms of productivity, flexibility, reliability and ease of use and maintenance. Also the electric and electronic systems are fully updated and, thanks to a router, offer the possibility to take advantage of the by-now indispensable remote service and to meet the specifications of a 4.0 industry ready machine. Like for the previous models, also a shorter version is available with 38 pairs of moulds and is addressed to markets more sensitive to the amount of the investment, which require lower productions but at the same time a reliable plant ensuring a high quality product too. www.itib-machinery.com
Thermoforming mechanics of emotions Since 1981
Via Dei Pioppi 3 . CH 6855 Stabio Switzerland Tel (+41) 91 6407050 Fax (+41) 91 6407059 sales@wm-thermoforming.com wm-thermoforming.com
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PLEASE visit us at PLAST 2018 Hall 13 - C31/D23
19/04/2018 09:38:26
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ANCILLARIES AND COMPONENTS NEWS Helios Quartz at Plast 2018
IR and UV solutions since 1940 A long standing group established in 1940, Helios Quartz boasts two factory sites, the historic one in Italy (Helios Italquartz) and the new factory premises in Switzerland (Helios Quartz Group) - together with a distribution network that covers all four corners of the globe (Europe, the United States, South America and Asia). The group, which has obtained the TÜV certificate, is extremely flexible and dynamic, with a highly international leaning, and is currently experiencing a period of sustained growth. It has become one of the leading international companies in the processing of quartz glass in the production of IR and UV lamps and appliances for industrial, scientific and medical applications. The key to its success lies in its over 70 years of experience in the field, with a highly specialized staff, and a multidisciplinary approach, which is geared to meeting customer needs and has the capacity for develop-
ing and delivering tailor-made solutions. This all means that Helios Quartz is able to supply high quality products and provide efficient and professional services. Its product range which was also presented during the Plast 2018 exhibition (stand C169, hall 13) includes: - Quartz IR lamps (in single or tworow tubes) either in short, medium or medium-fast wave; - IR units; - tubes, sheets and discs of quartz glass; - quartz glass articles according to drawings; - UV lamps and equipment for the curing of glues, inks, varnishes and resins that react to UV light; - UV ray kits and systems; - the Inve 2000 devices, for accelerated material ageing tests. The IR lamps and units made by Helios Quartz are particularly appreciated in the plastics and elastomers sector. The production range meets all the most common plastic
and rubber forming and processing needs from the sealing of plastic components to lamination, from the shrinking of heat shrink materials to the stretching/lengthening of plastic film. Furthermore, thanks to a thorough knowledge of production processing, Helios Quartz is able to design and develop tailored modules to meet specific customer needs. Its IR units in particular are fully wired and ready to connected on line, and fitted with a high temperature heat sensor and ventilation system in order to perfectly accommodate the IR lamps. Helios is also able to supply units ready to be assembled both on new and existing production lines. It can provide units of up to 6.5 m in length, complete with control systems to meet specific customer requirements. It has also set up a “Test centre” at its factory in Cambiago (near Milan) complete with instruments capable of testing the reaction of
IR unit produced by Helios Quartz
various kinds of materials (film and samples) when exposed to infrared radiation. Using the results of the testing undertaken with the various wavelengths, the company technicians are then able to go on to develop to best solution for each application and product. www.heliosquartz.com
25-year presence
Pelletizers at 360° In 2018 Filtec (hall 15, stand A21 at Plast 2018) celebrates 25 years of activity. Since its birth in 1993 the company has improved its machine technology and developed its presence in foreign markets. To be more and more present around the world giving
The Filtec staff in the renewed and enlarged lab
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an efficient support, it also cooperates with regional agencies. Another peculiarity of its activity is the high level of customization of its machines, always keeping in consideration the customer satisfaction. A wide range of machines and a high level of customization are the Filtec plus, but its strengths are the UW (Underwater) and GRO (Water-Ring) pelletizers. The first can granulate special products, even with high grade of fluidity, whilst the GRO simple and cheap model is suitable to granulate materials with a grade of fluidity lower than those processed through the UW type. The pelletizers range is completed by the GRO-D type (disaligned axes) and the GRV type (vertical axes). That means pelletizers at 360° ! The Filtec product range also includes other machines: VR vibrating classifiers/coolers, CV vertical dryers, CO horizontal dryers, UFR filtration unit and water cooling, CA sinlge or double plate screenchanger etc. Filtec also offers granulating trials and tests at its recently renewed and extended laboratory. www.filtec.it
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New cutter hub design
Increase the flow rate or reduce the rotation speed Leading European producer of films and laminates, Bischof + Klein reports that new-design cutter hubs by Nordson BKG (stand B152, hall 13), retrofitted on its pelletizers, have substantially increased blade life and improved pellet quality. Bischof-Klein uses BKG underwater pelletizers from Nordson Corporation within their compounding lines to mix colours and additives for its film manufacturing. When the company installed Nordson’s new BKG HiCut cutter hubs on two of its pelletizing lines, the blades mounted on the hubs lasted two to three times longer than those of the older design, and with some materials - particularly non-abrasive compounds - blade life was extended from a typical three days to nearly three weeks. In addition, the pellets produced with the blades exhibited fewer “tails”, which subsequently separated from the pellet as fines, can abrade or clog equipment, and represent a waste of polymer. “Because Nordson’s new design increased the number of blades on the hub by a factor of 50%, we were able to reduce the rotation speed of the cutter while maintaining our standard high level of throughput”, said Eduard Beifus, responsible for regenerates and concentrates at the Bischof + Klein site in Lengerich, Germany. “This decrease in driving speed led to a reduction in wear to the blades and a substantial increase in their lifespan”. In an underwater pelletizer, polymer strands emerge from the die plate,
solidify as they enter the water, and are then cut into pellets by the blades mounted on the cutter hub. The new HiCut design accommo- The HiCut hub and blades installed at Bischof + Klein dates up to 100% more angled blades per hub and up to 54% more straight blades. This makes possible an increase in throughput or, alternatively, a reduction in pelletizer RPM, which decreases wear to the die plate and blades. “The blades on BKG HiCut cutter hubs have round edges and smooth surfaces with countersunk screws. This optimizes the flow and reduces swirling, and there is more space between the blades so that pellets do not accumulate”, said Frank Asmuss, global product manager for BKG pelletizing systems. “For certain products, the increased throughput achieved with the new design makes it possible to invest in a smaller pelletizer, saving cost”. BKG HiCut designs are compatible with all existing pelletizer systems, and the hub accommodates both angled and straight blades. www.nordsonpolymerprocessing.com
29 MAY - 1 JUNE 2018 Stand 15 B/C 41/42
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ANCILLARIES AND COMPONENTS NEWS An important celebration for Fimic at Plast 2018
Human capital and quality products: strengths for 55 years At Plast 2018 (stand C152, hall 15), Fimic, together with its entire staff and the numerous visitors expected to visit its stand, is celebrating the company’s 55 years in the plastic materials industry. The fair sees the company presenting its most recent innovations, as well as its new ideas currently under development. The protagonists of the celebration of this important anniversary include, of course, well-established products from the manufacturer’s range, in particular the ERA filter, which was a finalist at the PRSE Awards in Amsterdam and one of the APR Plastic Recycling Showcase 2018 winners. Many years have gone by since Antonio Canaia, almost to test himself, produced his first filter, a photo of which he keeps in his office. But in all this time, the “engine” that has driven and guided him over the years, i.e. his passion, has never once faltered. Confucius said that if you do something you love, then you’ll never work another day in your life, and this is a motto that encapsulates the true strength of Fimic. Antonio is a team leader, who gets stuck in every day, getting his hands dirty and sharing the hard work with his “lads”; he is a great listener who instils confidence in them and gives them fuel for their ideas and initiatives. He is flanked by his wife Rosanna, a tireless factotum who takes care of the economic-financial and administrative side of things, working mostly “behind the scenes”, playing a key role as an organizer and pillar of the company, keeping everything on an even keel. And then there is their daughter Erica, who, embodying both the present and the future of Fimic, manages the commercial side with a mixture of tenacity, determination and farsightedness, injecting into the company the drive that has allowed it to grow exponentially in recent years. Last but not least is the 15-strong team of employees, who are regarded
A young team to pass on an experience of over fifty years
more as a family than a group of co-workers. This human capital, together with its high quality products, are the real strengths of Fimic. Each filter is made entirely in Italy, and sold only if the manufacturer is absolutely sure that it represents the ideal and most functional solution for the user. In the past two years, the company has undergone a rapid expansion and seen its payroll rise from eight to 15 people, partly a result of the growing attention paid to the after-sales phase. Indeed, Fimic considers the support it provides after the purchase of its products to be every bit as important as securing the purchase itself. www.fimic.it
South African supply for Herbold
From heavily contaminated waste to high quality film The first large-scale plant for the recycling of heavily contaminated PE film waste has recently started running in Germiston South, near Johannesburg (South Africa). Delivered by Herbold Meckesheim (present at Plast 2018 in the hall 15, stand D142), the plant can process up to 8,000 tons per year of film, used big bags and similar waste. The waste coming in bales are presorted, shredded and foreign bodies are separated by means of a prewashing unit in which also a first washing takes place. Afterwards, further contaminations are
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dissolved in a wet granulator under intensive friction; a subsequent friction washer separates the dirty water from the product. A hydrocyclone separates foreign plastics and specifically heavy contaminations from the target fraction. This separation process has a particularly high separation effect and ensures the high quality of the produced film flakes. In two drying steps, centrifugal dryer and hot air dryer, the product reaches a residual humidity, which is suitable for the further material processing to pellets in
Charles Müller (managing director) and Deon Swart (technical manager) in front of the Herbold plant
a downstream extruder. With this recycled material, high quality film can be produced. www.herbold.com
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A unique partner for a complete production line
Customized supply for coffee capsules Mouldmaking, vision control, liner cutting and insertion, welding and further camera control. A complete, precise and reliable process. A brand name that ensures value and absolute quality, from the study to the design and finally to the machinery manufacturing. Gefit (hall 24, stand B101) confirms its position amongst the leaders in manufacturing of equipment for production of coffee capsules, certainly one of the products that have been standing out in the packaging market during the latest years. The company presents itself as a unique partner: from design and manufacturing of moulds for thermoplastics, Gefit joins the production of vision control cells for capsules with lining machine, including the welding phase. In a few words, a complete production line, totally customized according to the specific requirements of every single client. In the Moulds & Assembly headquarters, the activity always starts with accurate preliminary analysis, deep study of materials and parameters, cooling circuits and systems, reliability and accuracy of tools for cutting and inserting the liner and of the welding system. Very often a prototyping phase is carried out before the industrial production, and also in this case Gefit can provide support to its customers, with solutions specially developed for each project. Besides the production of moulds for capsules, that are sometimes
