Published by Promaplast Srl - Centro Direzionale Milanofiori - Palazzo F/3 - 20090 Assago (Milano, Italia) - ISSN 0394-3453 - Poste Italiane SpA - Spedizione in abbonamento postale - 70% LOM/MI/2363
MACPLAS INTERNATIONAL
THE MAGAZINE FOR THE PLASTICS AND RUBBER INDUSTRY
ITALIAN MACHINERY MANUFACTURERS - TWO-SPEED IN THE FIRST HALF OF THE YEAR EU www.macplas.it DIRECTIVE FOR A MORE CIRCULAR ECONOMY DATA EXCHANGE BETWEEN INJECTION MACHINES AND MES PA-BASED ENGINEERING POLYMERS - DEMAND IS SET TO GROW IN THE COMING YEARS www.ultrasystem.ch
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CONTENTS
23
29
13
10
MARKETING 10 13 16 18 18 20 21
23 29
PLASTICS AND ENVIRONMENT 23 26 27 27
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EU DIRECTIVE FOR A MORE CIRCULAR ECONOMY MODERATE GROWTH IN BIO-BASED POLYMERS MICROBES FULLY METABOLIZE BIODEGRABLE PLASTICS COMMITTING TO RECYCLE 900,000 TONS OF PVC PER YEAR BY 2025
MACHINERY AND ANCILLARY EQUIPMENT 29 33 36 40 43
6
EDITOR’S LETTER BY RICCARDO AMPOLLINI ITALIAN MACHINERY MANUFACTURERS - TWO-SPEED IN THE FIRST HALF OF THE YEAR ITALIAN EXIBITORS AT FAKUMA 2018 THE USE OF PLASTICS IN INNOVATIVE AUTOMOTIVE DESIGN ON THE RISE SBC DEMAND TO GROW UNTIL 2022 SOLID BUT FLEXIBLE SUSTAINABILITY TARGETS AND ADDED VALUE ARE SHAPING THE MARKET
DATA EXCHANGE BETWEEN INJECTION MOULDING MACHINES AND MES THE ADVENT OF SPECIAL MACHINES MADE IN CHINA GROWING BEYOND THE EXPECTATIONS THE COMPANY HISTORY IN A NAME… AND MUCH MORE THE EVOLUTION OF SPECIES
46 48 50 52 52 55 58 60 62 64 68 70 72 74 74 75 76 78 79 80 81 82 83 83
KEEPING THE PACE WITH CUSTOMERS AND MARKET CHALLENGING RECYCLING AND COMPOUNDING THE DEVELOPMENT OF TANDEM REGENERATION LINES KEEPS ON SINGLE-STATION FOR BICOMPONENTS FOAM PIPES FOR INSULATION COOLING SYNCHRONIZED WITH PLASTICS PROCESSING TAILORED HOT RUNNER SOLUTIONS AN IMPORTANT MILESTONE A FIRST GREAT LANDMARK IN THE MIXING SECTOR IT’S THE EXPERIENCE WHICH MAKES THE DIFFERENCE DO NOT MAKE THE CONVENTIONAL CHOICE INNVATION AND ENERGY EFFICIENCY ALWAYS LOOKING AT THE FUTURE AUTOMATING SMALL PRODUCTION VOLUMES COST-EFFICIENTLY PURE EFFICIENCY FOUR MONTHS AROUND EUROPE THREE IN ONE HIGH-END SCREWS AND BARRELS PROVIDE PROCESSORS WITH INNOVATION, FLEXIBILITY AND SERVICE TURNKEY PACKAGE FOR CONTINUOUS FLOW THE ADVANTAGE OF BEING “SMALL” IR AND UV SOLUTIONS SINCE 1940 A LIFE FOR SCREWS AND BARRELS FILTRATION FOR ALL
MACPLAS INTERNATIONAL AT FAKUMA 2018
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COVER STORY
Published by Promaplast Srl - Centro Direzionale Milanofiori - Palazzo F/3 - 20090 Assago (Milano, Italia) - ISSN 0394-3453 - Poste Italiane SpA - Spedizione in abbonamento postale - 70% LOM/MI/2363
MACPLAS INTERNATIONAL
THE MAGAZINE FOR THE PLASTICS AND RUBBER INDUSTRY
ITALIAN MACHINERY MANUFACTURERS - TWO-SPEED IN THE FIRST HALF OF THE YEAR EU www.macplas.it DIRECTIVE FOR A MORE CIRCULAR ECONOMY DATA EXCHANGE BETWEEN INJECTION MACHINES AND MES PA-BASED ENGINEERING POLYMERS - DEMAND IS SET TO GROW IN THE COMING YEARS www.ultrasystem.ch
85
94
85
MATERIALS AND APPLICATIONS 85 PA BASED ENGINEERING POLYMERS - DEMAND IS SET TO GROW IN THE COMING YEARS
90 ENSURING STABILITY BY ENHANCING LOGISTICS AND STORAGE CAPACITIES
90 HIGH TIGHTNESS DUE TO LOW WATER ABSORPTION OF THE CLOSED-CELL
91 DELETING THE BUILD-UP OF ELECTROSTATIC CHARGE 91 COLOURS AND EFFECTS FOR ENGINEERING POLYMERS 92 BIODEGRADABLE SOLUTIONS TO REALLY SAFEGUARD THE PLANET
92 AN EXCITING TARGET FOR A YOUNG COMPOUNDING COMPANY
93 GROWING, INNOVATING, QUALIFYING 93 AN IMMINENT REVOLUTION IN PURGING
94
TRADE FAIRS AND CONFERENCES 94 94 96 96
With headquarters and main production site in Switzerland and different production sites in the world, Ultra System has been focusing exclusively on research, developing and production of purging compounds for plastics processing machines (injection moulding presses, extruders, blown/cast film extruders, blow moulding machines) for the cleaning up to 420°C without any smoke or smell. Almost all its products can be used for the screw and for the hot runner systems as well, as the maximum diameter admitted is 20 microns. Ultra Plast products (different types and grades according to the plastic resin and the temperature) are a helpful and precious support to reduce production costs by decreasing scraps, energy- and labour costs as well as production downtimes. For those companies with a low budget Ultra System also offers special products which can be used on a wide range of plastics and which are easily to handle. By using a high-quality purging compound correctly and regularly it will eliminate all deposits of burnt materials (plastics and masterbatch) which on a medium-long term may originate black specs due to the carbon rests, also in dead spots and those areas with negative flow. Ultra Plast products can be used as well for a regular preventive maintenance: with a regular cleaning, the life of plastics processing machines will be longer. Almost all grades, standard products, Qualipurge CS as well as low cost products are certified FDA, apply to European food rules CE 10/2011 and some of them can be used as well in white rooms for medical, cosmetic and pharmaceutical production. Ultra System is not only a reliable supplier of purging compound, but it also offers technical support for solving specific problems during colour and/or material change in production. www.ultrasystem.ch
PLAST EURASIA - A FAST GROWING MARKET EXHIBITIONS & TRADE FAIRS MEETINGS & CONGRESSES THE “HOME” FOR THE ELASTOMERS INDUSTRY
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Not a miracle, but a precious help to reduce production costs
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MACPLAS INTERNATIONAL
ADVERTISERS’ LIST
Supplement of MacPlas August/September 2018
25 BD PLAST
www.bdplast.com
19 BIESSE
www.biesse.com
75 BINOVA
www.binovapm.it
Editor in chief Riccardo Ampollini
26 BLAUWER
www.blauwer.com
95 CHINAPLAS
www.chinaplasonline.com
32 COLOR TECH
www.colortech.biz
Editorial staff Luca Mei, Girolamo Dagostino, Stefania Arioli
89 COMPOSITES EUROPE www.composites-europe.com
31 DE-GA
Sales office Giuseppe Augello
www.dega-plastics.com
45 DOSS
www.doss.it www.ecomondo.com
73 ELASTOMERS UNION
www.elastomersunion.it
71 EPROTECH
www.eprotechsrl.it
Editorial assistant Giampiero Zazzaro
97 ECOMONDO
Editorial committee Alessandro Grassi, Andrea Franceschetti, Massimo Margaglione, Corrado Zanga
www.purgingit.com
41 FILTEC
www.filtec.it
59 FM FILTER
www.fmfilter.com
79 FRANCESCHETTI ELASTOMERI
www.f-franceschetti.it
Contributors to this issue Amaplast, AMI, BCC Research, Ceresana, Euromap, European Bioplastics, Freedonia Group, Nova Institut, Plast 2018, Angelo Grassi, Oreste Pasquarelli, Plast Eurasia, Smithers Rapra, Vinylplus
54 ERRETI
35 FRIGEL FIRENZE
www.frigel.com www.friulfiliere.it
27 GAMMA MECCANICA
www.gamma-meccanica.it
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
3 FRIUL FILIERE
9 GIURGOLA www.giurgolastampi.com
42 HELIOS ITALQUARTZ www.heliosquartz.com 21 HERRMANN ULTRASCHALLTECHNIK www.herrmannultraschall.com 100 IMG
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39 INGLASS
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2 IPM
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88 MACPLAS
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Managing director Mario Maggiani
67 MAGIC MP
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51 MAKLAUS
Administration Alessandro Cerizza
20 MAST www.mastsrl.it
Layout and prepress Nicoletta Albiero
12 NOVA FRIGO www.novafrigo.it
84 PLAST EURASIA
www.plasteurasia.com
77 PLAST 2021
www.plastonline.org
69 NINGBO SUPERIOR MACHINERY www.superior-machinery.com
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11 PLASTORE www.plastore.it
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53 POLIBLEND
15 PROMIXON www.promixon.com 98 PSE EUROPE www.pse-europe.com
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28 RADICIGROUP www.radicigroup.com 81 SARA www.sarasrl.eu
57 SIPOL www.sipol.com 4 STAR AUTOMATION EUROPE www.star-europe.com
1 , 7 ULTRA SYSTEM
www.ultrasystem.ch
22 VANETTI
www.vanettimaster.com
63 WM THERMOFORMING MACHINES
www.wm-thermoforming.com
99 ZAMBELLO www.zambello.it
INSTITUTIONAL SPONSORS AMAPLAST ITA LIA N PL ASTIC S A N D RU B B ER PRO CESSING M ACHIN ERY A N D M O U L DS M A N U FACT U R ERS’ ASSO CIATIO N
ASSORIMAP ASSO CIATIO N O F ITA LIA N PL ASTIC S R ECYCLING A N D R ECL A IMING C O M PA NIES
SPE ITALIA SO CIE T Y O F PL ASTIC S ENG IN EERS
AIPE I TA LI A N AS SO CI AT IO N O F E X PA N D ED PO LYST Y R EN E
CIPAD C O U NCIL O F IN T ER N ATIO N A L PL ASTIC S ASSO CIATIO NS DIR ECTO RS
UNIONPLAST ASSO CIATIO N O F ITA LIA N PL ASTIC S PRO CESSING C O M PA NIES
IIP ITA LIA N PL ASTIC S INSTIT U T E
UNIPLAST ITA LIA N STA N DA R DISATIO N BO DY FO R PL ASTIC S
ASSOGOMMA ITA LIA 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’ ASSO CIATIO N
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EDITOR’S LETTER
“
RICCARDO AMPOLLINI
3D PRINTING VS INJECTION MOULDING Plastics and rubber industry operators are increasingly of the opinion that 3D printing could seriously hit sales of moulds and injection moulding machinery in the not too distant future. Certainly, judging by what “gurus” from HP and Stratasys say, 3D printing looks set to bring about some truly revolutionary changes in the way in which plastic objects are conceived and produced, now on a semi-industrial scale, too. These two companies are perhaps the ones that best represent the changes taking place in the world of 3D printing, and they are investing considerable amounts in the research and development of their new printers and related materials, almost as though they were competing with each other to be the first to arrive at certain solutions, as in the case of multi-colour and multi-material 3D printing, for example. But they are not the only strong players in this sector; indeed, there are also several Italian companies that have thrown themselves into the fray, and are coming up with equally valid solutions. The main advantages of 3D printing (or, better put, additive manufacturing) might be summarised in the following points: it eliminates the need for moulds; it provides plenty of scope for customising articles; it can be used to produce components with very complex geometries; it uses compact machines; and it produces less waste, or no waste at all. Furthermore, although the technique is decades old, a considerable number of designers are still unable to design injection moulding equipment to perfection, which means that there is plenty of space that can be occupied by designers of additive manufacturing equipment. That said, as pointed out by numerous technicians, there are also some downsides: additive production is not yet carried out on an industrial scale, or as rapid as moulding; the surface quality is often inferior; and it has not yet been established whether the mechanical properties of the products are comparable to those of injection-moulded articles. Equally, it is not yet clear whether 3D printing ensures the same repeatability, especially when working with narrow tolerances. Finally, a further drawback is the price of the powders used in additive manufacturing, which are often 10 or 20 times more expensive than plastic granulate. While it is possible that increasing volumes might bring their cost down, this nevertheless remains a serious problem in the short and medium term, also considering that, as pointed out by many processors, the raw materials used generally account for around 70% of the overall production costs. It is therefore possible that, at least for a few more years, 3D printing will continue to be a complementary technique, not one in competition with injection moulding. Nevertheless, to echo something I wrote in an editorial as long as four years ago (MacPlas 342, Italian version), I suggest to keep a close eye on the changes taking place in this sector. You could well “see something really good”!
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”
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Plast 2018
MARKETING
FOREIGN TRADE FOR ITALIAN MANUFACTURERS
TWO-SPEED IN THE FIRST HALF OF THE YEAR FAST AND SLOW LANES IN FOREIGN TRADE FOR ITALIAN MANUFACTURERS OF MACHINERY, EQUIPMENT AND MOULDS FOR PLASTICS AND RUBBER. VERY POSITIVE RESULTS FOR THE EIGHTEENTH PLAST EXHIBITION, IN MILAN
I
talian imports of plastics and rubber processing machinery racked up an impressive 23% increase in the first half of 2018
with regard to the same period in 2017. On the other hand, the growth of exports is instead fractional, evidencing the lacklustre performance heralded in the early months of the year. While still well into the black at over one billion euros, the balance of trade has bogged down somewhat, losing over 7%. This is the situation captured by the statistical studies centre of Amaplast based on foreign trade data published by Istat, the Italian national institute of statistics. The dynamism of purchases from abroad may be interpreted as renewed faith in the domestic market, mainly due to investment incentives that are likely to be renewed and
“The July order books for Amaplast member manufacturers are stable with a slight trend toward improvement; this gives us reason to hope for a rebound in production and exports in the last quarter of the year”, said Amaplast’s president, Alessandro Grassi MACPLAS INTERNATIONAL AT FAKUMA 2018
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naturally hoped for by businesses in the industry. Amongst the main machinery categories, the greatest gains are recorded for imports of injection moulding machines (+31%) and blow moulding machines (+75%), accompanied by flexographic printers (+111%) and moulds (+12%). Some of the sources of this performance may be found in the positive trend in the Italian packaging industry - the principal consumer of plastic raw materials and processing machinery - as also determined by the Italian packaging machinery manufacturers association (Ucima), which observed growth of over 14% in 2017 for packaging companies in the domestic market, with the results for the current year also expected to show positive performance. The principal supplier country for the Italian plastics and rubber processing industry is Germany, which has significantly improved its leading position with respect to the period January-June 2017, widening its gap over China, in second place. Germany also maintains its status, one which it has held for decades, as the main destination for Italian exports in the sector, evidencing the continuing faith of German customers in Italian-made technology.
13 03/10/18 17:28
MARKETING Fig. 1 - Italian machinery exports by areas (% shares and, below, Δ% 2018/2017)
ITALIAN MACHINERY EXPORTS BY AREAS AND GOODS A broad look at the geography of exports (see figure 1) shows: - the primacy of Europe as a whole, with some 61% of the total, remaining substantially unvaried with respect to the first half of 2017, with growth over other markets measured in decimals. This stasis is mainly due to a falloff of sales to Russia (-32%) after the hope-inspiring recovery in 2017; enthusiasm has definitely waned in the first half of this year; - good performance in exports to the three Nafta countries (+7%), placing North America in second place among export destinations, counterbalanced to some extent by the overall contraction of Central and South American markets; - an overall slowdown in Asia (-6%), mainly deriving from weak sales in the Middle East; - positive progress in Africa (+23%), thanks to increased sales both to Mediterranean and Sub-Saharan countries; - weakening (-21%) in the already modest supplies to the distant markets of Oceania.
As regards goods categories, positive growth in exports is observed for all principal types of primary transformation machinery and moulds, which together account for more than half of the sector’s sales abroad. The commercial balance is in the black across the board, with the sole exception of injection moulding machines, which have slipped into negative territory by about 14 million euros. “The July order books for Amaplast member manufacturers are stable with a slight trend toward improvement - with respect to both June 2018 and July 2017 - and this gives us reason to hope for a rebound in production and exports in the last quarter of the year”, commented Amaplast president Alessandro Grassi regarding the most recent end-of-period sentiment survey, completed at the beginning of September by the association’s statistical studies centre.