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co-injected, the company also proposes a large range of machinery to complete the production process. The fast Gefvision is a cell for A complete cycle of coffee vision control, that recently has nearly capsules production reached the output of 100,000 piecthrough Gefit equipment es per hour and that can perfectly fit the requirements of coffee capsule producers. Geflining is a platform particularly created for cutting, inserting and welding the liner into the coffee capsules, able to reach the same amazing output levels. Thanks to its long experience in production of machinery for food packaging, Gefit has successfully stepped in the market of single-serve capsules, a product that is nowadays present in shops and supermarkets with several shapes and flavours. Offers and proposals for this particular range of products have quickly met the strong interest of customers, not only for complete lines but also for moulds, lining machines or cells for quality control of the production. www.gefit.com
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ANCILLARIES AND COMPONENTS NEWS Frigosystem between present and future Moulds for 360° packaging
Practical and light food containers
Practical and light containers for food sauces made by a single injection moulding through two OMMP moulds
One of the latest projects of OMMPMoulds (stand B76, hall 22, at Plast 2018) for injection moulding consists in two moulds with four cavities suitable for producing 30 and 50 ml plastics containers for food sauces. The moulder needed to realize a simple item with body and cover in a single piece, with a high productivity rate and reliability. Therefore OMMP developed two moulds with valve gate nozzles able to produce 3,200 container per hour. Moreover, the moulder also needed the products to be as light as possible and the moulds from OMMP allow obtaining containers of 30 ml weighing 3,7 grams and containers of 50 ml weighing 5 grams. Today OMMP-Moulds is an expert in manufacturing injection moulds for caps and closures, especially for the beverage industry. The mould-maker covers the packaging field at 360° by manufacturing both blow moulds (for extrusion blow moulding and PET blow moulding) and injection moulds (for closures and PET preforms), offering processors the possibility to produce a complete package. www.ommp.it A modular PFV system
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Ready for the changing industrial refrigeration Strengthened by the research and experience of 50 years of activity, Frigosystem (hall 15, stand B82 at Plast 2018) finds itself well positioned by the request to increase energy efficiency, imposed by the new European regulation Ecodesign 2018 in the field of industrial refrigeration. The legislation, which came into force on January 1, requires compliance with minimum thresholds for the SEPR (Seasonal Energy Performance Ratio), that are the parameters that determine the energy class, and which must be complied with for CE certification purposes. Frigosystem has welcomed this orientation, finding it in tune with its corporate philosophy. The developments recently proposed by the company reflect the attention paid to technological innovations in refrigeration: some high efficiency gases have already been introduced in many ranges and, for some years now, Frigosystem also offers chillers with magnetic levitation compressors, where SEPR reaches double values compared to the minimum required by the updating of European legislation. The completely new project of the Natu-RA chillers involves units of up to approx. 100 kW of cooling capacity. The combination of R410 gas with increased microchannel condensers, totally in aluminium, allows for smaller compact units, with considerable savings in electrical consumption. The field of use has also been expanded, especially regarding minimum and maximum environmental temperatures. Being “plug & play” units, the Natu-RA series maintains the characteristics of versatility and easy installation that have always distinguished Frigosystem units. The Italian manufacturer is strongly referenced in large installations and have developed the new series of Raca Heavy Duty (RHD) industrial chillers, using refrigerant R134 and robust screw compressors, state-of-the-art electronic controllers, efficient shell and tube heat exchangers, and microchannel condensers specific for heavy-duty applications. All of which allow the RHD series to obtain increased cooling capacities of up to 25% compared to the standard models. The series offer units of up to 2300 kW, also available with inverter drive and integrated free-cooling, to further reduce payback times of the plant where environmen-
tal and operating conditions allow. The RHD series guarantees high precision and constant temperature. The available versions can operate in all the climatic zones of the world, including those with the most extreme conditions. All Frigosystem production can be interfaced with the innovative FS i-Link system, the exclusive and proprietary electronic device that allows you to connect any units to the internet, allowing remote control as well as the teleservice from every continent. Machine status, alarms and temperature management can all be viewed and managed from every connected web device, be it a mobile phone or a more complete management system. FS i-Link is a crucial accessory for speedy diagnosis and intervention, a great support both for OEM customers and for end users. At events in 2018, important innovations in the field of thermoregulation will be presented. New models in the TMO series are aimed at customers of Corema, a part of the Frigosystem group. Improvements include: increased pump capacity and heating power up to 200 kW; the repositioning of the expansion vessel facilitates start-up; improved optimisation to various applications operating when diathermic oil is not always of good quality, and resolution of any issues caused by air sometimes present in the circuit, or from poor maintenance to the plants. www.frigosystem.it
Fifty years of activity allow Frigosystem to be always ready for change, both for the plastics processors needs and for industrial refrigeration regulations MACPLAS INTERNATIONAL AT PLAST 2018
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Screen changers for extrusion lines
BDOx3 BF triple-plate continuous flow back flushing screen changer
Turnkey package for continuous flow With an output rate up to 1,200 screen changers per year, BD Plast confirms itself as the favourite partner of extrusion line manufacturers in Italy, Europe, North America and Asia. The steady and sustainable growth of the last few years has further strengthened and cemented the company position in an increasingly demanding market in terms of quality, product customization and safety standards. In this sense, the participation at Plast 2018 (hall 15, stand B61) assumes an even more incisive and relevant significance for the level of development and evolution of the products on display. Three absolute novelties are presented in advance. BDOx3 BF is a triple-plate continuous flow back flushing screen changer. The result of an accurate study deriving from a number of machines already tested in several applications, it represents a technical solution quite different from those most commonly seen on the market. Both from the technical and management stand point, the BDOx3 BF fully reflects the BD Plast philosophy of creating high performance machines that are at the same time user friendly and of easy maintenance. First of its kind, it provides an automatic system for extracting the filtering packs completely controlled by PLC. This system considerably simplifies and speeds up the replacement operations of screen packs for a full efficiency advantage and for the level of automation achieved.
The extremely effective back flushing system allows to reduce, up to two thirds, the amount of purged polymer thus generating a significant reduction of waste. The polymer discharge channels during the replacement of screen packs are inspectable and easily accessible in case of obstruction. Both during the back flushing phases and the replacement of the filtering media, 66% of the total filtering area remains in the working position, allowing a high flow continuity and pressure homogeneity. The purged polymer is then collected in a cooling tank connected to the protections by means of a magnetic sensor so as to guarantee absolute safety during the material purging phases. The machine is combined with a PLC control equipped with a touch screen that permits the most extensive adjustment of the functions of the cleaning cycles as well as remote control via LAN. BDOx-6 is a double-plate continuous flow changer with optimized
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flow channels. The sixth generation of continuous flow screen changers has been subjected to a careful ergonomic and functional study which led to a significant reduction in the angle between the flow channels, which has passed from 100° to 40° of inclination. The polymer stream is therefore much more linear and favourable in terms of flow. The overall dimensions have been reduced (by 20%) as well as the number of components in order to obtain a simpler but at the same time more performing product. The level of safety has been significantly increased by adopting coded and certified magnetic sensors in “performance level E”, interconnecting the position control sensors of the screen changer plates with the hydraulic control unit in a crossed and redundant way. BDLG is a manual changer with gear and ratchet drive. An accurate study made it possible to create units of medium-large filtering area on more compact and
rigid machine housings. The reduction of the mass led to a 20% reduction of energy consumption, emphasizing the company’s sensitivity towards an eco-compatible approach. The increasingly particular market demand have led BD Plast to develop in recent years a growing number of machine systems fully customized according to the specific requests of each customer. Integrated platforms have been designed where the screen changer is completed with adapters, volumetric pumps with gearbox and cardan shaft, melt pipes and static mixers. These systems offer to extrusion lines manufacturers the opportunity to concentrate on their technology, receiving a turnkey package designed to integrate perfectly with their system, reducing design costs and simplifying internal management. Quality of products and service aimed at customer satisfaction. www.bdplast.com
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ANCILLARIES AND COMPONENTS NEWS 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 22, stand B141) has continually worked to provide processors with innovation, expertise, flexibility, service and, of course, high quality moulds. Primary emphasis has been placed
A multi-cavity mould from Giurgola Stampi
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 fairs 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 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
An exhaustive range of products
Filtration for all Specialized in filtration, FM Filter Monza operates in the sectors of pneumatic transport, dust extraction, compressors and vacuum pumps. Its production range includes air filters, dust filters, oil filters, oil separators filters, coalescing filters and separators, filters for industrial applications. The filters supplied have a structure made of materials that employ the latest technologies in order to offer a product with features targeted to use. The filters have excellent retention and separation capabilities. The materials used in the products offered use media such as resin filter paper, polyesters
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also laminated with meltblown, laminated microfibres. In other cases the products have nanofiltration, alumination, hydroscopic, oleophobic, PTFE coating. Stainless steel is adopted for applications where a high thermal or mechanical resistance is required, or for contact with water or solvents. This extensive experience on filters and their applications means that customers, present mainly in Europe, during plant maintenance turn to FM Filter Monza for filter replacement, also to solve the problems of filtration/separation in their products. www.fmfilter.it
The FM Filter product range includes air filters, dust filters, oil filters, oil separators filters, coalescing filters and separators, filters for industrial applications
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May 29 th - June 1st Hall 22 stand A41-B42
Come to see our applications LET YOURSELF BE AMAZED BY HIGH QUALITY OF ITALIAN BRAND PAR EXCELLENCE
14 Featured applications at Plast 2018 - Come and see how you can optimize productivity. Let yourself be surprised by the speed of Gunshot, the versatility of SM2, the performance of Mini Modula IML and by all our solutions designed to meet the challenges of the market in terms of performance, reliability and safety, paying utmost attention to the integration of Smart technologies according to INDUSTRY 4.0 directives.
Hall 24 Hall 24 Stand A21-B22 Stand A151-B152
Crates
Cutlery
Hall 24 Stand B81-C82
IML
Hall 22 Stand A41-B42
Hall 22 Stand B41-C42
24
Hall 22 Stand A101-B102
22
w w w. c a m p e t e l l a . c o m
Campetella Robotic Center Srl - Via Grazia Deledda, 40/42 - 62010 Montecassiano (MC) - Italy - Tel. (+39) 0733 29891 - Fax. (+39) 0733 298912 FOLLOW US:
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RUBBER OR THERMOPLASTIC? BOTH IN ONE SOLUTION
ThermoplasTic copolyesTer elasTomers
Via Leonardo Da Vinci, 5 - 27036 MORTARA (PV) - Italy Tel. +39 0384 295237 • Fax + 39 0384 295084 sipol@sipol.com • www.sipol.com
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MATERIALS AND APPLICATIONS
EPTA
The properties of pultruded profiles make them well suited to numerous applications in the residential housing market, where they provide strong, durable solutions, outperforming traditional materials
AN EPTA INDUSTRY BRIEFING
Opportunities for composite profiles in the residential housing market 25 YEARS AGO PULTRUDED GLASS FIBRE COMPOSITE WAS WIDELY UNKNOWN IN THE BUILDING AND CONSTRUCTION MARKET. TODAY, MORE ARCHITECTS, ENGINEERS AND BUILDERS ARE DISCOVERING ITS BENEFITS AND FINDING WAYS TO INCORPORATE IT AROUND THE HOME BY EPTA*
P
ultrusion is a continuous process for producing linear fibre reinforced plastic (FRP, or composite) profiles with a uniform cross-section. In the pultrusion machine the reinforcing fibres are impregnated with resin and pulled through a heated die, where curing takes place. The finished profiles are cut to length at the end of the line and can then be stored and used as structural units when required. The pultrusion operation can be readily automated, allowing for low labour involvement, and is therefore a fast, efficient way of producing high performance composite parts. Pultrusion offers the designer major freedom regarding the geometry, properties and design of the finished profile. In fact, both solid and hollow profiles can be manufactured, in simple and complex cross-sectional shapes, including tubes, rods, I-beams, T-, U- and Z-profiles. Since pultrusion allows for extremely high fibre loading and accurately-controlled resin content, pultruded parts have excellent structural properties and are produced at a consistently high quality. A range of reinforcing fibres, and formats, can be used, including glass and carbon fibre, and a variety of thermoset matrix resins, including polyester, epoxy and vinyl ester, as well as thermoplastic resins. Reinforcement, resin and additives can be combined in innumerable ways to ensure that the finished profile provides the optimum combination of properties required for a specific application. In the residential housing market glass fibre MACPLAS INTERNATIONAL AT PLAST 2018
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An immense variety of profile shapes is possible with pultrusion
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MATERIALS AND APPLICATIONS
reinforced polyester resin (GRP) is the preferred choice. Pultruded profiles are pigmented throughout the thickness of the part and can be made to virtually any colour. Surfacing veils may be employed to create special appearances such as wood grain, marble and granite. Profiles can also be painted, cut and drilled using conventional hardened tools, and connected using bolts, screws, rivets or adhesives. A durable UV-resistant coating is typically applied to profiles intended for outdoor use. A number of standards have been developed covering the design, fabrication and installation of pultruded profiles. Work towards new European technical specifications for the design and verification of composite structures used in buildings, bridges and construction works is currently being conducted by Working Group WG4 “Fibre Reinforced Polymers” under the European Committee for Standardisation (CEN) Technical Committee 250 (CEN/TC250). At the end of their service life pultruded profiles can be recycled. A grinding process results in a by-product that can be used as a filler in building materials such as concrete and asphalt, or reused in the pultrusion process as a filler in the matrix resin. An important advance in Europe involves the recycling of glass fibre-based composite regrind through co-processing in cement kilns. This route is becoming increasingly popular since it is highly cost effective, helps to improve the ecological footprint of cement manufacturing, and is compliant with the European Waste Framework Directive (WFD) 2008/98/EC. The composite regrind used for co-processing in cement kilns is both an alternative fuel and raw material (AFR).
TAB. 1 - A COMPARISON OF THE PROPERTIES OF PULTRUDED COMPOSITE WITH ALTERNATIVE BUILDING MATERIALS Material
Specific weight (g/m3)
Tensile strength (MPa)
Elastic modulus (GPa)
Thermal expansion coefficient (K-1)
Thermal conductivity (W/mK)
Wood
0.7
80
12
14 x 10-6
0.1
PVC
1.4
70
3
85 x 10
-6
0.1
Pultruded glass fibre composite*
1.8
240 (axial) 50 (transverse)
23 (axial) 7 (transverse)
11 x 10-6
0.3
Aluminium
2.7
250
70
23 x 10-6
170
Steel
7.8
400
210
12 x 10
40
*According to EN 13 706
nation of properties not available with the traditional building materials of wood, steel, aluminium and PVC (see table 1). Lightweight - Pultruded profiles are 80% lighter than steel and approximately 30% the weight of aluminium. They are therefore easily transported, handled and installed, resulting in lower costs. Complete structures can often be pre-assembled and shipped to the job site ready for installation. High strength - Glass fibre composites have excellent mechanical properties, delivering higher strength than steel and aluminium on a kgfor-kg basis. Composites are anisotropic materials and pultruded profiles deliver their highest strength values in the lengthwise (axial) direction. By varying the orientation and format of the reinforcements it is possible to optimise the required strength or stiffness in the direction in which these properties are required. Considerable design freedom can be gained by the capability of adding extra strength in highly stressed areas. THE COMPOSITES ADVANTAGE Parts consolidation - With composite materiPultruded glass fibre composites offer a combi- als a designer is able to integrate various separate parts and functions into Pultruded profiles offer one profile and to design flexibility in the construction of highly energy create complicatefficient window systems ed shapes which are not possible with other materials. This reduces the number of fabricated parts and, as there are less parts to join together, installation is easier. Single composite parts can replace complex assemblies of multiple
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-6
parts that are produced with traditional materials such as wood, steel or aluminium. Corrosion resistance - Glass fibre composite is stable, inert, and impervious to moisture and a broad range of chemical elements. Pultruded products will not rot or rust and require minimal maintenance compared with traditional building materials. Composites are the material of choice for outdoor exposure - in coastal areas, for example, where homes are exposed to airborne and waterborne salt agents. Durability - Composite structures have a long life span. Many well-designed composite structures are still in use after 50 years of service. Coupled with their low maintenance requirements, this longevity is a key benefit. Thermal insulation - Glass fibre composite has a low thermal conductivity. This is a significant advantage for applications where energy loss must be minimised, such as window and door systems, thermal breaks and cladding. Dimensional stability - Glass fibre composite has a low coefficient of thermal expansion and pultruded profiles will not expand, shrink or warp. High and low temperature capabilities Glass fibre profiles maintain excellent mechanical properties at elevated and very low temperatures (even down to -50°C). Electrical insulator - Glass fibre profiles are electrically non-conductive and ideal for components in current carrying applications.
APPLICATIONS IN THE RESIDENTIAL HOUSING MARKET Pultruded glass fibre composite is viewed as a new material option that can meet the most stringent demands and offers manufacturers, dealers and distributors the ability to differentiate themselves in a highly competitive marketplace. The low maintenance, durability and high strength characteristics of pultruded composites are attractive to both home owners, who MACPLAS INTERNATIONAL AT PLAST 2018
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want to reduce maintenance time and expense, and contractors wanting to reduce service recalls. Pultruded profiles in window systems have earned a maintenance-free reputation over the last 20 years and are recognised for superior performance in dimensional stability and thermal performance. This has led to opportunities for pultruded composite to replace wood, PVC and aluminium in a variety of other applications including exterior trim, decking, columns, pergolas and arbours, as well as railings, fencing and decking. Projects have also demonstrated the application of pultruded profiles to low cost modular housing systems.
ENERGY EFFICIENT WINDOWS AND DOORS Pultruded glass fibre composite was introduced to the window market in the 1980s. Initially employed in individual components, all-composite framing systems were gradually developed. The benefits of composite profiles include better overall strength, durability and thermal performance, combined with excellent flexibility in design. Today pultruded composite is widely accepted by window producers as a premium material that must be considered when designing top of the range, energy efficient systems. Composite frames enable the production of window systems with very low U factors, delivering significant energy savings for the home owner. Composites also answer the needs of designers and builders wishing to go beyond the limitations inherent with wood, PVC or metal frames. The thermal performance of glass fibre composite makes it a natural choice for energy efficient windows. As an excellent thermal insulator
it limits thermal bridging, reducing condensation and subsequent issues with mould. Pultruded frames exhibit superior dimensional stability in hot and cold environments and will not warp, expand or shrink. The low coefficient of thermal expansion of glass fibre composite is very similar to that of glass, and so the frames expand and contract at the same rate as the glass. This results in less stress on the window seals and lower incidents of seal failure, limiting air leaks and moisture infiltration. Given their inherent corrosion resistant properties pultruded frames are also extremely durable. They will not rot or rust and can be used in harsh coastal environments. Frames are typically painted or coated to provide a finish that provides UV resistance against fading and cracking and enhanced abrasion resistance. These factors combine to give composite frames a longer life expectancy than PVC, wood and aluminium alternatives, with minimal maintenance requirements. The high mechanical strength of pultruded composite means slimmer frames are possible, which enables a larger viewing area and lets more light into the home. Composite systems can be designed to withstand high levels of wind load, and they provide increased security through greater resistance to forced entry. Pultruded profiles also offer great design flexibility. Taking advantage of the mechanical properties of pultruded composite architects are able to create bigger units, holding larger expanses of glass, and different shapes, to meet unique customer specifications. Frames can be produced to closely resemble painted wood or other finishes, and the customer is able to change the colour of the frames by painting if desired.
There are numerous applications for pultruded profiles in the window and door sector, such as: window sashes, frames and mullions; door and sliding door sills and frames; door internal stiffener profiles; insulating cores for metal windows and doors; internal profiles for fire safety doors; thermally insulating stiffeners for PVC; thermal breaks; and brise-soleil (solar shading) systems and shutters. Green building codes and standards driving the design and construction of more energy-efficient buildings will favour the increased use of pultruded window and door components. Glass fibre composite systems are also becoming more competitive on price, and this, together with considerations of life cycle costs and return on investment, will make pultruded products more attractive to buyers.
THERMAL BREAKS Thermal bridging through steel and concrete framing can have a significant impact on a building’s energy performance. Reducing thermal bridging reduces conduction of heat and energy consumption, and prevents surface condensation from forming inside the building. Because of its superior thermal performance, glass fibre composite is a good option to provide thermal breaks between the home’s interior and exterior steelwork or concrete to prevent thermal bridging. Various projects and applications are being developed in this area.
EXTERIOR TRIM The corrosion resistant properties of composite materials make them ideal for products exposed to the weather. Pultruded roof trim, fascia and soffit are extremely tough and durable and provide a low maintenance solution whilst maintaining the appearance of wood. The lightweight profiles are easy to transport, handle and install. Pultruded profiles are also being used in roof rain gutters. In some cases the gutter system and fascia are combined in a single pultruded piece, reducing the labour required for installation. Pultruded gutters have a smooth inner finish to prevent deposits.
CLADDING
A heightened focus on green building practices and energy efficient homes will lead to more opportunities for pultruded profiles MACPLAS INTERNATIONAL AT PLAST 2018
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Pultruded glass fibre composite offers a stronger, more durable cladding (siding) system than wood, metal, PVC or fibre cement cladding. The installed product is almost maintenance-free, providing the look of painted wood without the need for regular staining, treatment or painting. Composite cladding is impervious to moisture, withstands extreme temperatures and will not buckle like PVC alternatives. It is resistant to chipping,
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MATERIALS AND APPLICATIONS
breaking and splintering, and unlike many types of wood siding is not affected by ants and termites. Lightweight composite products are easier to install than heavy fibre cement boards. Available in a range of widths and colours, pultruded cladding provides a hard-wearing, protective layer against the elements and is an excellent insulator.