UPCOMING EVENTS After Iranplast (Tehran, September 24-27) where Amaplast coordinated the Italian collective, including about ten companies, with
ICE-Agenzia - and Plastex Uzbekistan (Tashkent, October 3-5), the Italian association will take part in other important specialized international tradeshows in the coming months to promote the Made in Italy: • Plastics & Rubber Indonesia (Jakarta, November 14-17), • Plastprintpack West Africa (Abidjan, November 20-22) • and the year will close with Plast Eurasia (Istanbul, December 5-8). www.amaplast.org
Plast 2018
The show met all objectives in big win A strongly positive outcome for the eighteenth Plast, the international exhibition for the plastics and rubber industries, which took place at the Fiera Milano fairgrounds in Rho-Pero, from May 29 to June 1, 2018. “It couldn’t have gone better. Our organizational office is quite satisfied with the outcome of the exhibition for at least two reasons”, stated Alessandro Grassi, president of Amaplast and the commercial company Promaplast.
“First of all, because our decision to introduce - together with the organizers of the other four exhibitions (Ipack-Ima, Meat-Tech, Print4All, Intralogistica Italia) the trade-fair project “The Innovation Alliance” has proved to be a winning choice: the more than 150,000 operators who participated were treated to an exhaustive range of plastics and rubber technology without precedent. The Innovation Alliance takes it place as the second largest
The core of the exhibition Plast 2018 was machinery, equipment and moulds for plastics and rubber processing, with over 3,500 units on display. Industry 4.0 technology was also well represented, and also the topic of discussions in the many conferences, augmenting the programme of this preeminent trade fair
14 013_014_Amaplast.indd 14
tradeshow after the Salone del Mobile. From day one through to the closing, Corso Italia and the seventeen halls at Fiera Milano were packed with visitors”. “Even more important, regarding Plast in particular, and a great source of pride for us, was the great satisfaction of the exhibitors, who enjoyed the significant attendance by qualified operators and an impressive number of contracts signed directly at the fair. The expectations - already quite ambitious - ended up being outstripped by reality”, added Grassi. Plast 2018 recorded a total of some 1,500 exhibitors in 55,000 square metres of exhibition space, with significant growth of over twenty percentage points in foreign participants, affirming the international stature of the exhibition. One example of this was the significant expansion of the Chinese and Iranian collectives.
The organizational office estimates over 63,000 visitors based on statements of priority interest made by operators during the registration process. Unluckily, the exact number cannot be determined with any precision since the admission tickets to the five contemporary exhibitions allowed access to all 17 exhibition halls of The Innovation Alliance. Foreign visitors made up 27.5% of the total from a total of 117 countries, with Spain, France, and Germany being the most represented. Some 30 official delegations were welcomed to the fair. They expressed strong admiration bordering on astonishment in interviews by the organizational office for the magnitude and completeness of the Plast 2018 technology showcase, and for the satellite fairs Rubber (representing the rubber industry), 3D Plast (additive manufacturing and related technologies), and Plast-Mat (innovative plastics) that were part of The Innovation Alliance. www.plastonline.org
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MARKETING
ITALIAN EXHIBITORS AT FAKUMA 2018 ABATE BASILIO & C. AIGLE MACCHINE ALEA AQUATECH ARCA AUSERPOLIMERI BATTAGGION BAUER COMPRESSORI BESSER TTS BINOVA BLAUWER BMB BMZ MOULDS BORDIGNON TRADING BRUNO FOLCIERI CALDARA PLAST CAMPETELLA ROBOTIC CENTER CB STAMPI CELLOPLAST GD CF CIMBRIA CMC CMS COFIT INTERNATIONAL COIM COMEC ITALIA COSSA POLIMERI CS PLASTIC DEPA STAMPI DIAP DIOMA ELIOS EPAFLEX POLYURETHANES EPROTECH ESSETI PLAST GD EUROCHIMIND FB BALZANELLI FILTEC
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HALL STAND A7 7106 A7 7205 A5 5120 A7 7201 A5 5117 FOYER EAST 22 A6 6111 A1 1515 FOYER WEST 66 A6 6207 FOYER EAST 53 A4 4105 A5 5117 FOYER WEST 76 FOYER EAST 60 FOYER WEST 134 A7 7208 A7 7008 A5 5116 FOYER EAST 18 B1 1308 A5 5303 A1 1428 A6 6414 B2 2121 A1 1403 B4 4503 PASSAGE EAST 15 PASSAGE EAST 15 FOYER EAST 19 A5 5117 A4 4012 B5 5417 A2 2115 A5 5116 B4 4407 A6 6304 A6 6422
FIMIC FI-PLAST FORMAC FP SERVICES FRANCESCHETTI ELASTOMERI FRANPLAST FRATELLI VIRGINIO FRIGEL FRIUL FILIERE GAMMA MECCANICA GAMMAPLAST GEFIT GEFRAN GENERALSTAMPI GROUP GIANECO GIBA STAMPI GIMATIC GIROL GIURGOLA STAMPI GRUNIVERPAL GTO HBI HEKLA HELIOS ITALQUARTZ HEROFLON HRSFLOW (INGLASS) HTM STAMPI ICMA SAN GIORGIO IHR IMI FABI INNOVATECH INPROS INTERCABLE ISPER ITI POLYMERS LATI INDUSTRIA TERMOPLASTICI LORANDI SILOS LUCCHINI RS MACPLAS
A6 6209 B4 4503 FOYER EAST 77 A1 1500 B5 5212 B5 5305 A7 7212 A5 5108 A6 6111 A6 6218 FOYER WEST 116 A3 3306 A3 3005 FOYER WEST 49 A6 6505 A5 5117 A7 7204 FOYER EAST 20 A5 5117 A7 7300 FOYER EAST 33 FOYER WEST 111 FOYER WEST 76 A4 4201 B5 5212 A2 2217 FOYER WEST 125 B5 5314 A2 2405 B4 4108 FOYER WEST 76 A4 4129 A7 7503 A5 5121 A5 5115 B2 2205 B3 3207 A1 1328 FOYER WEST FP (PRESS CORNER)
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ITALIAN EXHIBITORS AT FAKUMA 2018
MAIP MB CONVEYORS MEPOL MILLUTENSIL MIOZZO MORETTO NUOVA RET NUOVA SITT OMG SRL OMG SPA OMS DEI F.LLI MAINA OREMPLAST OTS PEL PLASTIC PENTA PHT - PETRELLI HEATING TECH PIOVAN PLAMATIC PLASTICFINDER PLASTIC METAL PLASTIC SYSTEMS PLASTICWOOD.IT PLASTORE PLASTRADING POLIBLEND POLIPLASTIC POLIS POLISERVICE POLITEC PRODUFORM PROGIND RB REAGENS RIALTI RITMO RMP SAVOINI ROMAGNANI STAMPI ROSÀ PLAST RP INJECTION
B5 5111 B1 1106 A5 5115 A6 6104 FOYER WEST 47 B3 3208 A1 1511 A1 1222 FOYER EAST 17 B3 3004 FOYER WEST 66 A6 6012 A7 7003 FOYER EAST 88 A7 7201 A6 6421 A7 7201 B3 3207 PASSAGE EAST 19 A7 7212 FOYER EAST 53 B2 2123 FOYER EAST 70 FOYER EAST 15 A5 5116 FOYER WEST 141 B4 4305 B2 2221 B4 4110 FOYER WEST 03 A1 1402 A7 7009 B4 4113 A4 4210 A4 4113 A1 1402 A5 5117 A6 6216 A6 6317
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SABO B4 4113 SAGITTA A6 6111 SALA MAURIZIO STAMPI FOYER WEST 41 SCS - SOCIETÀ COSTRUZIONE STAMPI A1 1320 SERISTAMPA B3 3008 SIDERTOCE A1 1002 SIMATEC A7 7314 SIR FOYER WEST 143 SIRMAX B2 2207 SOREDI B2 2221 SPA (STAMPAGGIO PLASTICA AFFINI) A2 2102 STAMPLAST A5 5226 STAR AUTOMATION EUROPE A7 7113 TARO PLAST B5 5207 TECNICA DUEBI A3 3113 TECNOMATIC A7 7405 TECNOSTAMPI FLLI PELIZZARI B5 5201 TECNOVA A6 6207 TECNOVITI A6 6207 TEXER DESIGN A6 6415 THERMOPLAY A1 1211 TOSH A1 1124 TOYO EUROPE A6 6317 TRAFLEX A6 6005 TRIA B3 3118 TVMP FOYER WEST 142 UCISAP - ITALIAN ASSOCIATION OF PRECISION MOULDS, DIES A5 5117 UNIFORM A5 5117 VAMP-TECH A4 4004 VIBA FOYER WEST 91 VIGNATI A2 2113 ZAMBELLO RIDUTTORI 2 A6 6105 ZANOLA A5 5120 ZOPPAS A5 5209 ZRE A5 5310
17 03/10/18 17:22
MARKETING The development of the automotive sector will stimulate the research for more performing materials and more efficient injection moulding processes
NEWS Global injection moulding
The use of plastics in innovative automotive design on the rise Injection moulding of plastics is continuing its dominance within the processing of polymers to manufacture products for everyday use, including kitchenware, toys and packaging, amongst other end-use industries, according to the new report “Injection Moulding: Global Markets and Technologies Through 2023” from BCC Research. In 2017, the global market for plastics injection moulding was valued at 117 billion dollars and is expected to reach 233 billion dollars in 2023, reflecting a Compound Annual Growth Rate (CAGR) of 10.9%, as indicated in the BCC’s report. The thermoplastic polymer segment is expected to witness substantial growth through 2023, owing to the rising demand for plastics across several vertical industries such as packaging and food and beverages. Increasing urbanization, growing income and rising demand from enduse segments further propel the market forward. More in detail, global demand for polystyrene thermoplastics is expected to increase at higher growth rates over the next few years, due to the increasing popularity of recycled expanded polystyrene products, which has helped the market recover from the setbacks posed by disposal. The medical device segment accounts for 18.7% of the plastics injection moulding market and is expected to see strong growth over the forecast period as healthcare becomes an increasingly integral part of
Global thermoplastic elastomers market
SBC demand to grow until 2022 The freedonia Group Worldwide Styrenic Block Copolymers (SBC) demand is expected to expand at a 3.9% annual pace through 2022 to 2.4 million tons, valued at 8.9 billion dollars, a rate consistent with the growth of the 2012-2017 period. The Asia/Pacific region will remain the leading consumer of
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SBCs, continuing to account for about 60% of demand. Advances in the large Chinese footwear market will continue to decelerate, with growth transferred to smaller but fast-advancing footwear industries in India, Indonesia, Vietnam, and other Southeast Asian countries. These and other trends are presented in “Global Thermoplastic Elastomers Market”, 10th Edition, a new study from The Freedonia Group, a Cleveland-based industry research firm. The footwear market overall
household expenditures, especially in more developed countries with aging populations. The Asia-Pacific region will be the largest market geographically, accounting for 35.3% of the global market. “As the market for injection moulding of plastics continues to grow, so will innovations in resin selection, injection moulding machinery and processing guidelines”, said Christopher Maara, BCC Research analyst and the author of the mentioned report. “With the emergence of new resins with improved properties, moulders can process polymers to fabricate new designs with different properties. Furthermore, with stronger plastics and ease of processing, thermoplastics can save production time and energy compared with making parts from metals”. Innovations in plastic vehicle interiors are expected to continuously emerge in upcoming years, including advancements such as smart surfaces and 3D-printed tooling, as well as external autonomous driving sensors. Some manufacturers today are even beginning to explore the possibilities of building large portions of the chassis, or the entire chassis, using plastic moulding. The efficiencies and possibilities of such a change, especially as safety improvements, loom closer on the horizon, presenting an exciting development for manufacturers, entrepreneurs and consumers alike. www.bccresearch.com
continues to mature, restraining thermoplastic elastomer (TPE) sales opportunities to a certain extent. Nevertheless, the Asia/ Pacific region remains the foremost global supplier of home appliances and other consumer products, which are both fast expanding markets for SBCs in soft touch applications like personal care products and office supplies. North America and Western Europe remain significant markets for styrenic block copolymers, although their combined share of global demand dropped from 42% in 2007 to 30% in 2017. Countries in these regions boast large and technologically advanced construction industries, a key segment for SBCs used as asphalt modifi-
ers and sealants. Additionally, North America and Western Europe generate substantial demand for SBC-based adhesives in tapes and labels for packaging and nonwoven disposable products. Demand for all types of TPEs is expected to expand 4.1% annually through 2022 to 6.8 million tons, valued at 25.5 billion dollars. Robust growth in developing markets like Thailand and India will drive gains in the near term, stimulated by rapid economic development and slow but steady market penetration of TPEs. Adoption of TPEs will also continue to advance in the developed world, as concerns about competitive materials bring TPEs to the forefront. www.freedoniagroup.com
MACPLAS INTERNATIONAL AT FAKUMA 2018
03/10/18 17:22
SYSTEMS, SOFTWARE AND SERVICES FOR THE AUTOMATION AND DIGITALISATION OF FACTORIES.
INSIDE 2018 25-27 October Pesaro
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MARKETING
Vehicle tires are main application for synthetic rubbers
NEWS Global market for synthetic rubbers
Elastically deformable polymers have been necessary for several technical applications but also for various everyday objects. Per year, more than 12.7 million tons of these types of polymers are consumed worldwide. Ceresana analyzed the global market for synthetic rubbers already for the third time, with data for the years starting in 2009 and forecasts data until 2025. These rubbers include styrene-butadiene rubber, butadiene rubber, ethylene-propylene-diene rubber, acrylonitrile-butadiene rubber, chlorobutadiene, and polyisoprene. The most important sales market for synthetic rubber in 2017 was
the segment tires: 58% of total global demand were accounted for by applications in original equipment and replacement tires. Rubbers are also used for numerous other products in the automotive industry: for example for hoses, cables, seals as well as window and door profiles. For the automotive segment, the analysts of Ceresana expect an increase of global rubber demand by 3.0% per year until 2025. The second largest application area for rubbers are elastically deformable engineering products with a stable shape such as conveyor belts, roll covers, hoses, profiles, seals, cables, moulded parts, and roofing films. Rang-
Lanxess
Solid but flexible ing from the chemical industry, engineering, and construction to electrics and electronics, increasing number of rubber products are needed. For the period until 2025, analysts expect global demand for rubber in the segments industry and construction to increase by 2.4% p.a. By far, the most important rubber type is styrene-butadiene rubber (SBR): about 5.1 million tons were processed in 2017. SBR is produced by emulsion polymerization (E-SBR) or solution polymerization (S-SBR). While E-SBR accounts for approximately 72% of total SBR demand, the mar-
ket for S-SBR develops at significantly more dynamical growth rates of 3.8% p.a. The tire industry is the dominating sales market for these two products as well as for butadiene rubber (BR), butyl rubber (IIR), and polyisoprene (IR). A different picture is presented in the case of ethylene-propylene-diene rubber (EPDM), chlorobutadiene rubber (CR), and acrylonitrile-butadiene rubber (NBR): these rubber types are mainly used in industrial and construction products, as well as for modification of other materials. www.ceresana.com
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MACPLAS INTERNATIONAL AT FAKUMA 2018
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Ultrasonic welding technology. For robust enclosures. Blow moulded bottles in Europe
The outlook for the blow moulded bottle market is positive with further output growth, increasing demand for added value products and for the use of recyclates shaping the landscape, according to a newly published report from industry consultants, AMI Consulting. Blow moulded bottle demand in Europe was 189 billion units in 2017, up from 176 billion in 2013, with the fastest growing market segments have been sweet and savoury spreads and still water. In some food applications penetration of plastics is increasing strongly, driven by opportunities for brand development. Where penetration of plastic bottles is already high such as in household care products the competitive battleground will centre on inter-material and inter-format competition, supply-chain efficiency and premium brand opportunities. Sustainability is becoming increasingly important and it has been incorporated in the agenda of all significant brand owners and their suppliers. Most have established long term sustainability targets, encompassing ways to reduce, reuse and recycle the packaging. Emphasis on packaging weight reduction is adversely affecting polymer demand and at the same time it drives the development of better-performance materials and technology. The use of PET and HDPE recyclates has been steadily gaining in importance but in
the next future it will accelerate. Recyclates growth will be driven by the European Commission’s Circular Economy Action Plan and some of the major brand owners’ commitment to increase the recycled content in their packaging to 25% or more by 2025. The growth of recyclates requires a balance between financial and environmental considerations and to meet the industry targets will require the development of a new supply chain, investments in capacity, closed-loop recycling and sorting technology. As price pressures are increasing, the supply chain is forced towards maximising operational efficiency and minimise costs. Brand owners are reducing the role of the converter by increasingly controlling polymer procurement, gaining competence in blow moulding and injection moulding, and acquiring cost-transparency through self-manufacture. As value-capture decreases, converters are becoming specialists and reduce cost through operating fewer sites. Several players have focussed their development efforts on their preform business looking at how to add value, for example focussing on barrier technology. Ten groups control 28% of volume throughput which makes the European blow moulded bottles market highly fragmented. The largest producers in Europe include Alpla, Logoplaste, Plastipak, RPC and Serioplast. www.ami.international
Fig. 1 - Demand for blow moulded bottles in Europe by end-use applications (2017)
Prothelis GmbH
Sustainability targets and added value are shaping the market
Our experts are there to help you: 25 ultrasonic labs worldwide Personal consulting Solutions provided for 30,000 applications
www.herrmannultraschall.com
Source: Ami Consulting report - “Blow moulded bottles - The European market 2018”
Meet us in Friedrichshafen
MACPLAS INTERNATIONAL AT FAKUMA 2018
16.10. - 20.10.2018 Hall A4 · Stand 4108
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ARTHA MILANO
masterbatches for technopolymers
masterbatches
BIOmasterbatches®
Research&Develop
Additives
Vanetti S.p.A., founded in 1971, produces masterbatches, Biomasterbatches ® , and additives for plastic materials. With over forty-five years experience in the industry, Vanetti masterbatches are used to colour and additivate all thermoplastic resins. Passion for colour and customer service are the company’s strengths. The excellent performance of the masterbatches is guaranteed by technologically advanced equipment and attention to the quality of raw materials.