PERGOLAS AND ARBOURS Pergola systems based on glass fibre composite beams offer advantages over wood, PVC and aluminium. Corrosion resistant pultruded beams can deliver the look of painted wood without the maintenance requirements or risk of rot. They are stronger than PVC, with less expansion and contraction in extreme temperatures, and will not dent like aluminium. The composite will not rust, chip, fade or crack. Because of the strength of composite profiles, rafters can span longer lengths than wood or PVC versions, with minimal deflection, and fewer columns are needed. These strength and spanning capabilities also enable accessories such as lattice and canvas to be supported. A pultruded structural pergola system allows for designs ranging from simple to highly elaborate, and ease of assembly makes installation quick and simple.
roto cast glass fibre columns and are lighter in weight, making them easier to ship, handle and install. Unlike wooden columns, pultruded columns are not prone to rot, fading, attack by insects, warping and moisture.
FENCING AND DECKING SYSTEMS Pultruded glass fibre composite handrails and fencing systems are strong, attractive and offer a longer lifespan than wood, metal and PVC products. Wood splinters, stains, warps and requires regular repainting. Aluminium, steel and wrought iron oxidise, discolour and rust, increasing maintenance costs and risking safety. PVC offers no comparable strength or durability to composite and degrades rapidly in coastal environments. Composite fencing enables longer spans than PVC, reducing the number of vertical posts required. Composite is the clear material of choice for a coastal environment, since it can survive corrosive salt water environments without rot, rust or corrosion. Glass fibre composite handrail and fencing can be made in a variety of colours, and pickets and rails can be combined to create a unique system. Pultruded decking is an attractive, low-maintenance alternative to traditional decking materials such as wood and is particularly suited to applications where stronger decking is required. The panels will not rot, rust, chip or mildew, and are ideal for high-moisture environments, including saltwater.
AFFORDABLE HOUSING SYSTEMS COLUMNS Another growing trend for pultrusion is columns to support porticos, porches and other roof assemblies. Pultruded exterior decorative and structural columns are strong, easy to install, and maintenance free. They can achieve higher structural/load bearing ratings than
Demand for affordable housing is growing throughout the world. Pultruded profiles open up opportunities for low maintenance, highly energy efficient homes that are fast to build and easy to alter and reuse. The lightweight pultruded components result in reduced shipping costs, and lightweight houses are easier to build and require
less energy to heat. Modular buildings can be designed in which all the parts are prefabricated to fit neatly together without cutting, reducing labour and waste on site. The Startlink system is one example of a modular construction system for low-cost thermally efficient homes based on a small number of pultruded profiles that bolt and “snap-fit” together enabling rapid assembly. House builder Larkfleet Homes opened a Startlink test house alongside its UK headquarters in 2012; this weighs just 18 tons compared with a conventional 40-ton house. Because of the snap-fit assembly it is easy to alter or extend Startlink buildings, and they can be dismantled for reuse elsewhere if desired. The composite is stable, inert and impervious to moisture, requiring only the addition of insulation to build houses. Thermal bridging is eliminated and the inherent dimensional stability of pultruded profiles means that air tightness is easily achieved. By avoiding steel and concrete, Startlink houses are quick to build and up to 25% cheaper than traditional buildings. Because pultruded profiles are so light, concrete foundations would not be needed. Instead, a Startlink building would be best supported on pultruded piles driven into the ground and the quantities of raw materials and energy required to construct the foundation would be a tiny fraction of those required in a conventional building. With appropriate insulation, the Startlink house has embodied energy only 20% greater than that of a conventional timber framed building (containing kiln-dried, double vacuum treated timber and raised from mass concrete footings) of the same floor plan area and built to the same Passivhaus compliant standard. However, the Startlink house needs no maintenance and is rot and termite proof. It may also be possible to construct such homes in areas where flood risks mean that the construction of conventional buildings is not viable. If built and furnished with suitable flooring material and decorative finishes on the ground floor, Startlink homes are highly “flood resistant” since the absence of extensive foundations and the nature of the pultruded materials means that the structure is unaffected by water. Lightweight flat-pack houses also have a role in disaster relief. Easy to transport and simple and fast to construct, pultruded buildings could be employed as temporary accommodation for people displaced during natural disasters such as hurricanes. When no longer required the buildings could be dismantled and transported to another site, or stored until needed again.
www.pultruders.org
Startlink is a pultruded component kit which can be rapidly assembled into a variety of low-rise building forms without metal fastenings
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Conta-Clip
MATERIALS AND APPLICATIONS
AT PLAST 2018 (STAND D62, HALL 9), KRAIBURG TPE WILL PRESENT ALL ITS NEW DEVELOPMENTS, WHICH INCLUDE, FOR EXAMPLE: HALOGEN-FREE FLAME RETARDANT MATERIALS (CATEGORY V0) FOR E&E APPLICATIONS; NEW THERMOLAST K FAMILY FOR 2-COMPONENT AUTOMOTIVE APPLICATIONS WITH EPDM; FOOD COMPLIANT AND ABSOLUTELY LEAK-PROOF SEALS FOR BOTTLES AND CUPS; THERMOLAST M COMPOUNDS APPROVED FOR USE IN DIRECT CONTACT WITH BLOOD AND MEDICATIONS
Easy assembly and fast installation thanks to the modular cable entry system KDSClick from Conta-Clip with inlays and seal elements of thermoplastic elastomers from Kraiburg TPE
CUSTOM-ENGINEERED TPES AND MORE
STRONG ADHESION FROM THE VERY START W ith KDSClick, the German connection technology manufacturer Conta-Clip has created an extremely flexible cable entry system that comprises inlays and various seal elements manufactured using thermoplastic elastomers (TPE) from Kraiburg TPE. The halogen-free system offers users in the electric and electronic industry a very flexible and efficient solution for new installations and retrofitting of cables and hoses, as well as pneumatic and hydraulic lines in enclosures and control cabinets. The systems make use of no fewer than five different thermoplastic elastomers from Kraiburg TPE: a PA adhesion-optimised Thermolast K compound for the system inlay seal, in addition to flame retardant and custom-engineered TPE materials for sealing elements (see opening picture at the beginning of this article). One of the challenges of the system was to
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ensure an absolutely reliable seal of the frame mounted on the control cabinet in accordance with IP 66 protection, as required in process and industrial automation. The frame consists of glass-fibre reinforced PA 6.6 and a TPE compound. It was necessary to find a TPE material that enables excellent adhesion to polyamides and is soft enough to adapt to different surfaces in order to seal the system. Conta-Clip decided to use a Thermolast K adhesion-optimised TPE compound that is processed with the polyamide of the inlay in a two-component injection moulding process. The material features excellent adhesion and ensures a reliable seal even on painted or rough surfaces. The system also includes seal elements of different sizes, which enclose the cables, hoses and profiles. In close cooperation, Conta-Clip and Kraiburg TPE optimised the design of the
Window trim and sealing profiles made of EPDM with moulded Thermolast K corner joints and end elements
seal elements to achieve IP 66 protection. The slotted elements are designed for easy installation and exact enclosure of the cables without deformation. The Thermolast K materials used for the KDSClick are self-extinguishing in accordance with UL94 and are rated as non-dripping (Category V0). In addition, they are halogenfree in accordance with IEC 61249-2-21. MACPLAS INTERNATIONAL AT PLAST 2018
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The automotive industry is the largest and fastest-growing market for thermoplastic elastomers. New applications exist for the segment of door and window seals, which require dimensionally stable corner joints and end elements. This has been achieved in the past with styrene-butadiene compounds (SBC) and crosslinked thermoplastic vulcanized (TPV) rubber. The cost-effectiveness of TPV is limited, however, due to diverse factors in the manufacturing process, in particular the window trim. The EPDM adhesion series from Kraiburg TPE offers a good alternative with added value. “The production of diverse sealing frames and window trims of EPDM profiles with moulded corner and end elements requires new material solutions”, declared Michael Pollmann, sales and marketing director EMEA at Kraiburg TPE. “The versatility of our TPE technology has made it possible to develop a competitive material that solves the phase separation problems of the systems that are currently used”. The core requirements for corner joints and end elements of window trim profiles include excellent adhesion and weathering resistance, which are ensured by the long-term process stability of the TPE/rubber connection. It is also necessary to minimise the injection temperature of the TPE solutions in order to reduce the cooling and cycle times of the 2-component elements. The AD/EPDM/UV (where AD = adhesion, EPDM = ethylene propylene diene monomer rubber, UV = UV resistance) series fulfils all of these requirements by combining optimal adhesion properties with long-term resistance to UV radiation and thermal effects, with a hardness of 70 Shore A. Compared to competitive materials, these special TPE products exhibit superior stability. The EPDM profile is neither compressed, nor destroyed or deformed. The compounds feature uniform colour fastness of EPDM and TPE and there is no tendency of stickiness or phase separation.
ABSOLUTELY LEAK-PROOF WITH TPE A cup of coffee in the morning, tea at lunchtime and mineral water during the evening workout. Whether at home, in the fitness studio or at work, we always have to ensure a sufficient intake of liquids for our well-being. The trend is away from disposable bottles and paper cups toward intelligently designed reusable containers of high-quality materials that are both pure and durable. The reusable Omni Line and Cruise Line products from Timolino are available in diverse MACPLAS INTERNATIONAL AT PLAST 2018
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models of stainless steel, plastic or silicate glass for cold, hot and carbonated beverages. Different quick-release lids - from the classic flip top to the screw or dial top, both with a tea strainer, as well as the sports or kids top, with an integrated straw - fulfil specific requirements for the respective use. All lids feature an absolutely leak-proof sealing, as a result of a special Thermolast K developed by Kraiburg TPE for contact with foods and beverages. The TPE compounds are used as a sealing ring in the lids of the beverage systems and as part of a preformed, injection moulded block. Like all parts of Timolino products, the sealing components are 100% neutral in taste and odour, free of bisphenol A (BPA), dishwasher-safe and recyclable. The application fundamentally required a technologically advanced seal compound with guaranteed compatibility with foodstuffs and a long life. The TPE compound used by the company fulfils the stringent requirements of the Code of Federal Regulations, Title 21 (CFR21) of the USA Food and Drug Administration (FDA), as well as EU directive 10/2011 for plastic materials and plastic objects. In addition, the material features an outstanding compression set throughout a broad temperature range. This property was decisive for sealing components that feature permanent resiliency and elasticity without embrittlement even after repeated contact with hot beverages, after cleaning in a dishwasher or at low refrigerator temperatures.
Omni Line drinking bottles from Timolino made of copolyester with Flip Top, including a sealing made of food compliant Thermolast K
passed standard biocompatibility certifications. These portfolio materials are certified according to DIN ISO 10993-5 (cytotoxicity), -10 (intracutaneous irritation), -11 (acute system toxicity), USP Class VI (chapter 88), and DIN ISO 10993-4 (hemolysis). These certifications enable processing of the compounds for use in direct contact with medications and blood. In addition, a drug master file (DMF) for the materials is on file with the US Food and Drug Administration (FDA). MAXIMUM PURITY AND CONFORMITY Kraiburg TPE is therefore committed to consistent adherence to the speciFOR MEDICAL AND PHARMA fied formulation and manufacturMARKETS ing process. After announcement Purity, tolerance, quality, continof a change, the company guaruous availability and safety of the antees delivery for a period of 24 materials used are top priorities in months and also has the purity of medical technology and are subject the raw materials guaranteed by to stringent regulations. These are its suppliers. the principles Aptar Pharma also The Aptar “Ophthalmic Squeeze focuses on. For decades the comDispenser” is thus the only repany has been setting standards peated-use dosing system far for spraying and dosing systems approved by the FDA for liquid for medical applications includmedications that do not contain ing nasal spray pumps, inhalers, preservatives. The design condrop dispensers and injectors. To tains no metal parts whatsoever further optimize their “Ophthalmic in the drug flux and is therefore Squeeze Dispenser”, the manufacalso suitable for very sensitive turer sought a thermoplastic proformulations. The purely mecessable material that allows direct chanical functioning principle of contact with medications. The re- Ophthalmic squeeze the seal membrane and spring sult is a new component manu- dispenser (OSD) from unit eliminates the possibility of factured from a new Thermolast M Aptar Pharma with components made of microbiological contamination of material developed for the medical Thermolast M medical the liquid. and pharmaceutical market. grade for direct contact Thermolast M compounds have with medications www.kraiburg-tpe.com Aptar Pharma, 2017
EXCELLENT ADHESION AND UV RESISTANCE
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MATERIALS AND APPLICATIONS
MODIFIED PPG FOR THERMOPLASTIC COPOLYESTER ELASTOMERS
ENHANCED CRYSTALLIZATION RATE A MAIN DISADVANTAGE OF TPC-ET IS ITS RELATIVELY SLOW HARDENING SPEED FROM MOLTEN TO SOLID STATE, WHICH LEADS TO LONGER CYCLE TIMES IN INJECTION MOULDING. THE HARDENING SPEED OF A TPC-ET CAN BE IMPROVED BY USING PTMEG WITH HIGHER MOLECULAR WEIGHT BUT INVOLVING A DETERIORATION OF THE BEHAVIOUR. VARIOUS POLYETHERS WERE TESTED BY SIPOL TO DEVELOP A POLY-ETHER-ESTER WITH INCREASED CRYSTALLIZATION RATE
T
hermoplastic copolyester elastomers (TPC-ET) are segmented block copolymers obtained through the combination of rigid segments (polyesters) and soft segments (polyethers). These products offer outstanding properties for what concerns the mechanical properties (tensile strength, tear strength, impact strength, and creep resistance) which, compared to most other thermoplastics, are much less affected by temperature variations. In addition, their partial “polyester” backbone provides these products with a chemical resistance which is superior to other common thermoplastic elastomers. Typically the crystalline part of a TPC-ET is a PBT short chain (or a modified PBT) and the amorphous component is a polyether based on polytetramethylene ether glycol (PTMEG).
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The ratio of the two components as well as the length of their polymer chains provide the product with different combinations of hardness, melting point and other distinctive properties. The Sipolprene range, developed and manufactured by Sipol (stand B111, hall 9, at Plast
2018), covers hardnesses from Shore D 25 to 72 with melting points between 150 and 220°C. One of the main weaknesses of TPC-ET is connected to their processing: their relatively slow hardening speed from molten to solid state leads to longer cycle times in injection moulding because of the long cooling time in the mould. Similar limitations can be observed when TPCET is extruded.
EFFECT OF DIFFERENT POLYETHERS ON CRYSTALLIZATION RATE
Typical applications of Sipolprene TPC-ET
Studies proved that the hardening speed of a TPC-ET can be improved by using PTMEG with higher molecular weight. Disadvantage is a deterioration of the behaviour at low temperatures. An alternative way to increase the hardening speed without compromising on the MACPLAS INTERNATIONAL AT PLAST 2018
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TABLE 2- PHYSICAL AND MECHANICAL PROPERTIES Properties low temperature behaviour is to use a different polyether than PTMEG. The Italian company Sipol started working on the evolution of Sipolprene 55200 (PTMEG-based TPC-ET, 52 Shore D) by testing various polyethers chemically different from PTMEG to develop a poly-ether-ester with increased crystallization rate. After several tests, a class of modified polypropylene glycols, offering a good balance of reactivity, availability, and performance, was identified. The improvement of the crystallization rate was tested by injection moulding and was measured via DSC (Differential Scanning Calorimetry).
INJECTION MOULDING TESTS AND MECHANICAL CHARACTERIZATION Sipolprene 55211 (with modified PPG) and
TABLE 1 - COOLING AND CYCLE TIMES Material
Sipolprene 55211
Sipolprene 55200
Cooling time measured (s)
11
14
Total cycle time (s)
19
22
U.M.
Sipolprene 55211
Sipolprene 55200
Density ISO 1183 g/cm3 1.21 Sipolprene 55200 were Hardness (instantaneous) ISO 868 Sh D 54 processed under similar conditions on the Melting temperature ISO 3146 °C 215 same injection moulding Strength at break ISO 527 MPa 39 machine and trying to Elongation at break ISO 527 % 570 achieve the fastest cyIzod impact strength ASTM cle time during the proJ/m 120 (notched at -40°C) D256 cess. Table 1 shows an Water absorption (24h improvement in cool% 2.10 immersion at 23°C) ing time and cycle time, while table 2 shows the comparison of mechanical properties of the two Dynamic crystallization is generally used to asproducts. sess the ability of a polymer to start the crystalThe selected polyether causes a moderate re- lization process in non-equilibrium conditions: duction of tensile/flexural properties but also a higher crystallization temperature indicates leads to a substantial improvement of low tem- that the polymer has the tendency to start nuperature impact strength. The change of poly- cleation of crystals sooner than polymers with ether leads to a higher melting point of the poly- lower Tc. Isothermal crystallization is used mers even if hardness is the same. to determine crystallization kinetics and behaviour of polymers. The same temperature CRYSTALLIZATION KINETICS is maintained for a set period of time and the The investigation of crystallization kinetics was polymer is free to release all the energy related carried out with DSC at the Laboratory of Ma- to the crystallization process over time. Both terials and Polymers (LaMPo), Università degli these studies proved the high tendency of Studi di Milano. This technique is fundamental Sipolprene 55211 to crystallize in comparison both for the study of dynamic and isothermal to Sipolprene 55200. crystallization behaviour. www.sipol.com
Hall 13 Booth B72
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MATERIALS AND APPLICATIONS
POLYAMIDE 6.6
IMPROVING AUTOMOTIVE PERFORMANCE A
utomotive trends are driving demand for high-performance engineered plastics. One of the world’s largest fully integrated producer of polyamide 6.6 resins, Ascend Performance Materials, is meeting that demand with PA66 solutions for internal combustion, hybrid and electric powertrains. Innovative engineered plastics, like Ascend’s Vydyne J series, are helping OEMs reduce weight, increase electrification and improve fuel efficiency. The company is committed to continuous, reliable supply throughout the polyamide 6.6 value chain. Recent and planned capacity expansions are designed to grow with the market and ensure moulders, tier one suppliers and OEMs have the materials they need to move automotive technology forward. Ascend Performance Materials exhibited a
AT VDI PLASTICS IN AUTOMOTIVE ENGINEERING CONGRESS AND DURING RECENT PLASTICS INDUSTRY EXHIBITIONS LIKE PLAST 2018, ASCEND PERFORMANCE MATERIALS FOCUSED ON HYBRID AND EV SOLUTIONS AND RELIABLE SUPPLY
wide number of automotive solutions, including Vydyne J series for hybrid and electric vehicles, at the VDI - International Congress of Plastics in Automotive Engineering, March 1415, Mannheim, Germany. John Saunders (EU regional business director), Volker Kessler (segment manager Automotive Europe) and Frank Volg (business development) were on hand to speak to the company’s efforts to meet demand and develop plastics for an ever-increasing number of automotive applications.
PA66 AUTOMOTIVE AND E&E INNOVATIONS TAKE CENTER STAGE UTO ED E&E IN PRIMO PIANO
Ascend PA66 automotive and E&E innovations take centre stage at Plast 2018
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After its participation at the exhibitions Fakuma and Plastindia, Ascend Performance Materials showcases at Plast 2018 (Stand B01, Hall 9) numerous product and application innovations for automotive and electric and electronic applications.
Growing Vydyne family is helping solve automotive industry challenges to increase fuel efficiency and improve performance and comfort. These products find use in applications ranging from fasteners and electrical connectors to under-the-hood and external components, and are particularly prized for their ability to perform in harsh environments. Ascend’s latest PA66 compounds exhibit enhanced high temperature and hydrolysis resistance. PA66-based compound ranges include the glass-filled, heat-stabilized Vydyne H series, Vydyne HR series with best-in-class hydrolysis performance, and Vydyne HT series which provides high levels of resistance to property degradation after long-term heat exposure beneficial in turbo-charged systems. The company will also show several compounds with critical roles in hybrid and electric vehicles. The impact-modified Vydyne 40H and the electrically-neutral Vydyne J series are used to manage and protect the wiring that relays power MACPLAS INTERNATIONAL AT PLAST 2018
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and information throughout the vehicle. These compounds are ideal for hybrid and EV connectors, cable jacketing, cable ties and fasteners. “The shift already underway in the auto industry requires innovation and technology,” said Scott Rook, Ascend’s vice president of Polyamide business unit. “Our newest Vydyne PA66 compounds are not only innovative in their own right, but they spur innovation in engineering and design”.
SUPERIOR INSULATION, HIGH FIRE RESISTANCE FOR E&E For consumer, commercial and automotive E&E, Ascend offers Vydyne grades developed to meet increasing demands for safety, reliability and performance. The company’s new Vydyne FR350J, for example, is an unreinforced, flame-retardant material ideal for connectors used in unattended domestic appliances. A second recent introduction, Vydyne ECO366H, is an unreinforced PA66 grade that obtains a UL94 V-0 rating at thicknesses as low as 0.4 mm; it exhibits best-in-class RTI electrical (the relative thermal index associated with critical electrical insulating properties) of 150°C, making it ideal for terminal blocks. ECO366H exhibits superior melt flow and low plate-out for intricate parts and delivers good stiffness/impact balance, chemical resistance and superior thermal resistance. “Our E&E products are pushing the envelope in terms of performance and processing”, said Ed Nerlich, Ascend’s E&E global segment leader. “FR350J and ECO 366H offer unique properties and finished part performance. They are also very easy to process; saving time and money”.