VANETTI S.p.A. - Italy - Tel: +39.0331.389077 - Fax: +39.0331.389078 - vanetti@vanettimaster.com - www.vanettimaster.com
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Shutterstock
PLASTICS AND ENVIRONMENT
PACKAGING AND PACKAGING WASTE
EU DIRECTIVE FOR A MORE CIRCULAR ECONOMY I
n 1994, the European Community addressed the problem of packaging waste through a directive (94/62/CE) which was intended to encourage the packaging production industry to start designing materials in a way that would create real possibilities for their post-consumer reuse, recycling and recovery. The latest European directive on this topic, EU 2018/852, which was approved on May 30 and came into force on June 19, 2018, must be seen as more than just an update; indeed, its clear aim is to move the industry even more decisively towards a circular economy-type model. The novel aspects of this new directive concern, above all, “reuse” (article 5) and “recycling” (article 6); in particular, new articles have been introduced entitled, respectively, “Rules on the calculation of the attainment of the targets” (article 6a), and “Early warning report”, the latter dealing with reporting on the progress towards the attainment of recycling targets (6b). The new directive, EU 2018/852, must be transposed into national legislation in the various EU member states, by July 5, 2020.
THE NEW DIRECTIVE, ARTICLE BY ARTICLE The introductory part of the EU 2018/852 sets out the framework for the verification and evaluation of the various operations designed to allow better use of packaging, as well as its
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THE NEW EUROPEAN DIRECTIVE EU 2018/852 AIMS TO IMPROVE THE WAY IN WHICH POST-CONSUMER PACKAGING IS RECOVERED AND RECYCLED, IN ORDER TO PROMOTE THE TRANSITION FROM A “LINEAR” TO A “CIRCULAR” ECONOMY BY ORESTE PASQUARELLI
reuse and recovery. Moving on to the single articles, the most significant changes compared with the 1994 version are detailed below. Objectives (Article 1) Improved reuse and recycling are crucial for the transition towards a “circular economy”. Definitions (Article 3) Definitions relating to certain illustrative examples of special packaging (e.g. CD cases, flower pots, release paper of self-adhesive la-
bels, wrapping paper) have been eliminated, but definitions of other types of packaging, e.g. “reusable”, “composite” (i.e. packaging made from different materials which cannot easily by separated during recycling), have been inserted. Prevention (Article 4) The EU member states can take special measures to prevent the generation of packaging waste, and to minimise the environmental impact of packaging.
The European Directive 2018/852 has introduced measures aimed at reducing the amount of post-consumer packaging abandoned in the environment and increasing the percentage of reusable waste
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PLASTICS AND ENVIRONMENT
Reuse (Article 5) Measures have been introduced that should have the effect of reducing the abandonment of-consumer packaging in the environment and increase the percentage of reusable waste. These include: - the use of deposit-return schemes for empty containers; - the introduction of qualitative or quantitative targets; - the use of economic incentives; - the establishment, for each packaging stream, of a minimum percentage of reusable packaging to be placed on the market each year. Member states may choose to attain, for a given year, an “adjusted level” of the targets (see section on Article 6 below). This is done by considering the average share, in the preceding three years, of reusable sales packaging placed on the market “for the first time”, and thus certainly reused. The “adjusted target level” is calculated by subtracting, from the targets laid down in article 6, the share of reusable sales packaging with respect to the total packaging placed on the market; the share of reusable sales packaging composed of the respective packaging material, as a share of all sales packaging composed of that material placed on the market. No more than five percentage points of the above defined shares are taken into account for calculating the respective adjusted target levels. In order to ensure uniform conditions for the application of the above-described methods, the European Commission shall adopt, by March 31, 2019, implementing acts establishing rules for the calculation, verification and reporting of data. Furthermore, by December 31, 2024, the Commission, after examining data of the management of reusable packaging in the different EU member states, shall prepare a summary report and, if appropriate, submit a legislative proposal. Recovery and recycling (Article 6) This article introduces the quantities that must
be recovered and recycled in the coming years, broken down by type of material used for the production of packaging. Table 1 reports the recycling targets, as percentages, that must be achieved by 2025 and 2030 compares these with the old Directive 94/62/CE targets. Furthermore, still with regard to the percentages reported in table 1, an extension is envisaged as specified in the three points below: • achievement of the listed targets may be postponed by up to five years subject to following conditions: - the extension may not exceed a total of 15 percentage points, which may be either from a single target or shared between two targets; - the recycling rate for a single target must not be allowed to fall below 30%; - any extension of the deadline for reaching the recycling targets must be communicated to the Commission 24 months before the dates set for achieving these targets. By December 31, 2024, the Commission shall review the targets laid down with a view to increasing them if appropriate.
Return, collection and recovery systems (Article 7) By the end of 2024, member states are required to establish return, collection and recovery systems and to define responsibility schemes extended to packaging producers.
Rules on the calculation of the attainment of the targets (Article 6a) Precise rules have been defined which must be the same for all EU member states. The most important points of these provisions are the following: - the amount (weight) of packaging waste generated must be equal to the amount (weight) of packaging produced; - the weight of packaging recycled must be equal to the weight of packaging that has become waste, not including the weight of waste materials generated in recycling operations; - the weight of waste materials that are incinerated, backfilled or landfilled shall not be counted towards the attainment of the recycling targets; - packaging waste sent to another member state may be counted as recycled only by the member state that collected and dispatched it.
THE WASTE HIERARCHY ESTABLISHED DIRECTIVE 2008/98/EC CONTINUES TO BE RELEVANT
TAB. 1 - RECYCLING OBJECTIVES (EXPRESSED AS PERCENTAGES OF THE TOTAL) ACCORDING TO THE OLD AND NEW DIRECTIVES DIRECTIVE 94/62/CE
All packaging waste
Directive (EU) 2018/852
31 dicembre 2001
31 dicembre 2025
31 dicembre 2030
50 - 65%
65%
70%
Plastic
50%
55%
Wood
25%
30%
Ferrous metals
70%
80%
Aluminium
50%
60%
Glass
70%
75%
Paper and card
75%
85%
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Information systems (Article 12) Detailed constraints are envisaged with regard to the communication of data to the EU community regarding both recycled materials and reusable packaging. By March 31, 2019, the Commission will finalise procedures for data communication that will render documents prepared by different EU countries easier to compare. Specific measures (Article 20) These measures concern packaging materials placed on the market in very small amounts (having a weight amounting to around 0.1% of that of the packaged product). Examples include: primary packaging for medical devices and pharmaceutical products, small packaging and luxury packaging.
As well as having to take note of the changes introduced by the new EU Directive 2018/852, companies will also need to remember that waste treatment and disposal continues to be regulated by Directive 2008/98/EC, which establishes measures to protect the environment and human health by preventing or reducing the negative effects of waste management. This directive also establishes a very clear “waste hierarchy”, to be applied, as a priority order, in waste prevention and management legislation and policy: • prevention: actions to reduce and prevent dispersion of waste; • preparing for re-use: planning packaging with a view to reusing it; • recycling: recovery of post-consumer packaging for new uses of the raw material; • other recovery: incineration with heat recovery (minimum calorific value: 5 MJ), biodegradation to produce compost suitable for use in agriculture; • disposal: landfilling as non-hazardous waste. Only the first three of these actions guarantee an optimised circular economy. Furthermore, this “hierarchy” it is very important from the perspective of re-use and recycling, since the “other recovery” option is not taken into account for the purpose of calculating quantities of materials recovered. www.macplas.it MACPLAS INTERNATIONAL AT FAKUMA 2018
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PLASTICS AND ENVIRONMENT
NEWS Market and trend report by nova-Institute
Moderate growth in bio-based polymers According to the last report published by nova-Institute, the production capacities of bio-based polymers continue to grow at around 3 to 4% per annum, i.e. at about the same rate as petrochemical polymers. Therefore, the market share of bio-based polymers in the total polymer market remains constant at around 2%. But the individual development of different bio-based polymers varies considerably. While some are virtually collapsing compared to previous forecasts (e.g. bioPET), many are showing constant or slightly increasing capacities and a few are even showing significant growth (such as PLA). Additionally, for some bio-based polymers, such as PHA, PEF, bio-PE and bio-PP, the prospects for the future are quite positive. Overall, the market environment remains challenging with low crude oil prices, little political support and partially underutilized capacities. In 2017, the worldwide capacities for bio-based polymers reached 4.6 million tons (including hard-to-estimate bio-based PU this number goes up to 6.4 million tons). The forecast for 2022 shows 5 million tons - including bio-based PU: 7.5 million tons. All in all, after strong growth between 2011 and 2014, nova-Institute sees less growth with a CAGR of 3 to 4% from 2014 to 2017. According to the latest forecasts, this trend will continue until 2022 and is approximately in line with expected growth in the petrochemical polymer market. Only higher oil prices, better support from governments or technological breakthroughs will make it possible for growth to rise again. With a CAGR of 10% between 2017 and 2022, Europe has the highest growth of bio-based polymer capacities compared to other regions of the world. Sub-group of dedicated bio-based polymers has no direct counterpart in the petrochemical world, therefore price pressure from cheap crude oil is lower than for other groups. Moreover, these polymers are offering new properties and functionalities, and they show a higher CAGR compared to the drop-in groups. Bio-based polymers such as PLA become more and more established, additional capacities are created and new polymers such as PHA and PEF are introduced to the market. As a consequence, the highest innovation takes place in this group, and a number of new developments are still to be expected. www.bio-based.eu/reports - www.nova-institute.eu
Million tons
Bio-based polymers - Worldwide production capacities (without PU)
Source: nova-Institute
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VinylPlus has backed the European Commission pledging call
Committing to recycle 900,000 tons of PVC per year by 2025 An interdisciplinary study
Microbes fully metabolize biodegradable plastics Researchers at ETH Zurich and the Swiss Federal Institute of Aquatic Science and Technology (Eawag) succeeded in an interdisciplinary study to demonstrate that soil microorganisms metabolically utilise the carbon in the PBAT polymer both for energy production and also to build up microbial biomass. The researchers used the biodegradable polymer PBAT (polybutylenadipatterephthalate) labelled with a carbon isotope. This isotope label enabled the scientists to track the polymer-derived carbon along different biodegradation
Hasso von Pogrell, managing director of European Bioplastics
pathways in soil. It showed that the carbon from PBAT was not only converted into carbon dioxide (CO2), as a result of microbial respiration, but also incorporated into the biomass of microorganisms colonizing the polymer surface. The researchers are the first to successfully demonstrate where the carbon of a polymer ends up and that a plastic material is effectively biodegrading in soils. “This clarifies that nothing remains after biodegradation besides water, CO2 and biomass”, declared Hasso von Pogrell, managing director of the association European Bioplastics. “With this study, two concerns that are constantly being raised about biodegradable plastics have been rebutted - the doubt that microorganisms fully metabolize certified biodegradable plastics and the concern that the oil-based part of the polymer will not biodegrade completely”. www.ethz.ch/de www.european-bioplastics.org
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Since 2000, VinylPlus, the voluntary commitment to sustainable development of the European PVC industry, has been a pioneer in the Circular Economy. It has backed the European Commission’s pledging call to increase recycling of plastics by comIn Aarhus (Denmark) potatoes, herbs and mitting to recycle at least tomatoes grow in large PVC pipes. The 900,000 tons of PVC per year scene is a VinylPlus-supported project, into new products by 2025, a that aims to establish sustainable food significant contribution to the production with reused PVC building waste overall 10 million tons objective set by the Commission for the plastic industry. Looking further ahead, VinylPlus has also committed to recycling a minimum of 1 million tons per year by 2030. “For nearly 20 years, VinylPlus has led the way to a circular economy by improving the sustainability performance of PVC. Because our programme brings together the entire value chain - PVC manufacturers, additives producers, converters and recyclers - we responded immediately to the Commission’s call for voluntary pledges from the plastics industry. We welcome this initiative, which highlights the foresight shown by VinylPlus in establishing its first voluntary commitment”, stated Brigitte Dero, VinylPlus’ general manager. Thanks to VinylPlus’ unique role in engaging an entire value chain, the voluntary commitment has succeeded in recycling more than 4 million tons of PVC since 2000. Ensuring targets are met is of paramount importance to VinylPlus’ success. Recycled volumes are verified by an independent auditor and presented to the VinylPlus Monitoring Committee, composed of representatives of the European Commission, European Parliament, consumer organisations, trade unions, academia and industry. www.vinylplus.eu
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PROCESSING MACHINERY
EUROMAP 77 IS THE FIRST STANDARD FOR DIGITAL INTERFACES
DATA EXCHANGE BETWEEN INJECTION MOULDING MACHINES AND MES TO INCREASE PRODUCTION EFFICIENCY, MORE AND MORE PLASTICS PROCESSORS BET ON INDUSTRY 4.0. IN MOST PRODUCTION FACILITIES EQUIPMENT OF DIFFERENT MANUFACTURERS IS USED. IF THE PROCESSOR CAN ACCESS STANDARDIZED INTERFACES WHEN CONNECTING, THE HIGH CONFIGURATION EFFORT FOR ADAPTING INDIVIDUAL SOLUTIONS BECOMES OBSOLETE. EUROMAP DEVELOPS OPEN AND MANUFACTURER INDEPENDENT STANDARDS FOR INDUSTRY 4.0 BY LUCA MEI AND RICCARDO AMPOLLINI
R
eleased on May 4, 2018, Euromap 77 is the new industry standard for the exchange of data (via OPC UA) between injection moulding machines and central computers or Manufacturing Execution Systems (MES), which is ready for Industry 4.0. In fact, connected production is not only about collecting as much data as possi-
ble but also to organize and interpret them in an intelligent manner. Manufacturing Execution Systems plays a crucial role in managing the data transfer. Only then, the collected data will have the desired added value for the user. Euromap 77 will prove this also in serial implementations, all of those involved are convinced.
According to Industry 4.0 principles, Euromap 77 sets the new industry standard for the exchange of data between injection moulding machines and central computers or Manufacturing Execution Systems (MES) via OPC UA MACPLAS INTERNATIONAL AT FAKUMA 2018
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FUNCTIONALITY PROVIDED BY EUROMAP 77 With Euromap 77, machines from different manufacturers can be easily connected within one network for production data acquisition. This allows monitoring of the process quality, calculation of key performance indicators like Overall Equipment Effectiveness (OEE) and enables traceability of the products. In addition, functions for a central job management and for transferring whole datasets for machine settings have been included. The existing Euromap 63 served as the basis, but Euromap 77 not only uses state of the art communication technology, it also extends the functionality with additional information and interaction possibilities. The modular architecture allows for covering a broad range of applications from standard machines to machines with several moulds and injection units.
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PROCESSING MACHINERY
EMBEDDED IN A FRAMEWORK MODEL FOR PLASTICS AND RUBBER MACHINERY The developers of Euromap 77 set a high value on a good and sustainable structure of the information model. Therefore, reusable information blocks (e.g. general information on the machines, such as manufacturer, model, serial number and their machine status) are defined in Euromap 83 to avoid duplicating work and, most of all, inconsistencies. All future models of plastics and rubber machinery will build on it and specify the generic definitions for individual applications and machine combinations.
OPC UA AS THE BASIS Open Platform Communication Unified Architecture (OPC UA) is the interoperability standard for the secure and reliable exchange of data in the field of industrial automation of several industries. The OPC Foundation, a non-profit industry association, is responsible for its development. Since it is platform independent and ensures the seamless flow of information amongst multi-vendor devices, it serves as an ideal basis for Euromap 77.