A HIGH PERFORMANCE PA66 FOR ELECTRICAL COMPONENTS IN UNATTENDED APPLIANCES Vydyne FR350J is a new high performance compound based on PA66 that brings extra safety to electrical connectors used in unattended home appliances. In addition to excellent electrical and flammability properties, Vydyne FR350J also exhibits high ductility and elongation at break (15%), providing engineers with greater freedom when designing parts such as living hinges and snap fits. The new unreinforced, flame-retardant compound also has superior melt flow and requires lower pressure to fill moulds; reducing cycle times and production costs. The unreinforced grade is better than the reinforced one, because it allows to produce more flexible electrical connectors for this application (home appliances). FR350J has a wide processing window and is colour stable for natural and colorable applications. MACPLAS INTERNATIONAL AT PLAST 2018
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“Home appliances are getting smarter and demand for these so-called ‘smart’ products continues to grow. That means they will incorporate more electronics and more connectors”, said Vikram Gopal, Ascend’s vice president of technology. “Vydyne FR350J will make sure that appliances are safe as well as smart”. Additional features of Vydyne FR350J include an RTI electrical rating of 130°C (RTI is the relative temperature index; RTI electrical is an indication of how critical electrical insulating properties vary with temperature) and a UL94 V-0 flammability rating at thicknesses down to 0.4 mm. The flame retardant additive package is Reach and RoHS compliant and exhibits low corrosion for improved electrical contact performance. FR350J exhibits also the best-in-class GWIT (Glow Wire Ignition Temperature) rating with
Ascend introduces new high performance PA66 for electrical components in unattended appliances
zero flame: 960°C at all thicknesses (up to 3.0 mm), according to the test method IEC 606951-13. Finished moulded parts tested according to IEC 60335-1 achieved glow-wire end product test values of 750°C at all thicknesses. Vydyne FR350J also achieves PLC 0 ratings in hot wire ignition (HWI) and high amp arc ignition (HAI) tests carried out according to UL 746A. www.ascendmaterials.com
To address growing market demand
Ascend to increase capacity of PA 6.6 building blocks On October 30, Ascend Performance Materials announced its plans to increase production capacity across its intermediate chemicals and polymers portfolio by 10 to 15% to support the continued growth of its customers. “The global demand for polyamide 6.6 and our intermediate chemicals continues to grow at 3 to 4% per year in a range of diverse applications”, said Phil McDivitt, Ascend’s president and CEO. “Ascend has cost effective expansion opportunities that allow us to bring additional capacity online as the market needs it”. The company will increase capacity of adiponitrile (ADN), hexamethylene diamine (HMD), adipic acid and polymers through 2018. Ascend’s unique production process allows for quick capacity additions
with high capital efficiency and without disruption to operations. “We have consistently added capacity through our entire polyamide 6.6 value chain since 2015, increasing our production by 10 to 30% depending on the product with no impact on our customers. We are committed to a continuous, reliable supply to our customers”, added McDivitt. Unlike many other PA66 producers, Ascend sells polymers and intermediates into nearly every end use market and geography. “Our more than 60year history of serving a wide variety of markets has given us an unparalleled understanding of the entire polyamide 6.6 value chain”, said Scott Rook, Ascend’s vice president of nylon business. “The unique qualities of PA66 have made it the material of
“Our energy and capital are focused on supporting customers throughout the PA 6.6 value chain. Our recent capacity additions in Greenwood and Foley are in line with our current expansion plan and help us keep pace with market demand”, declared Scott Rook, Commercial VP, Polyamide
choice in numerous innovative applications”. “Our capital efficient expansion plans ensure that market demand is met and pricing remains competitive”, continued Rook. Earlier in 2017, the company also consolidated PA fibre production at its plant in Greenwood, South Carolina, and added compounding capacity at its site in Foley, Alabama, to better align its business with the market. The company did not disclose the amount of capital investment related to the expanded production capacity.
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MATERIALS AND APPLICATIONS
NEWS Technical compounds and masterbatches
Plentiful array of colours and effects Established in 1997 and built on over thirty years of experience in the production and colouring of engineering polymers, Color Tech has become a specialist in the production of technical compounds and masterbatches. Its main goal is to act as a reliable partner for customers, assuring both competence and professionalism. Over the years a wide range of products has been developed to best meet the needs of different markets by making know-how available, to study and advise on tailored products that provide the specific technical and colorimetric characteristics required by processors. From compounds to masterbatches, the products in
the range are used in a whole variety of applications and sectors, including the household appliance, automotive, electric & electronic industries as well as furniture, toys, houseware, food and packaging. The compound division has specialized in the production of ABS, ASA, SAN, PC, PS, PP, PMMA compounds and PC/ABS and PC/ASA alloys, with a whole range of different grades offering specific features: high-impact, heat resistant, flame retardant, added with various mineral fillers, glass fibre reinforced, natural, coloured according to Ral, Pantone, NCS samples, special effects and with various kinds of additives. On request, the company is also able
Different application fields for Color Tech compounds and masterbatches
to provide eco-sustainable grades of most of its compounds, which are made using selected raw materials, either totally or partially originating from industrial waste. The masterbatch division produces various types of colours and effects for every plastic material, white, black, coloured according toRal, Pantone, NCS samples, transparent, fluorescent, metallised, pearl effect, special effects with various kinds of additives such as anti-UV, antistatic, antibacterial, anti-oxidant etc. All the products are available on various carriers (PE, PP, PS, SAN, PC, PA, PMMA) compatible with the type of material and the sector for which they are used whether it be for moulding, blow moulding, ex-
trusion etc. All formulations are free of heavy metals and comply with the RoHS directive and the Reach regulation. According to the customer’s specific requests, they can comply with the various Italian and international standards for food and toys. The company is able to assure that its products are of the highest standard thanks to ongoing technological investment into the most advanced production equipment and laboratory instruments, the care given to raw materials selection and its constant commitment to research. The ISO 9001 and ISO 14001 certificates guarantee product quality and environmental sustainability. www.colortech.biz
Gummiwerk Kraiburg at Plast 2018
Direct integration of rubber in fibre composite materials and metal
Use of Kraibon for a B-pillar project with Topia
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To meet the growing requirements for chemical resistance and thermal stability, Gummiwerk Kraiburg has expanded its product portfolio to include perfluor-elastomer-based (FFKM) compounds. This high-tech material is suitable for different applications. The materials of this product family start where other elastomers reach their limits. They are used in vacuum technology, as well as the chemical industry, machine construction and the semiconductor industry. They are also used in the oil and gas sector. Furthermore, the company developed Kraibon for the lightweight construction sector. It consists of non-crosslinked rubber foils that can be integrated in a production step of the existing manufacturing process: Kraibon can be processed like prepreg (fabric that is pre-impregnated with resin) and adheres excellently to FRP (FRC, GFRP, SMC
etc.) and also to metal during the joint hardening process. At Plast 2018 Gummiwerk Kraiburg, a company of the Kraiburg Group, presents its materials in hall 11, stand C31. Amongst other products, it shows a roll in the Italian colours, as well as innovative roll compounds with special adhesive properties and extremely good abrasion. The company has been producing rubber compounds since 1947 and, today, it offers compounds based on virtually all elastomer types, including silicone and fluoroelastomers for all common dry rubber processing technologies. Kraiburg compounds are used in the automotive sector, in machine construction, oil and gas production, roll production and by numerous other manufacturers of moulded rubber components.s. www.kraiburg-rubber-compounds.com
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MATERIALS AND APPLICATIONS
Purging compounds to improve the regeneration process
NEWS Decrease of production costs and environmental impact
Purging compounds for waste All polymers are generated from hydrocarbons or their derivatives, either originating from crude oil or biological sources such as cellulose, fatty acids or other sources. The chemical bonds on which a polymer is based, are very strong and stable during time. Polymers have a long-lasting life, are weather resistant and extremely strong: they can be found almost everywhere in daily life under form of different objects. But unfortunately they have a very low degree of biodegradability and consequently a remarkable environmental impact. Due to this fact it is very important that polymers are either recycled and re-used when waste or reduced to a minimum quantity. It is
also important to change as few as possible virgin polymers into waste material without having completed the function for which they are processed. A polymer cannot be recycled infinitively, particularly PET recycling includes regradation too. But if production becomes waste before entering the end user markets, these polymers must be recycled in a correct manner. During a colour change from a dark colour to a clear one, the first shots of processed parts have the socalled “stripes”, or other kinds of pollutions originating from the previous production. If we consider that a certain first choice virgin material has a price (X), a certain electric energy quantity (E) has been
used for its production, machine and operator time (T) employed, as well as a regranulation and/or regradation time (Tr) and an energy quantity for its regranulation/ regradation (Er), in order to obtain a final product decreased by value (Xr) compared to the initial product price, we can observe a time and capital loss (Ls - loss due to scraps) which can be quantified as follows: Ls = X+E+T+Er+Tr-Xr From this equation we can deduce that there are three different manners to reduce the production costs: 1) reduce waste production; 2) increase production duration; 3) improve the regeneration process for scraps. The best way to reduce the production costs is point 1 as it is not
always possible to act on points 2 or 3. Thanks to modern purging compounds it is possible to reduce from 2 to 200 times the waste production during colour change. The higher is the efficiency of the purging compound the lower will be the consumption of material for the scrap. Marketed by Ultra System (stand B101, hall 22 at Plast 2018), the grades Ultra Plast PET-C, PETCS, and PAC (for barrier material) for PET items , PO-C and PO-CS for caps and PE/PP bottles as well as POE-CS for film/foil production, can help considerably in reducing waste production. Last but not least, all these purging compounds are FDA and food approved (CE 10/2011) and can be recycled. www.ultrasystem.ch
Francesco Franceschetti Elastomeri at Plast with new products
Expanding masterbatches for injection moulding and extrusion In January 2018 Francesco Franceschetti Elastomeri introduced on the market the new range of Masterefran expanding masterbatches announced by Giulia Franceschetti at the TPE conference, on November 2017 in Munich (Germany): “We decided to invest our 30 years of experience in the development of a new process on a new production line specifically designed in collaboration with All Masterfran products are Leistritz”. designed for both The Masterfran range, that injection moulding Francesco Franceschetti and extrusion Elastomeri also presents
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at Plast 2018 (stand C75, hall 9), are expanding masters where the active principle is incorporated in a polymeric support (often EVA) which makes it compatible with many plastic materials such as TPE-S, polyolefins, PVC, EVA, EPDM, polyurethane etc. The careful management and the strict control of pressure and temperature in the production line allow a steady reproducibility from batch to batch as well as a consistent dispersion of the active ingredient inside the carrier. Masterfran are based both on physical expanding principles and on mixtures of physical and endothermic expanding principles with concentrations up to 65% in order to offer different levels and different types of expansion and to satisfy all the markets and applications. In addition to the innovative product, we offer technical support to the customer by validating the degree of simulated expansion for the
final product in the laboratory and we also provide assistance during the moulding phase. “To date”, says the sales manager Domenico Uccheddu, “we sell these products to customers who need excellent performance in light weighting, to customers who are looking for a lightweight material but with high mechanical performance but also to customers who use small quantities of expanding masters to solve common problems of sink marks and shrinkage, typical of injection moulding. Excellent results obtained in extrusion with important lightening of the finished product”. The product is sold in 25 kg bags, appropriately initialized according to product class, and it also complies with the following regulations for food contact: (EU) No 10/2011 and amendments; Italian Ministerial Decree of March 21, 1973 and amendments; FDA, US Food & Drug Administration. www.f-franceschetti.it
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Masterbatches
When colours represent an added value 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 its biodegradable ommp-pagina-pubblicitaria-172x125-v3 products, Biomasterbatches (registered trademark), develop14-05-2018.pdf 4 14/05/2018 14:39:39 ing a second generation for these biopolymers, molecularly modified and
Since 1971, Vanetti has been producing masterbatches, biomasterbatches and additives to colour all types of thermoplastic resins for a diverse range of applications. Quality of products is ensured by ISO 9001:2008 certification
rendered even more adaptable to processing. In recognition for its work, the Italian company received the “Vinçotte OK compost” certificate which attests to the quality of the Biomasterbatches and ensures their suitability for colouring new-generation biopolymers. The greatest advantages of using Biomasterbatches are the ease of dispersion and easy processing during production, in compliance with the latest European regulations governing biodegradation. These products are designed for application with PLA, Mater-Bi, and all the new biodegradable polymers. In addition to masterbatches and biomasterbatches, Vanetti also offers customers a 360° service for the processing of plastic materials. Its additives, for instance, supplement the basic molecular aspects when added to plastic during the production of a finished product, thereby creating a new product with technical characteristics specifically designed to satisfy the processors’ requirements. The company exhibits its products at Plast 2018 (stand C131/D132, hall 9), the most important European plastics and rubber trade show of this year. www.vanettimaster.com
MOULDS MANUFACTURING Target Industries C
PACKAGING for PHARMA BEVERAGE - FOOD HOUSEHOLD and INDUSTRY PERSONAL CARE
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INJECTION - PET PREFORM - EXTRUSION BLOW - PET BLOW
Technologies
OMMP-MOULDS S.r.l. Via Milano, 10 23875 Osnago (LC) - Italy
MACPLAS INTERNATIONAL AT PLAST 2018
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Phone: +39 039 952 31 info@ommp.it - www.ommp.it
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MATERIALS AND APPLICATIONS
NEWS Exciting target for a young compounding company Grafe Group at Plast 2018
Micro and fine granules for rotational moulding The company HD Kunststoffe, from Remscheid (Germany), has undergone many changes since becoming a member of the Grafe Group, in January 2015. At Plast 2018, the specialists in the manufacture of raw materials for rotational moulding presents its expanded service and product portfolio at the Grafe’s stand A02, in hall 9. In addition to PE grinding powder, the range of products from the Remscheid company includes primarily PE and PP micro-granules as well as pigment powder mixtures (Colormix) for dry blends. “The merger has resulted in many further advantages for our customers”, according to Carlos Caro, sales representative at HD Kunststoffe. “By utilizing Grafe’s comprehensive know-how in the area of manufacturing and stabilization of customized compounds and masterbatches, we have been able to significantly expand our production and development capabilities at HD Kunststoffe. Through the cooperation we are now also able to provide small quantities of customized, ready-coloured PE grinding powder”, adds Caro. Availability of minimum amounts is important for the small quantities of specific coloured products often required in the field of design elements which follow colour trends. In recent months, development has focused on expanding the HD product portfolio for halogenated and halogen-free flame-retardant PE micro-granules and powder, as well as electrically conductive PE powder. However, HD Kunststoffe also provides micro and fine granules in other rotational plastics such as ABS, PS, PC and PA6/12. In addition, the company from Remscheid offers antistatic PE and PP powder for ESD applications in light and bright colours. Measurements showed resistance significantly lower than 10E9 ohm. The compounds contain migrating substances making them suitable only for industrial applications where there is no contact with any food. In addition to providing a service technician for matching, HD Kunststoffe also has a mobile templogger to record real time machine parameters (furnace temperature, tool temperature, PIAT) during production. With roto-simulation software, it is now possible to provide Comparison customers with prebetween cise evaluation of standard granules and data and thus optimicrogranules mal support for their by HD needs. Kunststoffe www.grafe.com (Grafe Group)
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Fluoroelastomers 4.0 The challenges of any industrial sector are mainly focused on quality, price and efficiency. In particular, the rubber industries have to fight on a tough field, as it is defined and regulated by the needs of sectors that are always very sensitive to these aspects and are always looking for technological innovations that can improve, sometimes radically, the performance of finished products. In such context it is nowadays necessary that a company that wants to be successful on all fronts, takes action to become an industry 4.0. This expression was used for the first time in 2011 at the Hannover Fair to introduce a German project related to the industries of the future, which in its strategy also included schools, research institutes and infrastructures. It was then adopted by many governments, including the Italian one, which have implemented concrete measures and promulgated dedicated plans. Elastomers Union (stand A11, hall 11, at Plast 2018), an Italian company established in 2009 that produces fluoroelastomer compounds, decided to follow the path of innovation to pursue the goal of becoming a smart factory, renewing its production facilities, improving its IT infrastructure and taking care of the energy impact. The aim is to increase the quality of finished products, be
Processing of fluoroelastomer compound
Quality control during production process
economically competitive and respond effectively and efficiently to market requests, never forgetting the need for a lower impact on the environment. The weighing and dosing system, the main production line and the computerization of production processes are the major areas of prior intervention decided by the company, relying on top-quality suppliers and sector specialists. The weighing/dosing system has been designed and refined to eliminate human error and to achieve, thanks to an innovative transport system, a very high precision in the dosage of raw materials. The main production line will be soon replaced by a last-generation intermeshing mixer and its laboratory mixer. Today both the production lines are equipped with a dedicated laboratory mixer that allows, therefore, to conceive each compound according to the line on which it will be produced. Everything has been conceived and designed within the frame of a new and complete computerization of the production process, that makes it possible to trace the production, highlighting anomalies just in time and recording the complete history of production operations carried out for each supply. www.elastomersunion.it MACPLAS INTERNATIONAL AT PLAST 2018
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TRADE FAIRS AND CONFERENCES
MEETINGS & CONGRESSES Belgium June 20-21 - Brussels: Biobased Coatings Europe - ACI Europe (www.wplgroup.com/aci/ event/biobased-coatings-conference) September 25 - Brussels: Plastics Packaging Conference - EuPC (www.plasticsconverters.eu)
France July 4-5 - Lyon: MedPharmPlast Europe EuPC (www.medpharmplasteurope.org)
Germany June 19-20 - Cologne: Medical Tubing - AMI (www.ami.international/events/) June 26-28 - Düsseldorf: PEPP, Polyethylene/ Polypropylene Chain Global Technology & Business Forum - IHS Markit (www.ihsmarkit.com/PEPP2018) June 27-28 - Essen: Plastics Recycling World AMI (www.ami.international/events/) June 27-28 - Essen: Compounding World Conference - AMI (www.ami.international/events/) September 5-6 - Cologne: Performance Polyamides - AMI (www.ami.international/events/)