DEVELOPED BY THE INDUSTRY FOR THE INDUSTRY Euromap 77 was developed by experts from the industry in cooperation with the OPC Foundation and supported by Ascolab. Amongst them, there were some of the most important manufacturers of injection moulding machines, as Arburg, Engel, Fanuc, Ferromatik Milacron, KraussMaffei Technologies, Negri Bossi, Netstal, Sumitomo (SHI) Demag, Wittmann Battenfeld. Those ones worked side by side with controller manufacturers B&R and Beckhoff Automation, and with MES suppliers bfa solutions, BMS, Includis, Inray Industriesoftware, MPDV Mikrolab, ProSeS BDE, RJG Germany, Steinberger Software, Stöckeler Software Services and Logo of the new industry standard Euromap 77
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Thorsten Kühmann (on the left), secretary general of Euromap, and Stefan Hoppe, vice president of OPC Foundation
TIG. Furthermore, Lego Systems was one of the users who participated at this development. “Industry 4.0 stands for intelligent and digitally connected systems where data exchange across system boundaries should be possible. OPC UA, as an established standard, has the precondition to allow communication between acting and collecting systems and is, therefore, an important part of Industry 4.0”, commented Jonas Schwarz, product and technology manager at KraussMaffei. The Manufacturing Execution System (MES) plays a central role regarding the organisation of the data transfer. Heinz Gaub, managing director Technology & Engineering at Arburg, explained: “For the digitalization of production in the sense of a “smart production”, standardized interfaces are an important precondition for using various connectivity-modules, like MES, and to transfer, analyse and exchange large amounts of data consistently”. “Only standardization allows to globally exploit the opportunities offered by Industry 4.0 and to generate added value for our customers. Without a common language across all participants in the supply chain, we will not be able to master the complexity the Internet of Things brings, amongst other things”, emphasized Gerhard Dimmler, head of Research and Development Products at Engel Austria. Georg Tinschert, CEO of Wittmann Battenfeld, added: “A special challenge for industrial networks today is real-time communication. The new Euromap standards take this into account, if necessary. The Euromap Recommendations have been
recognized for decades in the global plastics industry. We think it is likely that the new interface standards will be internationally successful”. “We see Euromap 84 not only as a chance for our customers and for us to decrease complexity, but we also see it as an important step in creating more efficient and sustainable production processes”, concluded Henning Stieglitz, CTO of BC Extrusion Holding (battenfeld-cincinnati).
NEXT STEPS A small part of Euromap 77 was already demonstrated live at the exhibition K 2016, where live data from different machines running in different halls at manufacturers’ booths was transferred via OPC UA for visualization in a central computer. In January and April 2018, the working group members met for two so-called “plugfests”, which were very successful. They thoroughly tested prototype implementations in multiple server/client combinations. The specification with the documentation and computer readable files is available free of charge at www.euromap.org/euromap77. The manufacturers are working intensively on making the implementations ready for serial production. In the meantime, Euromap is working on further interfaces e.g. between injection moulding machines and robots or peripheral devices. For temperature control devices, a Release Candidate has already been published. However, also other machine types like extruders and blow moulding machines are in Euromap’s focus. The current projects are listed under www.euromap.org/i40. www.euromap.org MACPLAS INTERNATIONAL AT FAKUMA 2018
03/10/18 17:24
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For over 20 years we have been offering a wide range of compounds and masterbatches suitable for any field of application: electronics, automotive, furniture, toys, packaging and many more.
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PROCESSING MACHINERY
The IMG stand at Plast 2018
INJECTION MOULDING MACHINES FOR THERMOPLASTICS AND ELASTOMERS
THE ADVENT OF SPECIAL MACHINES MADE IN CHINA IN THIS INTERVIEW WITH DAVIDE BONFADINI, SALES DIRECTOR OF IMG, WE TAKE STOCK OF THE COMPANY’S PROGRESS IN WHAT WAS AN EXTREMELY POSITIVE YEAR. NEW SPECIAL MODELS ARE ABOUT TO BE MARKETED IN EUROPE AND THESE WILL BE UNVEILED BY THE PARENT COMPANY, HAITIAN, AT THE FAKUMA FAIR IN FRIEDRICHSHAFEN BY RICCARDO AMPOLLINI AND GIUSEPPE AUGELLO
A
round a month after the Plast 2018 fair, the MacPlas editors met with Davide Bonfadini, sales director of IMG, to take stock of the company’s progress in a year - 2017 - that turned out to be very positive both for the Haitian thermoplastic injection moulding machines (of which IMG is sole distributor for Italy), and for the elastomer processing machines designed and built, in house by this Brescia-based manufacturer. But, let’s start with a look at IMG’s market performance.
FIRST OF ALL, COULD YOU TELL US HOW IMG DID IN 2017 IN TERMS OF TURNOVER AND SALES? “2017 was an important year for IMG. Indeed, we ended it with a turnover of 45 million euros, an approximately 30% increase on the previous year; and this is on top of the already considerable +15% achieved in 2016 in comparison with MACPLAS INTERNATIONAL AT FAKUMA 2018
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IMG sales director, Davide Bonfadini, engages with a client at the Haitian stand at Plast 2018
2015. We can therefore say that IMG is growing strongly. In the course of the last year, we installed as many as 150 rubber injection moulding machines and/or special machines, mainly in Italy, generating a total of about 20 million euros. It was also a great year for us as the distributor of Haitian machines, we sold 310 machines on the Italian market, earning around 25 million euros. At the risk of sticking my neck out a bit, I would therefore say that we are now back to the levels we were recording before the crisis, if not doing slightly better than then. Instead, as regards the breakdown of our turnover (Italy/foreign markets), we buck the trend rather compared with the average Italian manufacturer in this the sector, as the majority of our turnover - around 80-85% - is generated in Italy. And there are two main reasons for this. First of all, we are just a stone’s throw away from “Rub-
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ber Valley” (near Bergamo) with a wide range of consolidated customers and potential buyers of IMG machines. The second reason we mainly sell on the national market is that we are the distributor for Haitian in Italy. In fact, the only Haitian machines we export go to Romania, as we currently cover that market, too. Last year we sold 35 units there for a total of around 3 million euros. On the other hand, we export our own (IMG) special machines and rubber processing machines to European countries, such as Germany, Spain, Poland, Slovakia, and the Czech Republic. Right now, with a view to increasing our market shares in these countries, we are working on expanding our sales network”.
DO YOU THINK THAT THE CURRENT YEAR WILL ALSO CLOSE POSITIVELY? “Given the excellent performances we have been recording in recent years, it is perhaps unrealistic to expect further growth; I therefore think it is more reasonable to assume that this year will see us consolidating our position, with a turnover similar to 2017. And that alone, for us here at IMG, would be a hugely important result, amounting to an endorsement of all the good work we have done up to now”.
WHAT ARE THE MAIN TECHNICAL ADVANCES YOU PRESENTED AT PLAST 2018? “As is traditional, we had two stands at the fair in Milan: one, as Haitian, in Hall 24, devoted to plastic moulding, and the other, as IMG, within the satellite show Rubber 2018 (Hall 11). As Haitian, we exhibited, first of all, two machines (a standard version and an Eco version) of the bestselling Mars series, of which there are now 150,000 machines installed worldwide. In particular, the Eco version, which we mainly recommend to moulders, is a servo-assisted hydraulic machine with toggle-joint clamping system. Indeed, it is equipped with a DC motor with gear pump, which allows the machine to work at a low engine rpm, and therefore to consume less power. Haitian has been producing the Mars series since 2008, but it is evolving all
The GUM and NEK (in the box above) injection moulding machines shown at Plast 2018
the time and has now reached its third generation: the Mars II S. We also exhibited two models (120-ton and 450ton versions) from the hybrid Zeries series, which is characterised by electric drives, with just two “hydraulic exceptions”. With over 400 models installed in Italy in the only three years since its launch, the important advantages of this series are already well known, namely its overlapping movements, greater extraction force, absolute precision, lower energy consumption and application flexibility. A two-platen servo-assisted hydraulic Jupiter II press was also on display; this was equipped with a Cartesian three-axis robot (a Success 22 Haitian by Sepro), which was being presented for the first time in Italy following the start of the company’s collaboration with the French manufacturer Sepro. Still with regard to thermoplastics moulding machines, we also displayed an image of the brand new Zhafir JE (where JE stands for Jenius): a two-platen press featuring an electric injection unit “borrowed” from the aforementioned Zeres series. The hybrid Zhafir JE can be considered to represent the “perfect marriage” between Zeres and Jupiter, whose best features have been combined to guarantee really high performances. Thanks to an innovative modular concept, it has proved possible to combine the “fully electric” solution and the servo-hydraulic two-platen system in an efficient way, retaining the advantages of each. Haitian developed this concept The very recent new arrival Zhafir JE, where JE stands for Jenius
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by drawing on the longstanding application experience it has built up with its customers, and monitoring particularly closely the trends in injection moulding technologies for medium- and high-tonnage machines, especially for the white goods and automotive industries. Haitian previously chose the Chinaplas fair in Shanghai as the stage for the world preview of Zhafir JE, before then exhibiting it at the NPE fair in Orlando. As IMG, we went to Plast with, first of all, our signature product: I am talking about GUM, which features horizontal Hydroblock clamping system and a punching screw-type injection unit, and is used for moulding seals. We exhibited a completely servo-assisted version with additional electric movements. We also presented a NEK swan-neck tiebarless press and featuring a two-piston vertical clamping system and vertical injection unit with a punching screw. This machine was used to mould spinners in EPDM, which we distributed during the fair; for this purpose, we used a two-cavity mould and a Kawasaki anthropomorphic robot to load the 12 inserts. Last, but certainly not least, Plast 2018 also provided us, as IMG, with the opportunity to present the fully electric toggle clamping device that we have spent the past two years or so designing and “field testing”. We plan to offer it for all our elastomer injection moulding machines, because in this sector too there is a growing tendency to prefer electric machines to hydraulic ones. Indeed, a number of our customers need fast and more productive processes in order to keep abreast of the fierce foreign competition. The raw materials producers have already tried to accommodate them in this sense, by developing new elastomers with shorter vulcanisation times than in the past, but if we really want to reduce cycle times, we also need to see machines featuring electric (and overlapping) movements. Through the solution developed by IMG, it is possible to increase the repeatability, accuracy and speed of the movements, thereby helping to improve the overall performance of the press”. MACPLAS INTERNATIONAL AT FAKUMA 2018
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HOW DID THE PUBLIC REACT TO THE MACHINES YOU EXHIBITED IN MILAN? “The visitors were extremely interested in the technologies we showed. The attendance at the IMG and Haitian stands was excellent and certainly better than at the last two Plast fairs, in 2012 and 2015. More generally speaking, the appreciation that has been shown towards our presses in recent times has helped us to further consolidate our market position in Italy. I believe that this has been made possible by the excellent market scouting work done in recent years, and can also be attributed to the fact that we have virtually eliminated the reticence towards Chinese products, and have thus been able to acquire new customers, which maybe already knew us by reputation, but not as well as they do now. In fact, many potential new customers came to visit us during the Plast fair and this is obviously very important for us”.
HAS THE CLOSE PROXIMITY OF THE DKT AND PLAST FAIRS CAUSED YOU ANY PROBLEMS? “No, because practically all of our Italian customers in the rubber sector - and there are many of them! - came to visit us at Plast, whereas at
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DKT (Nuremberg, July 2-5), apart from the odd Italian who came to see us there as well, I mainly met Brits, Portuguese, Spanish and Germans, who unfortunately weren’t present in Milan. Indeed, I would like to stress that for the rubber sector, DKT is even more important than the K fair in Düsseldorf. It is a small fair, but, as I saw for myself this year, all the European operators in the sector take part in it. In my view, none of the other fairs (which, not being devoted solely to the elastomer industry, are seen as more general) manages to draw in as many foreign customers in this field. In fact, the attendance at our stand was really very high. At DKT we exhibited only as IMG, and we took along nearly all the machines that were also present in Milan”.
HAVE YOU GOT ANY NEW PLASTIC OR ELASTOMER MOULDING PROJECTS IN THE PIPELINE? “Haitian has just launched Zhafir Jenius, its new series of hybrid machines, while IMG chose Milan as the platform for unveiling the new servo-assisted horizontal GUM, and is now aiming to build fully electric machines for injection moulding of elastomers. Consequently, for the moment both companies
are planning to concentrate only on these new projects, so as to evaluate their applications on the market and their post-marketing results”.
WHICH MACHINES WILL YOU BE SHOWING AT FAKUMA 2018 AND WHAT ARE THEIR MAIN FEATURES? “IMG won’t have a stand of its own at Fakuma, but our entire staff will be present at the Haitian International stand there (1101, in Hall A1), lending their full support to the parent company. On that occasion, in addition to a new generation Mars II S, the very latest hybrid Zeres for bi-injection moulding will be on show, in what will be its European market unveiling. Visitors to Fakuma will therefore be able to watch the Zeres live in various applications, working with two injection units (the second positioned vertically on the fixed platen). In fact, as a final remark, I would like to make it very clear that the launch of this new press is part of a broader corporate strategy being pursued by Haitian, which aims to acquire market shares also in the field of special machines, in which so far it has not been present. Indeed, the company is ready to enter this market segment in Europe, too”. www.imgmacchine.it
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PROCESSING ADVANCED MATERIALS
GROWING BEYOND THE EXPECTATIONS F
our years after making its debut in the advanced materials sector with a range of machines dedicated to the machining of plastics and composite materials, Biesse has experienced growth beyond what was expected, with a 300% increase in sales in three years. Today the company offers technology that can meet all market demands and handle all machining processes. “The company achieved this growth by investing in strategic assets such as Sales Intelligence, Distribution, and Marketing and Communication”, stated Matteo Nazionale, business manager for Biesse Plastic and Composite Materials. “The resources dedicated to the technological materials sector at Biesse have increased by 30% over the past year and further significant growth is expected by the end of 2018 as well, in the technical, service, and commercial fields. All of this is meant to increase our presence on the ground, at the service of and closer to Biesse’s true asset: the client”, Nazionale continued.
FROM PESARO, ITALY, BIESSE OFFERS TO THE WORLD A COMPLETE RANGE OF MACHINES TO PROCESS ADVANCED PLASTICS AND COMPOSITE MATERIALS. THE COMPANY CONFIRMS ONCE AGAIN ITS ENGAGEMENT IN PUSHING UP THE TECHNOLOGICAL INNOVATION
gy to facilitate everyday work is entering not just large factories but also small businesses that have recognised the great value Biesse machines have to offer. The technology offered by the company has
been used with plastics and composite materials for several years, but in 2014 Biesse specifically created a range of products for the machining of plastics, composites and thermoformed materials. The range includes
RELIABLE, CUSTOMISABLE AND PERFORMANT TECHNOLOGY The Italian company is taking the spotlight in this sector and has once again confirmed its push for innovation, offering automated solutions for companies of every size. Technolo-
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A detail of the Selco Plast WN6, single line panel saw for producing average sized batches
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panel saws, machining centres, waterjet cutting systems, sanders and thermoforming machines. Selco Plast It is a range of single line panel saws that can meet the widest ranging production needs. The robust pushing carriage driven by a brushless motor on hardened racks and cemented gear wheels, together with the magnetic band positioning control and component locking via independent grippers, guarantee the utmost cutting precision and quality for panels of various formats and sizes. The range includes Selco Plast SK4, designed for medium and small industries, Selco Plast WN 6, designed and developed for producing average sized batches, and Selco Plast WN 7, which stands out for elevated performance with increasingly short time spans, particularly suited to the needs of medium and large industries. Rover Plast This is a range of machining centres developed both for artisans and medium to small industries, which, thanks to innovative developments for the machining of advanced materials, has proven to be extremely reliable and competitive on the market. One of the few solutions for performing milling and cutting operations on technological materials. The Rover Plast J FT is the ideal machine for artisans who need to bring automation to their production, preserving quality and reliability at competitive prices. Rover Plast A FT is a machining centre equipped with advanced technical solutions to guarantee high quality finishing with any machining operation. Rover Plast B FT is equipped with cutting-edge technology that allows complex machining of any type of material. Rover M5 is the machining centre designed for the creation of unusual, unique products, larger objects and design pieces. Materia It is the range of versatile, compact, 5-axis processing centres designed to meet a wide variety of high-speed milling needs for technological materials, mainly developed for the aeronautical sector, boats and the car industry. The range includes five models designed for use in different sectors and for pieces of different sizes: from particular three-dimensional shapes to structural components for satellites, train carriages, ships and planes. Materia CL was created for the machining of MACPLAS INTERNATIONAL AT FAKUMA 2018
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Inside 2018
The benefits of the technology in demonstration A Terma model from the thermoforming machines range designed by Luca Fraccaro
thermoformed materials and shaped components, designed for manufacturing, construction and machining of small train components. Materia LD works with the same dimensions as Materia CL but with greater performance, better suited to the motor sport and aviation industries. Materia FC is the most precise machine in the range and was developed for the heavier machining needed in the aerospace, aviation and motor sport sectors. Materia MR is dedicated to machining the large sizes typical of the nautical and railway sectors. Finally, Materia XC is a 5-axis portal machining centre with a mobile beam, specifically designed for the machining of isothermal equipment on vans, tractors and semi-trailers. Brema Plast This is the range for the real time machining of components. Brema Plast Eko 2.1 is the new patented vertical machining centre; a compact and versatile machine that can, with minimal space, handle formats of varying size and thickness made with advanced plastics and composites. It is the ideal solution for “just in time” production of a limited number of items, machined on all six sides with “zero time” recovery operations. Viet Plast It is the range of sanders that offers specific solutions for working composite, plastic foam or compact materials. A wide range of groups available, combined and repeatable within the machine, allows to calibrate, sand and glaze surfaces of various sizes. The high performance of Viet sanders,
From October 25 to 27, Biesse opens the doors of its Pesaro campus to demonstrate the benefits that its technologies offer to those who work with technological materials. “For us Inside is an appointment that is fundamental to being able to maintain a strong collaborative relationship with our clients and to confirming, year after year, the strong technological overtone that characterises us”, comments Raphaël Prati, marketing and communications director. In particular, visitors will have the opportunity to witness a demonstration of the the Rover Plast B FT + Winstore, the cell dedicated to nesting operations, capable of increasing productivity thanks to the optimisation of operations and space. Furthermore, the Materia CL will be in operation, the 5-axis work centre for high speed processing of advanced materials with complex shapes. For sectioning operations, the Selco Plast WN7 will be present, a panel saw with a single cutting line for the production of medium and large sized batches. As for water-jet cutting systems, there will be the Primus Plast, which satisfies the needs of companies that require the maximum versatility. The new Terma thermoforming machine, introduced at Plast 2018, dedicated to thermoform plastic materials with a mould and the use of vacuum will complete the range of machines displayed.
The appointment with “Inside 2018” is in Pesaro from October 25 to 27
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combined with the ability to manage up to 10 working units in a single machine, allow for removal of ample material as well as high quality finishes in one pass even with intense production rates. The vast range includes the Viet Plast S211, S1 and S2 belt sanders that can be significantly personalised to meet both generic and complex work needs. Viet Plast Opera 5 and 7 finishing centres were designed for small, medium and large companies depending on production needs. The one-of-a-kind Opera R robotic sanding machine offers levels of machinability, precision and quality never before achieved by technology in this sector. Viet Plast Valeria and Viet Plast Narrow were designed for more intense industrial-scale production. Terma This is the new Biesse thermoforming machine, presented at Plast 2018, for thermoforming plastic materials using a mould and vacuum. Sheets of varying materials, thicknesses and finishes can be used with Terma, to meet any market need. Designed by Luca Fraccaro, who has worked for 45 years in the sector and made use of his vast experience to create a machine with the best technology and innovation available to achieve ultimate results. Terma was born with all optionals already available, capable of meeting all machining needs with total flexibility and equipped with the most innovative technological solutions available on the market, making it a unique, high quality machine. All the components and technology used are of the highest quality for a perfect finish and ultimate precision in the details. The one-of-a-kind structure is extremely sturdy and guarantees unparalleled precision. The machine weighs three times more than
Sophia is the IoT platform that enables Biesse customers to access a wide range of services to streamline and rationalise their work management processes
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the average machine offered by competitors, which is beneficial for ultimate reliability and precision machining.
“AUTOMACTION” AutomAction is the new Biesse concept that represents the practicality of the new technological innovations developed by the company to create new business models based on automated, interconnected production. “Our goal is to help our customers understand that they can transform their factories into digital factories, gaining both flexibility and competitiveness”, explained Raphaël Prati, Biesse Group marketing and communications director. Besides stand alone machines, Biesse offers its customers specific solutions for the automation of machining processes for plastics and composite materials. Biesse Systems is a team of expert engineers capable of anticipating and interpreting what a business needs. The team accompanies the customer from the idea to the complete creation of the system, creating cells and integrated systems that are capable of maximising the customer’s competitiveness and harmonising the need for mass production with the high level of personalisation of the finished product requested by the end user.
SOPHIA Current technology offers all companies the option of evolving through a process that simplifies and optimises the design and production phases. “Biesse’s ability to create digital, automated and interconnected factories has become a reality. The firm advantages that our customers see every day are proof of the value that Biesse technology brings to the production processes. At Biesse Group, we have chosen to invest our skills and not only look to the future, but keep one step ahead of it. We create new-generation technologies to facilitate the daily lives of our customers. What was complex in the past, is now truly within everyone’s reach. Simplification, increased efficiency, and total reliability are foundational for our solutions”, continued Prati. The pursuit of this vision is what inspired Sophia, the IoT platform that enables its customers to access a wide range of services to streamline and rationalise their work management processes. It is based on a connection to a cloud service and to special sensors applied to the Biesse machines. The information and data on the technologies in use can be recorded and sent in real time to optimise performance, prevent malfunctions, and in-
Matteo Nazionale, business manager for Biesse Plastic and Composite Materials
crease the productivity of machines and systems. In addition, the direct connection to parts, the Biesse replacement parts portal, and the chance to upgrade software with just a click, provides clients with everyday work tools that can simplify a host of tasks. A wide selection of high quality products and services, derived from a careful survey of the market and a profound understanding of what companies that work with technological materials need. “We are very proud of the company’s rapid growth in this sector, which confirms Biesse’s innovation and technological leadership on the national and international market. It’s a testament to the fact that, regardless of size, our customers want to evolve and adopt a more productive and efficient methodology, with Biesse by their side”, added Nazionale.
CONSTANTLY IN DIRECT CONTACT WITH CUSTOMERS Biesse offers customers several opportunities to experience its technology first hand: at Tech Tours and internal events at its headquarters in Pesaro and at branch offices, and through numerous trade shows all over the world, where the company always stands out. “The trade shows and events that Biesse has participated in over the past years have been a great source of satisfaction thanks to the growing success achieved with visitors and customers who seek out and rely on our support for their growth. The interest we receive from them drives our own growth as we search for excellent technology that can transform the manufacturing process”, Prati said in closing. www.biesse.com MACPLAS INTERNATIONAL AT FAKUMA 2018
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hrsflow.com
FOR OUR FAMILY, THE E-VOLUTION IS ALREADY HERE
OCTOBER 16. - 20., 2018 Friedrichshafen, GERMANY We welcome your visit at our booth 2217/A2
Electric. Efficient. Evolved. We have used this vision of the future to create FLEXflow Family, the range of products that includes the servo-driven valve gate systems FLEXflow and FLEXflowOne. Ensure high-quality injection-moulded parts with independent processing at each gate. Our electrical world: • High quality part performance • Clamp force reduction • Wider process window • Reliability and repeatability of the process • Clean operation and easily operated
HRSflow Italy: Via Piave,4 San Polo di Piave, Treviso, 31020 Italy Ph. +39 0422 750 111 - info@hrsflow.com
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PROCESSING MACHINERY
40 YEARS OF FRIUL FILIERE
THE COMPANY HISTORY IN A NAME... AND MUCH MORE E
stablished as a manufacturer of dies for the extrusion of plastic materials, nowadays Friul Filiere sells complete turnkey systems all over the world to any processor looking for high-quality performance when manufacturing pipes and profiles, from technological extrusion lines and tooling, fully customized and guaranteed 100% made in Italy.
A VERY IMPORTANT MILESTONE FOR THE ITALIAN COMPANY, WHOSE CELEBRATIONS CONTINUE AT FAKUMA 2018 WITH THE NEW FUTURA40 LINE AND MANY OTHER TECHNOLOGIES, RESULT OF AN UNCEASING RESEARCH AND DEVELOPMENT ACTIVITY
A BRAND NEW DOWNSTREAM This year Friul Filiere is celebrating its 40th anniversary and Fakuma 2018 (stand 6111, hall A6) represents a great opportunity to celebrate such an important milestone showing the latest technological developments, firstof-all, amongst them, the brand new downstream Futura40, whose name wants to pay homage to this event. Its modern and appealing design states four decades of technological values, finding roots in the past but looking to the Future. Futura40 highlights are: - attractive and ergonomic design; - energy savings; - perfect alignment; - invisible wires and connections; - easier HMI; - motorized movement of the calibrating table;
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A detail of a calibration system
- process data control; - simplified maintenance; - remote assistance service; - higher safety standards; - low noise pollution. Moreover, Futura40 meets Industry 4.0 requirements, such as: - process data control; - remote assistance service; - PLC control; - simple and intuitive HMI; - latest safety standards; - predisposition for tele-diagnosis; - connection to the smart factory system; - separation between the network for remote assistance and the network for data interconnection.
ON DISPLAY AT THE FAIR During Fakuma 2018, Friul Filiere shows an MACPLAS INTERNATIONAL AT FAKUMA 2018
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Omega80 single-screw extruder equipped with a dedicated screw designed by Friul Filiere itself and with a special tooling for the production of TPU profiles. It combines energy savings and high output rates (160 kg/h) thanks to specific technology that reduces power absorption. But, there are many other novelties. Currently, Friul Filiere is the only company in Europe able to provide customers with a complete process know-how for the production of Resysta composite profiles: extruders, tooling, calibration systems, extrusion lines and auxiliary finishing machines. The sustainable material Resysta consists of approximately. 60% rice husk, it is 100% recyclable, and absolutely water-resistant. Therefore, it features an excellent eco-balance and impresses under harshest weather conditions. Resysta looks like wood, it feels like wood, but it can do much more.
R&D The commitment of Friul Filiere to research is straight and steady, also prompted by ambitious requests for applications in the most different sectors. This is witnessed by a series of new technologies such as:
Dual extrusion of Resysta composite profiles
- extrusion lines, extruders, tooling and process know-how for the production of: thermal-break multiple exits profiles in PA66 and glass fibres with application in the windows sector; PVC, TPE, HDPE bundling profiles; embossed PC profiles, transparent like glass, destined to the LED lighting sector; - complete lines, die heads equipped with Tubeasy system (patent for centring the flow thanks to only 2 screws), special calibration systems and know-how for the extrusion of: 6-8-mm diameter pipes in PA6-PA11 at the
highest speed ever achieved (110 m/min); rods with and without inserts but also tubes, in special materials such as TPU; corrugated and non-corrugated metal hoses coated with extreme thermoplastic materials such as TPU; - technical solutions design and special machines production for: punching, belling, cutting, stretching pipes and profiles; all surface finishes; coextrusion and post-extrusion of different materials. www. friulfiliere.it
Design by:
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TURN A NEW LEAF, DON’ T MAKE THE CONVENTIONAL CHOICE
www.filtec.it
HALL A6 STAND 6422
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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
PROCESS GLUING PROCESS Stand A4-4201
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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16 - 20 October 2018 Friedrichshafen - Germany 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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Magic MP
PROCESSING MACHINERY
FULLY ELECTRIC BLOW MOULDING MACHINES FOR THE US MARKET
THE EVOLUTION OF SPECIES “AFTER A NUMBER OF YEARS IN WHICH WE HAVE NOT BEEN PRESENT AMONGST THE EXHIBITORS, THIS YEAR WE FELT THE NEED TO TAKE OUR FULLY ELECTRIC MACHINES ALONG TO THE NPE FAIR. AFTER ALL, AROUND TWENTY YEARS AGO, WE WERE AMONGST THE FIRST TO INTRODUCE ELECTRIC MACHINES INTO THE BLOW MOULDING SECTOR, AND THUS PROVIDED THE MARKET WITH INDICATIONS TO FOLLOW FOR THE FUTURE”, FERRUCCIO GIACOBBE, PRESIDENT OF MAGIC MP BY GIROLAMO DAGOSTINO
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chines. Indeed, Ferruccio Giacobbe, president of Magic MP since 1995, in an interview with MacPlas during the Orlando fair, pointed out that the American market remains attached to rather dated solutions, with operators preferring the old hydraulic rotary machines. Only recently American manufacturers have started showing an interest in fully electric blow moulding technology, even though, from the users’ perspective, the advantages of these machines over the hydrodynamic ones, still so popular in the US, are well established. At NPE 2018, Magic MP put on a great display of its technology in the so-called “bottle zone”, a special themed area devoted to companies manufacturing systems for the production of containers for liquids.
TWO MACHINES AND FOUR PATENTS The Italian company exhibited two machines at
the Orlando fair: the ME-L5-8/D-LS, a fully electric machine designed for extrusion blow moulding of two-litre HDPE cans using a 2+2 cavity mould, and the MTM 152, also a fully electric The president of Magic MP, Ferruccio Giacobbe (first on the left), chats with visitors to NPE 2018
Magic MP
I
t was 1997 when Magic MP, began marketing its first fully electric blow moulding machine, designed mainly for the production of small pharmaceutical and cosmetics containers: Baby Electric - this was its “battle name” was the forerunner of the ME series of fully electric blow moulding machines, which, to this day, has continued to be the benchmark for many manufacturers active in the industry. The NPE fair in Orlando, which is this sector’s most important trade fair on the American continent, recently provided an opportunity to exhibit the latest “electric gems” developed by Magic, which the company, in the meantime, has flanked with injection stretch blow moulding machines, thereby completing a broad product range that today comprises 19 models. Many are of the opinion that the US market has yet to assimilate specific know-how regarding fully electric solutions for blow moulding ma-
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machine, in this case used for injection stretch blow moulding of PET cosmetics containers, which was fitted with a 2-cavity mould. These two Magic machines alone boast as many as four patents and, given the innovativeness and modernity of the technology design choices they embody, they are certainly to be considered forward-looking solutions. The medium-sized ME series comes in four versions, each designed and built entirely by Magic MP and offered with a wide range of components and accessories, e.g. for deflashing and for application of the level view stripe, the bottle-picking robot and the integrated vision system for bottle checking, IML and so on. The model exhibited at the fair was also equipped with a long stroke system and a fully electromechanical drive, making it possible to reach a
Magic MP takes over Automa
Historic blow moulding brand remains Italian Italian blow moulding machinery manufacturer Magic MP, a global operator, has recently taken over the brand and know-how of Automa, another Italian company operating on the international blow moulding market. Magic was motivated, in this action, primarily by the desire to ensure that Automa, a historical brand, remained part of Italy’s industrial heritage, given that a company based in Turkey was also interested in purchasing it. The Monza-based company decided to play its hand early, also wanting to prevent the Turkish competitor from stepping in - and thus increasing its strength on its domestic market, given that Turkey has always been very important for Magic MP - as well as taking over the international customer base of Automa. The Plast 2018 fair (held at the Milan fairgrounds from May 29 to June 1) provided Magic MP with a platform for its first public outing following the acquisition. The two brands were present side by side at the same stand, providing international visitors with official confirmation of the new ownership of Automa.