Italy May 29 - Milan: Plast 2018 - Inaugural Conference “Driving the change” - The Innovation Alliance (www.theinnovationalliance.it) May 29 - Milan: Plast 2018 - The digital DMAIC to support lean & energy management - Cesap (www.cesap.com) May 29 - Milan: Plast 2018 - New developments of composites in the circular economy age - Assocompositi (www.assocompositi.it) May 29-31 - Milan: Plast 2018, at 11 a.m. and at 3 p.m., Conferences of ChemOrbis about rate trends of PE, PP, PS/ABS, PVC and PET (h. 4 p.m.) - ChemOrbis (www.chemorbis.com) May 30 - Milan: Plast 2018 - Elastomers 4.0 AIM (www.aim.it) May 30 - Milan: Plast 2018 - Plasma technology for industrial solutions - Plasmapps (www.plasmapps.com) May 30 - Milan: Plast 2018 - Conference of Sumitomo (SHI) Demag - Sumitomo (SHI) Demag (www.sumitomo-shi-demag.eu) May 30 - Milan: Plast 2018 - 3D Printing for 4.0 Companies - Cherry Consulting, Netconsulting3 (www.cherryconsulting.it,
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www.netconsultingcube.com) May 30 - Milan: Plast 2018 - Arburg Press Conference - Arburg (www.arburg.com) May 30 - Milan: Plast 2018 - EPS Circular Economy - Future is today - Aipe (www.aipe.biz) May 30 - Milan: Plast 2018 - Austria Showcase Introduction of Austrian Companies - Advantage Austria, Consulate General of Austria (www. advantageaustria.org/it) May 30 - Milan: Plast 2018 - “To Inject” productivity through the use of advanced lubricants - ExxonMobil Fuels & Lubricants (www.mobil.com/industrial) May 31st - Milan: Plast 2018 - Circular Economy and Plastic Strategy: PVC, recycle and new formulations - PVC Forum Italia (www.pvcforum.it) May 31st - Milan: Plast 2018 - Think green: sustainability, safety and environmental quality of PVC - Laborplast (www.laborplast.net) May 31st - Milan: Plast 2018 - Radici Novacips Press Conference - Radici Novacips (www.radicigroup.com) June 1st - Milan: Plast 2018 - Innovation, safety and sustainability of plastic food packaging as part of the circular economy - Amaplast (www.amaplast.org); III (www.istitutoitalianoimballaggio.it); Plasticseurope (www.plasticseurope.org/it); Unionplast (www.federazionegommaplastica.it) June 1st- Milan: Plast 2018, from 10:30 until 11:30 a.m., Conferences of ChemOrbis about rate trends of PE, PP, PET and rPET ChemOrbis (www.chemorbis.com) June 5 - Cologno al Serio (BG): Polyamides: properties, uses and types - Plastinnova (www.plastinnova.it) June 6 - Cologno al Serio (BG): Preparation of the material before processing - Plastinnova (www.plastinnova.it) June 14 - Cologno al Serio (BG): Long Fibre-Reinforced Thermoplastic: Evolution, Advantages and Applications - Plastinnova (www.plastinnova.it) June 19-20 - Cologno al Serio (BG): Essential standards of design for manufactured articles realized by injection moulding - Plastinnova (www.plastinnova.it) June 27-28 - Cologno al Serio (BG): Vulcanizable rubber: properties, uses and processing - Plastinnova (www.plastinnova.it)
United Kingdom September 26-27 - Manchester: Carbon
Dioxide Utilisation Summit - ACI (www.wplgroup.com/aci/event/co2)
Spain September 3-5 - Madrid: Masterbatch - AMI (www.ami.international/events/) September 17-19 - Madrid: Agricultural Film AMI (www.ami.international/events/)
United States June 5-6 - Houston (Texas): Oil & Gas Polymer Engineering - AMI (www.ami.international/events/) June 5-7 - Grand Rapids (Michigan): Automotive Plastic Part Design Seminar - ETS, Engineering Training Services (http://ets-corp.com/automotive.htm) June 5-8 - Chicago (Illinois): WOW, World Of Wipes - Inda (Association of the Nonwoven Fabrics Industry - www.inda.org/events) June 19-20 - Pittsburgh (Pennsylvania): Polymer Foam - AMI (www.ami.international/events/) June 19-20 - Philadelphia (Pennsylvania): Polymers in Cables - AMI (www.ami.international/events/) June 25-26 - Atlanta (Georgia): PETnology Americas - PETnology (www.petnologyamericas.com) June 27-28 - Cleveland (Ohio): Silicone Elastomers US Summit - Smithers Rapra (https://www.smithersrapra.com/events/ conference) June 27-28 - Cleveland (Ohio): Thermoplastic Elastomers US Summit - Smithers Rapra (https://www.smithersrapra.com/events/ conference) June 27-28 - Chicago (Illinois): Composites in Transportation - JEC Group (www.jeccomposites.com) September 18-20 - Akron (Ohio): Thermoplastic Elastomers Conference - SPE (www.4spe.org/Events) September 20-21 - Atlanta (Georgia): Polymers in Flooring - AMI (www.ami.international/events/) September 24-26 - Forth Worth (Texas): Thermoforming Conference - SPE (www.4spe.org/Events)
Thailand September 25-26 - Bangkok: Thin Wall Packaging Asia - AMI (www.ami.international/events/) MACPLAS INTERNATIONAL AT PLAST 2018
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EXHIBITIONS & TRADE FAIRS 2018 May 29 - June 1 - Plast 2018 (Milan, Italy) May 29 - June 1 - Ipack-Ima (Milan, Italy) May 29 - June 1 - Print4All (Milan, Italy) May 29 - June 1 - Plastec (Minsk, Belarus) June 2-5 - DKT (Nuremberg, Germany) June 5-7 - 3D Print (Lyon, France) June 11-14 - Argenplas (Buenos Aires, Argentina) June 11-15 - Achema (Frankfurt, Germany) June 13-15 - Plastech Vietnam (Ho Chi Minh City, Vietnam) June 15-17 - Complast Myanmar (Yangon, Myanmar) June 20-23 - InterPlas Thailand (Bangkok, Thailand) June 27-28 - Plastics Recycling World (Essen, Germany) August 14-17 - Interplast (Joinville, Brazil) August 15-19 - Taipeiplas (Taipei, Taiwan) September 7-9 - Interplast East Africa (Dar-es-Salaam, Tanzania) September 11-13 - Utech North America (Charlotte, United States) September 13-15 - Propak Myanmar (Yangon, Myanmar) September 18-20 - Propak West Africa (Lagos, Nigeria) September 19-21 - Plastex Uzbekistan (Tashkent, Uzbekistan) September 19-21 - Rubbertech (Shanghai, China) September 19-22 - Indoplas, Indopack, Indoprint (Jakarta, Indonesia) September 24-27 - Iranplast (Tehran, Iran) September 24-28 - Colombiaplast Y Expoempaque (Santa Fé de Bogotà - Colombia) September 25-27 - FachPack (Nuremberg, Germany) October 1-3 - LuxePack Monaco (Principality of Monaco) October 2-4 ottobre - Filtration (Philadelphia, Pennsylvania) October 2-4 - Ramspec (Milan, Italy) October 3-5 - Plastex Uzbekistan (Tashkent, Uzbekistan) October 4-7 - VietnamPlas (Ho Chi Minh City, Vietnam) October 9-13 - Bi-mu (Milan, Italy) October 16-18 - SMT, Sustainable Materials for Transportation (Hannover, Germany) October 16-20 - Fakuma (Friedrichshafen, Germany) October 26-29 - India Plast (New Delhi, India) November 6-8 - Composites Europe (Stuttgart, Germany) November 6-8 - Feiplar Composites & Feipur (São Paulo, Brazil) November 6-9 - Ecomondo (Rimini, Italy) November 12-15 - Adipec (Abu Dhabi, United Arab Emirates) November 13-16 - Formnext (Frankfurt, Germany) November 14-16 - Central Asia Plast World (Almaty, Kazakhstan) November 14-17 - Plastics & Rubber Indonesia (Jakarta, Indonesia) November 20-21 - Africa Rubber Expo (Johannesburg, South Africa) November 20-22 - Plastprintpack West Africa (Abidjan, Côte d’Ivoire) November 30-December 3 - Indplas (Kolkata, India)
May 29 - June 1, 2018
International appointment with Plastics and Rubber industries Plast 2018, the International Exhibition for the Plastics and Rubber Industries, is taking place at the FieraMilano facilities in Rho-Pero from Tuesday, May 29, to Friday, June 1, 2018. Organized by Promaplast, Plast 2018 is the preeminent European event this year for the plastics and rubber industry, embracing the whole chain from raw materials to semi-finished and finished products, from machinery and equipment to support services. The international scope of this triennial tradeshow, now in its eighteenth edition, which enjoys again the sponsorship of the Italian Ministry of Economic Development, is confirmed by the impressive numbers of foreign exhibitors and visitors. Some 1,500 exhibitors have registered for Plast 2018. Of these, 57% are Italian and 43% foreign, representing 55 countries, covering a total of 55,000 square metres of exhibition space. The exhibition reflects the preeminent global position of the Italian plastics and rubber processing machinery, equipment and moulds industry, which forms the core of the exhibition. Over 70% of national production - which hit a new all-time record value of 4.67 billion euros in 2017 according to figures from the trade association Amaplast - is exported. Plast 2018 thus offers economic operators a full-spectrum technological showcase addressing all the various production processes (from extrusion to blow-moulding, from thermoforming to injection moulding) and applications (packaging, automotive, medical, construction etc.). Given the excellent performance of Italian exports in the industry and recovery in the domestic market, participants have every right to expect rewarding business opportunities at Plast 2018, with their order books swelling significantly directly at the fair. Again this year, Plast is featuring satellite fairs dedicated to three sub-sectors of excellence: Rubber (in its third edition), 3D Plast (focusing on additive manufacturing and related technologies, now in its second edition) and Plast-Mat (first edition, dedicated to innovative plastics). A jam-packed schedule of technical seminars and company meetings has been arranged, providing a full-spectrum view of the latest in materials, processes, machinery and services. These conferences, combined with the breadth of the exhibits, draw in not only professionals working in the field but also young people seeking a place in the job market. As happens at every Plast, school groups, most of them from technical high schools, are among the crowds in the exhibition halls, getting a first-hand experience of the materials and technologies in the plastics and rubber industry. But that’s not all. In keeping with tradition, the Art & Plastics area of Plast 2018 is featuring a splash of colour, with artists exhibiting works they have created using plastic, providing a further demonstration of the versatility of this material. www.plastonline.org
December 5-8 - Plast Eurasia (Istanbul, Turkey) MACPLAS INTERNATIONAL AT PLAST 2018
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EDITORIAL CONTRIBUTORS
THE FOLLOWING COMPANIES ARE MENTIONED IN THIS ISSUE:
MUCH MORE THAN A magazine MACPLAS SPLITS INTO THREE: MAGAZINE NEWSLETTER WEBSITE. MUCH GREATER VISIBILITY.À MANY MORE CONTACTS. MANY MORE BUSINESS OPPORTUNITIES.
ON THE MARKET FOR MORE THAN
YEARS
Publisher Promaplast Srl Centro Direzionale Milanof ori Palazzo F/3 - 20090 Assago (MI) phone (+39) 02 82283775 - fax (+39) 02 57512490 macplas@macplas.it - www.macplas.it For advertising: lerner-media@t-online.de
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COMPANY/ASSOCIATION/INSTITUTE PAGE AMAPLAST 10; 15; 146 AMUT 70 ARBURG 59 ASCEND POLYMERS 138 AVK 129 BANDERA 47 BD PLAST 125 BFM 70 BIESSE 74 BLAUWER 81 BMEC 116 CAMPETELLA 90 CARLASSARA 71 CHEMORBIS 21 CM EVOLUTION 107 COLOR TECH 140 COMAC 74 COMERIO ERCOLE 117 CONAI 31 CONEXTRU 77 COREPLA 31 DEGA 93 DOSS 118 ELASTOMERS UNION 144 ENEA 31 EPROTECH 116 EPTA 129 EREMA 70 EXACT 79 FEDERAZIONE GOMMA PLASTICA 31 FILTEC 120 FIMIC 122 FM FILTER 126 FKUR 32 FRANCESCHETTI ELASTOMERI 142 FRIGOSYSTEM 124 FRIUL FILIERE 76 GEFIT 123 GIURGOLA STAMPI 126 GLOBAL MARKET INSIGHTS 25 GRAFE 144 GUMMIWERK KRAIBURG 140 HAITIAN 63 HELIOS ITALQUARTZ 120 HERBOLD 122 IMG 63 IPPR 31 ISPRA 31 ITIB MACHINERY 119 KRAIBURG TPE 134 LEGAMBIENTE 31 LEISTRITZ 78 MACPLAS 24; 27 MARIS 53 MAST 113 MECCANOPLASTICA 73 MESSE DÜSSELDORF 24 MOBERT 67 MOLD MASTERS 118 MORETTO 86 NORDSON 121 NOVA INSTITUT 30 NOVAMONT 33 OMMP 124 PLAS MEC 104 PLAST PRINT & PACK NIGERIA 24 PLAST 2018 16; 147 PLASTIBLOW 56 PLASTIC SYSTEMS 81 PROFILE DIES 72 PROMIXON 110 RPM 77 SALDOFLEX 76 SARA 72 SIPOL 136 SPE 37 STAR AUTOMATION EUROPE 99 THERMOPLAY 102 ULTRA SYSTEM 142 VANETTI 143 WM THERMOFORMING 42 MACPLAS INTERNATIONAL AT PLAST 2018
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