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Magic MP
PROCESSING MACHINERY
clamping force of 140 kN. All this is combined with a system for linear carriage movement on prismatic guides, adjusted with micrometric accuracy, for conveying blow-moulded containers with capacities of up to 5000 cm3. Like all the models in the ME series, the one ex- The ME-L5-8/D-LS extrusion blow moulding machine hibited at the fair was also fitted with a patented exhibited at the Magic MP stand in Orlando device for recovering electric power during the braking phases. Indeed, the energy accumulated during braking of the motor is regenerated the smallest on the market; it produces conand fed back into the circuit. tainers ranging from 20-ml phials (when used Further bearing out the technological value, in with multi-cavity moulds) to 2.5-litre containterms of energy saving, of the ME series blow ers (when used with single-cavity moulds), and moulding machines, the particular model men- it is used for the production of cosmetics contioned here was taken as a reference for the tainers in PET”, explained Ferruccio Giacobbe, drafting of the Euromap 46.2 recommendation, who then went on to use the term “mechatronaimed at providing a precise standard for cal- ics” to describe the technology installed on this culating the energy efficiency of extrusion blow machine. moulding machines. The energy-saving capacity The interdisciplinary approach to the design of these systems is beyond doubt, considering of the machine, a combination of mechanics, that the ME-L5-8/D-LS records average con- electronics and computer science, results in sumption levels ranging from performances able to gener18 to 25 kW, as opposed to ate highly effective clamping the approximately 90 kW of a forces, with minimal energy hydraulic machine. expenditure. “Here there are Fully electric systems also ofadditional advantages to be fer a range of other benefits, had, given that, in this case too, such as their very small and on these particular maenvironmental footprint, nowchines, the forces in the field adays an increasingly importare superior to those of extruant consideration, given that sion blow moulding. In fact, environmental awareness is we use mechanical linkagbecoming a strategically imes which are electrically opportant factor shaping a comerated for injection and blow pany’s image and the range MTM 152, a single-stage injection moulding, electromechanical of solutions it offers. The ab- machine for the production of PET platen clamping systems (patcosmetics containers sence of hydraulic oil in sysented), and carriage motions tems used for the production of food packaging operated by electrically driven rotary tables. All translates into greater safety levels, as it limits the this, which allows you to work, according to the presence of contaminants in bottles; this is an necessary pressures, at very low power levels, important feature in the pharmaceutical indus- adds up to considerable energy savings” says try and “luxury cosmetics” sector, too. Addition- Giacobbe. It might even be said that what we al advantages are the reduced need for spare are describing here are interdisciplinary systems parts (saving 60% in comparison with traditional that make these production tools suitable for inhydraulic machines) and the added convenience clusion in the new Industry 4.0 models, which of not having to replace the oil unit, or dispose of can also be monitored remotely. used oil. Being oil free, these machines are suit- A synthesis of applied mechanics, Magic MP able for use in sterile rooms, clean rooms and technology is set to become even closer to US laboratories where safety is indispensable. users following the opening, in August this year, Over the past twenty years, Magic MP has in- of a new 200-square-metre site in Michigan. In stalled more than 1,000 machines of this type, other words, US operators will be able to see a figure that is expected to rise to 1,080 by the Italian blow moulding machines at first hand, at end of 2018. the headquarters of Magic North America. This site will initially be used solely as a show room, but subsequently, in order to provide these opTHE MECHANICS OF THE FUTURE “The MTM 152, a single-stage injection stretch erators with a local supplier, it will provide an blow moulding machine, also offers all the ad- on-site assistance service, with spare parts and vantages of the fully electric solutions. The components available in real time. model shown at NPE is considered one of www.magicmp.it MACPLAS INTERNATIONAL AT FAKUMA 2018
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PROCESSING MACHINERY
THERMOFORMING TECHNOLOGY
KEEPING THE PACE WITH CUSTOMERS AND MARKET THE PRODUCT RANGE OF WM THERMOFORMING MACHINES, HEADQUARTERED IN STABIO (SWITZERLAND) ALLOWS PROCESSING A WIDE SPECTRUM OF MATERIALS TO OBTAIN A LARGE NUMBER OF APPLICATIONS. THE MANUFACTURER PARTICULARLY FOCUSES ON THE DEVELOPMENT OF HIGH-SPEED AND HIGH-PRESSURE TECHNOLOGY
H
eadquartered in Stabio (Switzerland), WM Thermoforming Machines has been manufacturing thermoforming machines since 1981 and is currently recognized as one of the leading companies within the industry thanks to the close cooperation with their customers, mould makers and suppliers of raw materials. The specific knowledge acquired in the thermoforming technology and the continuous research and testing result in a strong presence on the market with innovative machines, equipment and devices responding the needs of the packaging industry. There are different applications and concepts in thermoforming, but WM Thermoforming Machines is particularly focused on the high-speed vacuum and high-pressure technology and its development. Through the years, the company has faced many challenges and has successfully responded to customers and market needs: - higher clarity of packaging: WM in-line ex-
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trusion and thermoforming technology ensures a better transparency of the PP thanks to solid forming for providing linear orientations; - more tamper evident solutions: WM has actively contributed to several successful projects in collaboration with renowned mould makers; - in-line labelling and marking system: WM can provide solutions with integrated label-
ling and marking system; - portion packaging instead of large containers and beverage downsizing: WM new stacking system allows to stack, count and bag also products with complex shapes, fully automatically; - flexible machinery to run small and medium productions, responding to the growing customized and downsized product packaging: WM Robot Stacker (RS) and quick
The company headquarters in Stabio, Switzerland
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mould change ensure 45-minute production changeover; - reducing resin cost by using fillers or expanded materials, especially with materials replacing PP such as EPS, PS, OPS; PET, on the other hand, replaces some of the PP products due to its lower density; - WM in-line extruders and thermoforming lines with in-mould trimming technology are a perfect solution for processing PP and 2-colour material with fillers to achieve close tolerance for food packaging at a lower cost; - lower energy consumption: WM offers a regenerative feeding system, heating elements of latest technology, improvements to align to the European Directive EuP2005/32/EC (Eco-Design of energy-using products); - labour cost reduction: the system is fully automated and can be operated by only one machine supervisor; continuous processing for increased efficiency, with consequent decrease in the dollars CapEx cost versus labour cost (fully automated vertical production). Furthermore, WM is keeping an attentive eye on the market demands and on customer feedbacks and requests, to keep the pace and provide tailored solutions to their needs.
Two machines of the FC and Intec ranges: together with the FT and Twist ranges they forms the wide offering of WM Thermoforming Machines
PRODUCT RANGE AND APPLICATIONS FC series These are vacuum and pressure thermoforming machines with steel rule cutting technology, suited for contract thermoformers who need to cover and satisfy flexible medium-high productivities. FT series This range includes in-mould trimming machines with punch-and-die and with lower tilting platen; they are suitable for high quality products and medium-long productivities, including a wide range of automatic stacking devices which are defined according to final product requirements. Twist series These in-mould trimming with punch-and-die thermoforming machines with lower tilting platen differentiate from the previous ones for the absence of mechanical cams. One-step-ahead technology that makes the Twist series one of the most interesting solution for medium-high productions of little tubs, dairy containers, pots, disposable cups and lids that require closed cutting tolerance, high product quality within a fully automated process. MACPLAS INTERNATIONAL AT FAKUMA 2018
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Intec series Showpiece of WM Thermoforming Machines product portfolio are the in-line plants of the Intec range, real production islands including sheet extrusion, thermoforming, direct scrap recycling, up to the final product packaging. One of the most efficient system to produce disposable cups, plates, margarine tubs and yogurt containers. The WM machines can be used to process a wide range of raw materials in order to produce a large number of applications; they can produce: - parts for industrial packaging and food trays for the retail channel; - disposable cups, plates and dairy containers.
CUSTOMER CARE AND AFTER SALES SERVICE The immediate and professional response of highly skilled professionals is valued by all of WM customers. The company also offers customized training courses at its headquarters in Stabio to instruct their customers on
the latest available technology and the optimal use of its thermoforming machineries.
DIFFUSION AND SALES ORGANIZATION Today WM Thermoforming Machines is worldwide recognized as one of the major and bestin-class thermoforming machines manufacturers, renowned for its high-quality products and advanced technological standards of its equipment and has installed more than 1000 thermoforming machines and 100 complete in-line plants in more than 60 countries. The company has a global presence through a diffused sales organization supervised by 7 area managers who maintain a continuous relationship with their agents and customers to cover their daily needs. www.wm-thermoforming.com
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PROCESSING MACHINERY
HIGH-LEVEL TECHNOLOGY DEVELOPMENT
CHALLENGING RECYCLING AND COMPOUNDING FOR THE MOST CHALLENGING PROCESSES OF RECYCLING AND COMPOUNDING BINOVA PROPOSES LINES BASED ON ITS LATEST TECHNOLOGY DEVELOPMENT, CONSIDERED THE MAIN ROAD TO BE TAKEN TO ENSURE THE PROCESSORS TO OBTAIN HIGH-PERFORMANCE END PRODUCTS
A
reality able to bring innovation and development in the field of recycling and compounding starting from production or post-consumer scraps, today Binova (stand 6207, hall A6, at Fakuma 2018) is mainly characterized by the capacity to realize plants able to completely fulfill the requirements of the end user. In most cases, such plants are developed in cooperation with the customer with the aim to find the most suitable solution to employ in the different situations. Respecting its “modus operandi”, Binova has completed the setup of a line based on a corotating EBB71 twin-screw extruder, equipped with automatic filtration, volumetric pump and forced feeding unit for material with low apparent density (0,06 kg/dm3), for recycling and compounding HDPE scraps, with an MFI from 0,3 g/10 min to MFI 1,3 g/10 min (190°C/5 kg), with a production of
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about 500 kg/h. The plant is able to compound light material scraps, such as films coming from production or from washing plant with a residual moisture up to 8%, with
The Binova line is equipped with a software that controls the whole production, even in the case of high working rhythms
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particular mixtures of pellets and/or grinded and/or densified material, also with the possibility to add mineral fillers based on CaCo3 base or talc up to 40%. The mixing of different raw materials, performed directly in the machine, ensures a perfect homogenization that increases the quality of the final product. The dosing system of the different components can be either gravimetric or volumetric. This plant is the latest level of development realized by Binova, and allows: - high quality final product with an MFI unchanged in comparison to the material introduced at the beginning of the cycle; - the reduction of processing costs with energy saving up to 40% with respect to the standard lines today on the market (for the whole plant from 0,29 to 0,33 kW/kg, in function of the MFI of the material introduced at the beginning of the cycle).
Two views of Binova recycling and compounding lines
SOFTWARE AND REMOTE CONTROL The line is equipped with a software that controls the whole production, even in the case of high working rhythms. The plant is equipped with an automatic OP control panel with Internet connection, which can also be remotely managed. In this way, the technician or the production manager can check the status of the line process data from their smartphones. The operator can set different production recipes or formulations to which single production parameters are connected (temperature, pressures, rpm etc.)
Power module The barrel is equipped with a particular loading opening, which can adapt to the application of different types of feeding hoppers: gravity fall or forced. On the screws, in this area, there are special sectors with a profile that ensures high transport capacity, especially when the extruder is equipped with a compactor, required for the introduction of low bulk density materials such as, for example, scraps of films (around 0,06 kg/dm3).
THE BARREL AND THE SCREWS
Standard module Inside this type of barrel, the thermoplastic inserted into the extruder is transported, heated, and melted. On the screws, in these areas, there are transport, mixing and homogenizing elements with profiles compatible with the processed material.
The corotating twin-screw extruders of the EBB BiReC series are equipped with modular barrels and modular extrusion screws, with self-cleaning sectors, mounted on grooved shafts. The barrels, with a different L/D ratio are thermostated by water and by pressurized air in high insulated conveyors that grants the maximum energy saving in warming up. To build them, special chromium steel is used, but in some cases anti-wear and/or corrosion proof bimetallic materials can be used. In addition, it is possible to employ special interchangeable bushes, made of hardened steel with a highly resistant core. Fully exploiting the principle of modularity, the twinscrew extruders can be configured in such a way as to optimize the use according to the applications.
THE BARREL IN DETAIL The sectors of the barrel can be briefly described as follows. MACPLAS INTERNATIONAL AT FAKUMA 2018
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Degassing/venting module The barrel is equipped with exhaust flues that can operate in the presence of both vacuum and atmospheric pressure. At the degassing groove, the screw has a specific profile suitable to facilitate the expansion and the evacuation of gases, vapours and all the volatile fractions formed during processing. Lateral feeding module The barrel is arranged for the lateral and/ or vertical introduction of powder products, resins and/or liquids. Depending on the additives to be added, the shape can take different aspects and the screw profile will be adapted to the type of product to process.
Binova’s product range also includes special recycling lines that exploit the connection in cascade of single screw to single screw, twinscrew to single screw or twin-screw to twinscrew extruders for the process of particular scraps or for double filtration needs. Such lines can be equipped with agglomerators/ compactors for the process of high printed materials and/or materials with up to 15% moisture. By means of corotating twin-screw extruders employed in these plants, the company intends to propose a high quality product, being convinced that this is the main road to be taken for the future of the recycling and compounding starting from scraps. A market analysis has shown that there will be more and more requests for this type of machinery. This is due to the need to be able to treat second-choice products or post-consumer scraps, trying to keep as much as possible the technical characteristics of the material introduced and/or even trying to ennoble it by adding mineral fillers or whatever. The final quality of the product, ensured by technologically advanced systems, allows the recycler or the compounder to also look at market sectors that were historically considered unrelated to his skills. Binova strategy is to keep the product at a high quality level, with the aim of convincing the market about the opportunity to face investments able to ensure results that meet with the expectations. www.binovapm.it
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PROCESSING MACHINERY
NEWS The recycle according to Gamma Meccanica
The development of Tandem regeneration lines keeps on The first half of 2018 was very positive for Gamma Meccanica (stand 6218, hall A6, at Fakuma 2018), Italian company specialized in the production of lines for the regeneration of plastic materials. The recent events NPE and Plast in which the company took place - proposing, in particular, the new GM Tandem range of regeneration lines - brought many interesting prospects and confirmed the growing interest in this type of technology. The Tandem technology has been developed for many years and recently has been redefined. The most recent systems delivered are the result of continuous technological improvements with a high level of automation, maximum quality of the recycled product (granules) and tremendous energy savings. Thanks to GM Tandem technology it is possible to recycle heavily printed, highly moist and highly contaminated plastic materials. The line is composed of a Compac unit equipped with the Ecotronic system, a primary extruder, a primary screen changer, a connection neck with a special
degassing chamber, a secondary extruder, and, as an option, a second screen changer for finer filtration/purification of the melt and then the pelletizing system. The Ecotronic system, by increasing the number of revolutions above the nominal speed of the motor, allows controlling the temperature without adding water and processing materials with a high percentage of humidity. Ecotronic guarantees a notable energy savings (up to 40%). An Italian customer has recently installed GM Tandem 160 line for the recycling of milled HDPE. The customer had to recover parts of agricultural plants, in particular irrigation pipes, with high level of contamination from the ground and other residual materials. The material to be recycled is sent to the Tandem regeneration line directly from the washing plant with a humidity rate of approx. 8%. Thanks to the patented and innovative degassing system, 10 times more efficient than traditional systems, humidity is expelled directly during the extrusion phase. The dual filtration up to 100 mi-
crons, guarantees the removal of even the smallest parts of contaminants. The production capacity of this Tandem line and with this type of material is 1200-1400 kg/h. A North American company, instead, purchased a GM Tandem 180 line for the regeneration of PP non-woven, PP raffia bags, BOPP heavily printed film and PE film. These post-consumer and post-industrial wastes have high rate of contaminants like paper, aluminium, PET, PA and sand. In this case the GM Tandem 180 line has the primary extruder with a diameter of 180 mm and the secondary extruder with a diameter of 210 mm and a guaranteed production up to 1500-1700 kg/h. Given the growing interest of recyclers for the Tandem lines, Gamma Meccanica is developing new models. The next line that will be manufactured is the GM Tandem 210, composed of two extruders, with diameters of 210 and 250 mm, and with a production capacity starting from 2000 kg/h. The company has always been aware of the importance of re-
covering such a precious resource as plastic. For this reason, in addition to offering lines for the regeneration of plastics with growing performances, it is participating, together with a group of Italian companies operating for many years in the recycling machinery field and the European association of plastic recyclers (PRE), at the project “Are you R?”. This aims to raise awareness amongst European people on the importance of plastic recycling. The goal is to spread the culture of recycling. Through a number of documents, photographs and funny animation films, the project reveals the advantages of plastics and explains how its impact on the environment could be reduced if correct behaviours were maintained. This was one of the topics of the “Packaging and Recycling” convention, held in Milan on September 26-27 and sponsored by Gamma Meccanica itself. www.gamma-meccanica.it
The GM Tandem 180 model
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nella nella nella progettazione progettazione progettazione e eproduzione eproduzione produzione dididi ribobinatrici ribobinatrici ribobinatrici per per per film film film estensibile estensibile estensibile ee e perforatori perforatori perforatori per per per materiale materiale materiale ininin movimento movimento movimento
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PROCESSING MACHINERY
A Presma single-station injection moulding machine equipped with BIC injection group, patented for the injection moulding of high-thickness articles
NEWS Presma supply
Single-station for bicomponents An injection moulding machine with a clamping force of 1,600 tons, capable of co-injecting a total shot weight of 20 kg (sandwich structure) has been recently supplied by Presma to an Italian processor. This machine is equipped with an automatic moulding cell and can optimize the production of large items in bicomponent material (solid/foam), that is already carried out using Presma machines, but of the rotary, multi-station type. This supply represents the first example of a medium-sized single-station machine equipped with the special “BIC” injection unit that, ever since it was patented in 1981, has been offered by this Italian company for the moulding of articles with high thicknesses. Co-injection, or two-component moulding, is the technology that
allows the simultaneous injection, through the same nozzle, of two materials: in this case, a solid one, and one containing chemical foaming agents. This technique makes it possible to obtain high-thickness articles that have a skin in solid material and a core in expanded material, thereby eliminating the problem of deformations, cracks, areas of shrinkage, and many of the problems typical of high-density articles moulded in the conventional way. Co-injection is a justified choice for articles thicker than 5 mm that need a smooth and shiny surface. Considering that for the exterior a high-quality material is required, while an inferior quality or recycled material can suffice as a filler, it is clear that there are considerable savings to be made. Further sav-
ings can be obtained from the colourant, which is needed only for the external material. The costs generated by the long moulding cycles needed for products of a certain thickness can be broken down intelligently if one exploits the possibility of working on multiple moulds and varying the model of the product. This is one of the most important advantages of combining co-injection with a multi-station system. The need to have single-station versions on hand as well is dictated by the fact that some articles have to be produced in different colours and/or different materials, and, in such cases, no series of moulds are provided. These are articles that have to be made according
to a special design and with reduced thicknesses and must, in any case, guarantee structural elasticity. In these situations, it is crucial to combine a solid material for the surface with a foamed one for the core, and in this way it is also possible to obtain excellent aesthetics and advantages in terms of the appeal of the product and its costs. In the first week of September a second single-station machine, also for co-injection moulding, was delivered to the same processor. This is a 400-ton machine with an injection capacity of 7,800 cm3 and it is destined to the moulding of items with low thicknesses that do not need long cooling times. www.presma.it
Produced by co-rotating twin screw extruders
Foam pipes for insulation A wide range of solutions for foam pipe extrusion is proposed by Sara. 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 according to
RS80 co-rotating twin screw extruder for foam pipes
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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. Corotating 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 is reached easily. www.sarasrl.eu
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comimm.it
only in group the finish line is reached
7
7
5
5
COMPANIES CONTINENTS
1
1
GROUP
poliblend.it poliblend.it
Poliblend S.p.a. - Via Piccinelli, 12 - 22076 Mozzate (CO) Italy - Tel. +39 0331 838911 - Fax +39 0331 833.295 - E mail: info@poliblend.it
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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”.
Purging it 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
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ANCILLARIES AND COMPONENTS
ECODRY SYSTEM 4.0
COOLING SYNCHRONIZED WITH PLASTICS PROCESSING THANKS TO AN APPROACH BASED ON THE COMPLETE DIGITAL CONNECTIVITY BETWEEN MOULD TEMPERATURE CONTROL SYSTEM AND INJECTION MOULDING MACHINE, FRIGEL HAS EVOLVED ECODRY SYSTEM AND ADAPTED IT TO THE CURRENT 4.0 INDUSTRIAL REVOLUTION
T
he revolutionary concept of Ecodry System in the plastics industry by Frigel integrates high performance mould cooling units (Microgel) connected to each mould with a close circuit adiabatic central system (Ecodry) for overall plant heat dissipation (replacement of old cooling tower technology). Microgel are super compact units specifically designed to significantly reduce cooling cycle time in moulding applications and combine, in one machine, a water cooled chiller with one or two booster pumps high precision temperature controllers.
brings plastics cooling and temperature control into the future: the Industry 4.0 revolution. From complex automotive injection moulded parts to high-speed thin wall packaging, this new “synchronized cooling” approach covers all cooling demands in plastics moulding with unbeatable
performance improvements, cycle time reduction and costs savings together with outstanding reduction of environmental impact. The system is based on two technologies. The first consists in process-synchronized mould temperature control units - a complete range
Now, Frigel (stand 5108, hall A5, at Fakuma 2018) takes Ecodry System to the next level. The new approach is based on fully digital connectivity between mould temperature control and moulding machine that, together with several innovative engineering improvements, MACPLAS INTERNATIONAL AT FAKUMA 2018
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Magic MP
ECODRY SYSTEM 4.0
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ANCILLARIES AND COMPONENTS
from 5 up to 200°C (Microgel, Turbogel and Thermogel). A complete range of mould temperature control units that cover every specific mouding application: number of zones and temperature range; heating, cooling and pumping requirements on each zone of the mould. Digitally-synchronized with the moulding machines and automatically operated by them, now processors can research the best cooling parameters and cycling sequence of heating and/or cooling on each zone of the mould that maximizes the processing quality and throughput for each specific product. These parameters may be memorized and then restored anytime the line manufactures the same product. The second technology is based on a central adiabatic water cooling system (Ecodry). To complete the Ecodry System, all the cooling units installed at each mould are connected to a central adiabatic water cooling system installed outdoors to reject the heat extracted from the processes to ambient. This modular system - an alternative to old-style open circuit evaporative cooling towers - is made of closed circuit adiabatic fluid coolers that can keep the coolant temperature even lower than ambient temperature. Additionally, this central system can also provide direct cooling to all other requirements above ambient temperature, such as hydraulic machines cooling, resin dryers, air compressors etc.
PERFORMANCES Increased productivity Process-synchronized cooling guarantees that each mould always runs with shortest cooling time, consistently producing high quality moulded parts at the highest throughput. This is due to two main reasons: - maximum flexibility: thanks to the complete range of units available, there is no limitation for settings of coolant temperature (from 5 to 200°C) and flow rate delivered to each mould zone for any kind of application; - perfect repeatability: the serial communication and synchronization capabilities assures precise temperature control of the mould, with no interference, while the processing equipment always runs steadily at the highest throughput. Reduced operating costs The Ecodry System 4.0 achieves remarkable running cost savings when compared to traditional central systems: energy savings (up to 30%), water savings (up to 95%) and maintenance costs savings (up to 90%). The new system based on synchronized mould temperature control units, results in high energy savings (up to 30%) due to the following main reasons:
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Components that can constitute the Ecodry System
- synchronized cooling: all the mould temperature controllers units, being serially connected to demoulding machines will automatically stop when production is stop saving both refrigeration and pumping energy consumption; - intelligent use of chilled water (Microgel): the new concept allows the use of chilled water only where and when it is needed and running at temperature required by each specific process. For all moulds requiring high coolant temperature no chilled water is needed so cooling could be provided from the central adiabatic cooling circuit connected to them, with minimum energy consumption; - free-cooling options: the main concept is to use low ambient air cooling instead of refrigeration whenever the ambient temperature allows to. For this purpose, every Microgel integrates the automatic free-cooling feature. The coolant returning from process will be diverted to the adiabatic coolers to be rejected to the ambient air with minimum energy consumption. As a result, the refrigeration compressors will be stopped during winter time. As anticipated the water savings reaches 95%. This concept uses a central adiabatic cooling system for heat rejection of the whole thermal load of the plant. This technology operates water evaporation only during short periods of time whenever ambient temperature is extreme (above 30°C). An on-demand intelligent saving software operates adiabatic mode only when needed. Otherwise, the system runs completely dry. Moreover, maintenance and safety costs are reduced up to 90%. The refrigeration units are made of relatively small chillers, which require low expertise to maintain or repair. The chillers are built with leak-free refrigeration circuits, which makes them almost maintenance free. Operating with innocuous gases, they do not require any specific safety infrastructure, saving
all costs involved, including safety insurance policies. On the other hand, the central adiabatic system is a close loop circuit that provides excellent heat transfer with maintenance-free coolant, avoiding scale accumulation and minimizing the need for ongoing water treatment. Modularity This modular, plug-and-play concept has many additional advantages compared to traditional systems. It is easily expandable at any time, which allows the installation of the precise capacity needed at every stage of the plant growth. Thanks to its modularity, it is also extremely easy to gradually implement even in existing plants, one unit at a time, requiring low level of expertise to engineer, install and operate. Eventually, it could be partially or totally relocated. An additional advantage of this new concept is that it allows processors to know the cost of refrigeration per line and per product because each unit can measure and record the specific energy consumption per product.
SUSTAINABILITY The Ecodry System achieves outstanding results in terms of environmental impact reduction. The carbon footprint is reduced up to 50% thanks to its unbeatable energy efficiency and free-cooling opportunities. Also the water footprint is reduced almost up to 95% thanks to the Ecodry adiabatic cooling heat rejection technology. Last but not least, the system uses innocuous refrigeration gas with the lowest GWP (Global Warming Potential) available today and is divided into several separated small circuits. So the risk of emissions in the case of leakage is reduced to a minimum. Finally, there are no water treatment chemicals to dispose as in the evaporative cooling towers. www.frigel.com MACPLAS INTERNATIONAL AT FAKUMA 2018
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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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ANCILLARIES AND COMPONENTS
INDUSTRY 4.0 IN THE SPOTLIGHT
TAILORED HOT RUNNER SOLUTIONS AT THE CENTRE OF THIS YEAR’S FAKUMA PRESENTATION BY HOT RUNNER SPECIALIST HRSFLOW ARE APPLICATIONS OF ITS FLEXFLOW TECHNOLOGY OF SERVO-ELECTRIC DRIVEN VALVE GATE SOLUTIONS
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t Fakuma 2018 (stand 2217, hall A2), HRSflow (Inglass Group) is demonstrating the universal application of its Flexflow technology of servo-electric driven valve gate solutions based on examples of complex, high-quality parts. Produced with the help of advanced hot runner solutions, they range from technical parts for the automotive industry to an extremely thin-walled laptop housing and an ultra-light tool box. In all cases, the ability to individually control the pressures and flow velocities at each
In the production of an ultra-light centre armrest, the thermoforming of the carrier is followed by encapsulation with PP and finally over-moulding with a flexible TPV with good grip properties
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gate makes the Flexflow technology an optimal solution for large and small applications, even with thermoplastics that are very difficult to process. As a first step in the direction of IMM integration (according to Industry 4.0 requirements), the company presents the option of using the touchscreen of the respective injection moulding machine to control the Flexflow settings, which only recently became available.
LIGHTWEIGHT CONSTRUCTION AND CLASS A SURFACES FOR THE AUTOMOTIVE INDUSTRY In cooperation with tool specialist GK Concept and injection moulding machine manufacturer Yizumi, HRSflow has developed and optimized a hot runner system for the production of an engine cover, using the Flexflow One technology. This servo-electric valve gate solution combines maximum precision with a broad process window and attractive cost efficiency. In the production of the large-sized component, an aluminium foil only 0.2 mm thick is first inserted into the mould and punched into shape during the closing process. Subsequently, the foil is thermoformed during over-moulding with a glass fibre-reinforced polyamide using a Flexflow hot runner system and physical foaming technology. During this back injection phase, in-mould graining (IMG) takes place, in which the fine texture of the mould is transferred both to
the foil and to the polymer surface. The resulting part combines lightweight with very high dimensional stability, low warpage and a premium surface without visible weld lines. A Flexflow 5-nozzle hot runner system is used for the production of the automotive spoiler also shown on the exhibition stand. A PP from A. Schulman, filled with 3M’s hollow micro glass spheres, enables weight savings of up to 15% compared to the unfilled version. Thanks to Flexflow technology, which ensures a more homogeneous pressure distribution in the cavity, the glass microsphere survival ratio is increased with even better distribution. The result is a lightweight component with no visible weld lines that meets the highest requirements for mechanical properties and surface quality. Another lightweight automotive exhibit is a centre armrest that is manufactured in a multi-stage process. Development partners in the realization of this project were the injection moulding machine manufacturer KraussMaffei and the US toolmaker ProperTooling. The load-bearing structure is created from a thin-walled, fibre-reinforced organosheet, using the FiberForm process developed by KraussMaffei. First of all, this is over-moulded with PP and finally with a TPV, whereby a soft, finely grained visual surface is formed. Injection moulding is carried out with two Flexflow MACPLAS INTERNATIONAL AT FAKUMA 2018
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hot runner systems with two (first phase) or three (second phase) hot runner nozzles. The servo-electrically driven, individually controlled valve pins ensure optimum cavity filling and enhance process reliability and cost effectiveness.
triple-nozzle hot runner system from HRSflow with back-injection. The finished part is characterized by a high-quality, finely structured surface.
THIN-WALLED, HEAVY-DUTY HOUSINGS
SYSTEM INTEGRATION INSIGHT
Other typical fields of application for the Flexflow hot runner technology are lightweight yet stable injection-moulded plastic housings. At Fakuma 2018, HRSflow is showing examples from the fields of electrics and electronics as well as general industry. A project that has been developed together with the heating and cooling specialist Roctool, KraussMaffei and the toolmaker Flex is a cover, only 1.5 mm thick, for a 14-inch laptop. It is produced using a high-glass fibre-reinforced PC (up to 50% by weight) injected in cascade moulding, combining a Flexflow 5-nozzle hot runner system with Roctool’s induction heating and cooling technology. The above technologies ensure highest standards in terms of functionality and appearance. In a single shot, this results in a visible surface with high-gloss and matt areas with a cost-efficient cycle time of around 50 seconds. A second example of an innovative housing shown at Fakuma is a toolbox made of microcellular foam, which is characterized by its low weight. Its production is based on the FoamPro foaming process from development partner Yizumi, and a Flexflow
In order to make the Flexflow utilisation smarter and the machine operator’s workplace easier, HRSflow has taken a first step in the direction of system integration, which will ultimately lead to full integration of the Flexflow technology into the world of Industry 4.0. Since June 2018, it has been possible to visualize, via VNC, the display of the control unit of the hot runner system on the touchscreen of the associated injection moulding machine and thus be completely autonomous in terms of settings and functionalities. As a result, the use of a second screen can be dispensed with, optimizing the workplace ergonomically and offering a smarter user interface.
THE FLEXFLOW FAMILY: SIMPLE, SAFE AND CLEAN The integrated servo-electric needle drive the common feature of Flexflow and Flex-
®
A Flexflow 5-nozzle hot runner system is used for the production of this automotive spoiler made of PP, filled with hollow micro glass spheres
flow One - opens up a variety of options for setting process parameters. Thus, the individual needles of a hot runner system can be independently controlled with respect to their stroke, speed and acceleration. This allows users to control the pressures and flow rates during the entire tool filling process in a particularly precise, simple and flexible manner, thus optimizing the quality of their injection moulded parts. The results are improved Class A surfaces and minimized warpage, and the technology also ensures low maintenance and user friendliness. www.hrsflow.com
FM FILTER MONZA FILTER
MANUFACTURE
TECHNOLOGICAL SOLUTIONS FOR INDUSTRIAL FILTERS EXE Spazio pubblicitario 172x90 ing 4_2018.indd 1
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fm@fmfilter.com www.fmfilter.com
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The apse of the Basilica of Sant’Apollinare in Classe, in Ravenna, during the concert dedicated to IPM
ANCILLARIES AND COMPONENTS
ITALIAN PLASTIC MACHINERY: ITS FIRST THIRTY YEARS IN THE BUSINESS
AN IMPORTANT MILESTONE
“SUCCESS IS NOT ONLY ACTION BUT ALSO, AND ABOVE ALL, PASSION, COMMITMENT, ANALYSIS, DIALOGUE, INTERACTION AND SHARING” IN THE EXACT WORDS OF SILVIA GEMINIANI BY ANGELO GRASSI AND RICCARDO AMPOLLINI
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magine the eternal cool of the interior of a Roman basilica, the name of which we won’t reveal for now. Can you? Now imagine being seated in the central nave of this basilica, with on the right and left, two side aisles. You cannot help but be in awe of the amazing decorations, in the apsidal conch in front of you, in the up-
per part is a large oval, which encloses a star filled sky where a jewel studded cross is situated. Discreetly around the cross is the hand of Christ. At the side of the oval are the figures of Elijah and Moses. Lower down Apollinaris, the Roman Bishop from Antioch of Syria, who was made a martyr in the town of Ravenna. SuddenSilvia Geminiani, CEO of IPM, with partners Bruno Barabani (left) and Claudio Argnani
ly the sound of instruments, merging with the choir, disturbs your architectural contemplation. A dream… an idyllic context; and anyway what has all this got to do with plastics? The connection was explained to MacPlas editors by Silvia Geminiani, the chief executive officer of IPM, during Plast 2018. It is in fact Silvia Geminiani herself, together with Claudio Argnani and Bruno Barabani, who founded the IPM company (acronym of Italian Plastic Machinery), here in Romagna, where the machines for the extrusion and processing of plastic piping and profiles are produced, such as automatic and semi-automatic socketing machines, haul-off equipment, cutters, threading machines, slotting machines, drilling machines, bending systems, automatic packaging systems, as well as others.
THE INTRINSIC VALUE OF SHARING IN THE COMPANY A SUCCESS STORY Both common sense and scholarly academic studies confirm that in order to make a winning
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company the production of high-tech products at competitive price levels is not enough. Successful companies are those that rely on teamwork. Successful companies are those that share their results with their employees, their clients, suppliers and friends. But this is no romantic notion of a company. “Success is not only a matter of action, but above-all of passion, commitment, analysis, dialogue, interaction and sharing”, pointed out Silvia Geminiani, allowing us to then reveal the name of the mysterious (but not really) Basilica described above: Sant’Apollinare in Classe, located about 5 kilometres from the centre of Ravenna, which has since 1960 been listed as a world heritage site. “The occasion being the important milestone of the thirtieth anniversary of our company IPM. We therefore decided to organize a special event, combining technology with the intrinsic excellence of our local area, in a fun and friendly setting. The true protagonists of the event being the IPM employees and obviously the clients, who surprisingly came in great numbers from all over the world... with the exception of Australia to say the truth, perhaps due to the enormous geographic distance involved. There were three key points to the event that began with a meeting of the 350 guests in the factory, with a welcome speech given by the shareholders and authorities, then a talk on the technological novelties, including the possibility of seeing the operating machines actually at the factory premises, with a tour of the R&D department, the technical office, the production departments as well as the assembly and testing lines and the post-sales organization. The second part of the event featured the wonderful setting of the Basilica di Sant’Apollinare in Classe, reflecting the history of Ravenna as the last capital of the Western Roman empire, and the special features of this building which is one of the most popular ancient Christian monuments of the city. Followed by a concert with some of the most famous works of Rossini, dedicated exclusively to our guests in Italian, English and Russian. The third part of the event was the gala dinner at the elegant “Al Caminetto” restaurant of Milano Marittima, with friend Arrigo Sacchi also there to celebrate IPM. The success of the entire event being much greater than even our most optimistic expectations”, as the IPM CEO proudly declared. An added note of colour being provided by the fact that the modern IPM factory was filled with flags that the after-sale service engineers bring back with them each time they return home from working a new country. It must be added that IPM machines are in fact in operation in no less than 122 countries and that MACPLAS INTERNATIONAL AT FAKUMA 2018
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exports account for approximately 90% of its turnover.
THE “LINE END” SPECIALISTS ADMIRED THE WORLD OVER Simply by looking at the two sets of figures cited above, it is possible to understand that this company is, metaphorically speaking, not like “a painting that is signed by a single artist” but rather “a murals that is the result of the combined work of many artists” in which there are different contributions but which together go to create a vision of a harmonic and well-run company. “In fact, if we talk about the competitiveness of our target markets the so called “end of line” is of great importance for extrusion systems as the productivity is directly proportional to the capacity of the end line itself to enhance the quality and quantity of the piping produced upstream”, underscored Silvia Geminiani, by which she wanted to point out that IPM makes heavy investment especially in a kind of R&D that is applied in a modular manner to the individual work orders, so as to assure that each client is able to fully exploit the global production capacities that it actually has available. This commitment is also the leitmotiv of the presentation at the factory premises of the latest technological novelties proposed to the guests present at the event organized to commemorate thirty years of IPM operation. Whilst remaining in line with the “technological theme”, in the same factory context a series of most recent IPM novelties were presented in the field of the automatic socketing of smooth PVC and PP piping. Together with those in the field of automatic in line socketing with injection system for corrugated PE pipes (patented), as well as those relating to cutting, featuring a new range of cutters (also patented), automatic packaging systems and special machines for off-line operations, such as bending systems, threading machines, slotting machined and pipe drilling machines. A primary example being the recent high speed
The IPM department dedicated to the production of haul-off equipment and cutters, decorated for the occasion with the flags brought back from different countries
RS (or Rieber System) electric socketing machine, that boasts at least two patents, and which can also undertake automatic testing on each socket produced, discarding any that do not conform. In this case the control and running of the machine is guaranteed by the latest generation of Siemens touchscreen panels, which thanks to broadband and wired and wireless network systems - meaning that remote control can be used - greatly facilitates the almost constant interfacing with processors themselves, that may be using IPM solutions anywhere in the world. Last but not last, there is the CT 63 system for automatic bending of high productivity piping (up to 800 bends per hour), which during the factory demonstration, undertook the simultaneous production of no less than four bends in cycle with angle of 90° and with socket at both ends of the pipe. In this context we must say that IPM is one of the few manufacturers in the world capable of offering one of the most extensive ranges of systems for bending with various radiuses and angles and for the socketing of pipes with diameters of between 16 and 500 millimetres. So that as a form of appreciation and admiration, and congratulations for the achievements of these first three decades; not only by the IPM founders, but by the actual clients, the industry and collaborators, that being proud of their role decided to commission and present the three founders with a special gift in the form of a unique ceramic work from the historic ceramic workshop of Gatti (Faenza), bearing the inscription “30 years of IPM. Continually striving, evolving - Always together”! www.ipm-italy.it
IPM partners and employees. On the right: the artwork of the historic Gatti ceramic workshop
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ANCILLARIES AND COMPONENTS
FIVE YEARS OF PROMIXON
A FIRST GREAT LANDMARK IN THE MIXING SECTOR THE FIFTH ANNIVERSARY OF ITS ESTABLISHMENT, A LANDMARK MOMENT, HAS PROVIDED PROMIXON WITH THE IDEAL OPPORTUNITY TO TAKE STOCK, FOR THE FIRST TIME, OF ITS ACTIVITY. FOUNDED DURING THE YEARS OF THE GLOBAL ECONOMIC AND FINANCIAL CRISIS, THIS IS A COMPANY THAT MANAGED TO TAKE ADVANTAGE OF THAT MOMENT, THROWING ITSELF INTO THE “MIX” OF GLOBAL COMPETITION, READY TO EXPLOIT THE OPPORTUNITIES THAT THE RECOVERY WOULD BRING ITS WAY
A container mixer from the FX series
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n the early summer 2018, Promixon has turned five years old, and the anniversary of its establishment has given the company an opportunity to take stock, for the first time, of its activity. This manufacturer has grown rapidly in these early years and its turnover, deliveries and staff are the elements that best illustrate its expansion. The company’s primary aim has always been to supply mixing systems able to offer companies maximum cost reductions, focusing in particular on cutting production times and energy consumption levels. From the outset, it has always been careful to analyse the needs of processors and the most common problems in the mixing sector, so as to be able to approach the market with modern solutions capable of making its customers’ businesses more efficient and com-
petitive. Its development of technological innovations and provision of technical assistance 24 hours a day, 7 days a week, are two aspects that have played a key role in this regard. Thanks to this approach, Promixon lost no time in exporting its systems all over the world, and its turnover has increased with each passing year. This rapid growth has seen the company constantly engaged in recruiting staff across all its departments, with the result that it now boasts a team of 55 highly qualified individuals. Its most important recent achievements include the extension of the production area of its site, the creation of an internal testing room, and the construction of one of the world’s largest mixing systems (model ref. XBlend-MC/2500/8600), designed for the flooring sector, as well as the development of mixers for special applications. MACPLAS INTERNATIONAL AT FAKUMA 2018
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can automatically link the production batch with the appropriate cone in the filling phase, checking the consistency of all the parameters entered.
CONTAINER MIXER
The Promixon headquarters in Magnago
POWDER COATINGS: PREMIXING AND INDUSTRY 4.0 For five years now, Promixon has been exporting, all over the world, tailor-made mixing systems designed to meet every application need it might be asked to address, regardless of the type of material to be processed. One of the most important projects the company has undertaken in recent months has concerned an Italian processor, which needed to replace six horizontal mixers with new high-speed FX container mixers, to be used for mixing thermosetting resins and pigments, fillers and additives. Careful analysis of the processor’s requirements and produc-
tion needs led the company to suggest using three FX-2500 systems, which were built, delivered and installed in less than four months. Furthermore, designed to be compatible with the existing mixing equipment, they also represent a re-engineering of the process along Industry 4.0 lines. Furthermore, a partnership with TraceToo (a company specialising in automatic identification), has led to the creation of smart conveyor cones that, thanks to RFID (Radio Frequency IDentification) batch traceability readers, eliminate manual operations and make product handling faster and more efficient. Intervening on a touchscreen control panel, the operator
The FX series of container mixers is offered as the ideal alternative to traditional high-speed mixers whenever production conditions require a high level of versatility and it is necessary to mix a wide range of different products using the same machine. Thanks to its special design, the container mixer is divided into two separate units: the mixing head and the portable container; the cleaning time between lots is reduced to a minimum and, as a result, so is the risk of contamination. Mixing, storage and transport are all optimised, as all three operations use, directly, the same containers, which can easily be inserted into a metering system equipped with weighing scales or into an extruder feeding metering device. The FX container mixers are also ideal for post-production blending with metallic pigments (metallic blending) ensuring their distribution in a safe and monitored environment, rendered inert by nitrogen. www.promixon.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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ANCILLARIES AND COMPONENTS
ZAMBELLO RIDUTTORI: CONSTANTLY “ON THE JOB” SINCE 1957
IT’S THE EXPERIENCE WHICH MAKES THE DIFFERENCE THE GEARBOX IS A RELATIVELY “SIMPLE” MACHINE, PROVIDING THAT ONE KNOWS HOW TO MANUFACTURE IT PROPERLY, ALSO TAKING INTO ACCOUNT A HOST OF DETAILS… AND ALSO PROVIDING THAT ONE KNOWS HOW TO MANAGE IT IN THE APPLICATION INVOLVED, FOR EXAMPLE MAKING SURE OF THE PERFECT ALIGNMENT BETWEEN THE GEARBOX AND THE MACHINE ETC. BY ANGELO GRASSI AND RICCARDO AMPOLLINI
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s it is known to those that have even only a little knowledge of mechanics, a gearbox is the most classic transmission element. It essentially consists of gears positioned between the machine to be driven and the engine that supplies the power to the machine itself. The main purpose of mechanical gearboxes is that of limiting the rapidity of power transmission, so that the final speed of the machine and the motor torque are actually compatible with each other, obviously with reference to the application involved. It must be said that it is very common to find small gearboxes in kitchen mixers, computers, conveyor belts, or on a larger scale, in vehicle engines as well as in wood, plastic and metal working machines. Without forgetting the large mechanical gearboxes
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used in machinery such as cranes, gantries, galvanic systems etc., right up to the mammoth machines used in quarries for the working of marble and granite, or in paper mills, cement factories, steelworks, and in a host of other various industries. There cannot be any doubt, the mechanical gearbox still today remains the best means of reducing engine speed, whatever type it may be, and for increasing the operational torque maintaining the same power levels - always with a good degree of approximation. Not even the most recent inverters have been able to supersede classic me-
Alessandro Zambello, marketing director (on the left), and Elio Zambello, R&D and internal production systems director, Zambello Riduttori MACPLAS INTERNATIONAL AT FAKUMA 2018
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chanical gearboxes. In fact it is increasingly common to see “inverter + motor + gearbox” combinations in large systems for paper mills or energy and material intensive machinery such as those for the steel and iron industry, for example… So, beyond any form of flattery, MacPlas editors had the pleasure of interviewing the representatives of the second generation of an authentic Italian company, highly esteemed and considered as one of the leading global players in the field of mechanical gearboxes, and in which the third generation is actually ready to join the management. The company we are speaking about is Zambello Riduttori (stand 6105, hall A6, at Fakuma 2108), based in Magnago (near Milan) and is famed for a unique feature - it makes products exclusively destined for the plastics and rubber processing industry. We interviewed Alessandro Zambello (marketing director of this family-run company) and his brother Elio (R&D and internal production systems manager), who both proudly pointed out, almost as one, that: “Aside from the recent boom of Industry 4.0 and other current factors, the company has for years now being experiencing constant growth not only in terms of technology, but also in terms of the global market shares”. Not a bad introduction to an interview!
A BRAVE CHOICE Before proceeding with our report on the state of the art of Zambello Riduttori “today”, it is also necessary to mention the change that took place in 1985 which led the company founded by Zevio Zambello - the father of Elio and Alessandro - to become a true point of reference for the leading rubber and plastics processing machinery manufacturers. “In agreement with our father, who at the beginning manufactured gearboxes for a host of different applications, when my brother and I joined the company there was a shift in terms of specialization towards gearboxes for the plastics machinery sector, the aim being to become the undisputed specialists in this field, not only to meet the needs of the manufacturers of extruders and injection moulding machines in Italy, but also of all those that operate at a global level”, commented Alessandro Zambello. It proved to be a winning strategy, as explained by Elio Zambello: “At present we are manufacturing 5,000 gearboxes a year, with no less than 350 different types of casing. Having said this, technology is always MACPLAS INTERNATIONAL AT FAKUMA 2018
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Examples of Zambello gearboxes for twin-screw and single-screw extruders
given top priority, in the sense that we do not manufacture, to give a basic example, gearboxes to customer’s design. However innovation is essential. For example, in the face of a very specific request on the part of users of twin-screw extruders, for torque and high performance levels with the same centre distance, thanks to our R&D department we are able to satisfy these demands by providing impeccable high quality solutions specifically dedicated to these clients”.
THE VALUE OF “SPECIALIZATION” LAUNCHED FAR BACK IN 1985 It must be said that it is precisely the contribution of the R&D department, just cited by Elio Zambello, that has made it possible for the company to cover such a wide range of applications; in fact the company, whilst always remaining in the sphere of plastics and rubber, can offer a fully extensive range of products, from gearboxes for single-screw extruders to gearboxes for co-rotating twinscrew extruders, as well as counter-rotating twin-screw extruders, in both parallel and
conical layout, not to mention gearboxes and gearmotors for injection moulding machines (both electric and hydraulic), as well as special gearboxes. It must also be said that if on the one hand the entire range has been conceived, engineered and manufactured in Italy, Zambello has also been able to set up an efficient sales network with offices in Switzerland, Germany, Austria, Spain, Benelux, United Kingdom… not to mention the United States, Canada, Brazil, Taiwan, China and Korea, as well as India, Japan, Turkey, Russia, South Africa, and Iran. Highly impressive for a family-run company!
FOCUS ON THE CHOICE BETWEEN “MAKE” AND “BUY” In strategic terms, the concept of “make or buy” refers to the choice that a company makes between undertaking operations in-house (make), or deciding to outsource (buy) a component, product or service that is necessary for production. The choice is often based on a comparison of the total costs involved in the two cases, bearing in
The headquarters in Magnano (Milan, Italy)
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ANCILLARIES AND COMPONENTS
Assembling of engines, gearboxes and extruder barrels
mind also both the actual availability of the components on the market - and therefore the risk of any critical situations - as well as the actual resources available for this purpose inside the company. This is often no easy decision for a businessman! It is a strategic choice that is essential for running a company as it determines the level of integration of operations - both upstream and downstream - and also impacts the cost structure, the company organization and market positioning. The “make” option offers the clear advantage of being able to assure direct control of operations, on the procurement and on the quality of the product/service offered. The “buy” option has instead the advantage of involving fewer overhead costs, and therefore a lesser degree of fixed assets, thereby allowing for greater flexibility in terms of production capacity. At Zambello Riduttori, there is no doubt, the “make” option has always been the buzzword! “So that the systems for cutting-off bars of up to 500 mm are ours, the systems for the mechanical turning and cutting of the steel gears are ours, the machining centres for the shaping of the casing made from cast iron and the grinding machines are ours (and have always been so) for the last finishing stage before assembly - a stage undertaken not by unskilled mechanics but by qualified toolmakers, who are capable of working with a variety of very different gearbox models with the greatest skill. All this obviously involves considerable costs, but it is because of our overriding corporate commitment that we have the timeframes and quality features of all our production processes under control, which at the end translates into real and tangible competitive
advantages for all our clients”, Elio Zambello proudly pointed out. Elio Zambello also went on to the explain, that as dictated by common sense in terms of manufacturing processes, only two types of production processes are entrusted to external specialists: the casting of the iron casings and the heat treatments of the steel used. “Going back to the issue of customer satisfaction as mentioned by my brother, I wish to conclude by remembering that for machinery manufacturers we make gearboxes for single and twin-screw extruders, as well as co-rotating, counter-rotating and conical types as well as gearboxes for driving injection screws. Another essential aspect is that we are the only company in the world to boast such a complete range in this field, with no less than five catalogues dedicated to each plastic processing machine type. In addition to all this, and once again, we are probably unique in the field of co-rotating and counter-rotating screws as we produce the complete series of gearboxes, with all relative centre distances and three torque levels. Having said this, each market is different and the degree of customization depends on the actual characteristics of the product itself. In the case of single-screw extruders, we try to
The recently expanded Lendinara premises, near Rovigo, Italy
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supply a standard product where the customized elements only involve the screw and barrel coupling. On the other hand, in the case of twin-screw extruders - and here we are always and only talking of extruder manufacturers (OEMs), and not the end users - we are required to be much more open minded, as in this case we always begin offering the standard product, but we almost always end up with incorporating customized features, both in terms of centre distances and layout. Other times the desired features may involve the gearbox aesthetics that may be more or less personalized according to the client’s corporate image, but almost always, I would say always, the true heart of the gearbox is something with depends essentially on our specialists know-how”, concluded Alessandro Zambello.
CONCLUSIONS From what has been clearly outlined by Elio and Alessandro Zambello, as well as what we have perceived from their “non-verbal language”, this historic family-run Italian company sells its mechanical gearboxes all over the world more by virtue of their intrinsic quality and technological features than for the price. The price must also be competitive, no doubt, but during the interview what emerged was that over and above the investments in R&D and in the production systems, the passion and commitment of both the internal personnel and suppliers is very important - for example the suppliers of the bearings, a very important element in transmission systems - as well as that the success is above all the result of the combined commitment of all the people involved. Ongoing commitment and passion coming together and being the principal reason for the success, generation after generation! www.zambello.it MACPLAS INTERNATIONAL AT FAKUMA 2018
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SINCE 1959 Magic A4 08_2018.indd 1 67 067_MagicMP_ADV.indd
MAGIC MP SPA - Via G. Medici, 40 - 20900 MONZA (MB) – Italy Tel. +39 039.2301096 - Fax + 39 039.2301017 - E-mail: customercare@magicmp.it - www.magicmp.it
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ANCILLARIES AND COMPONENTS
The Filtec team in the company testing laboratory, recently renewed and enlarged
FILTEC TURNS A NEW LEAF
DO NOT MAKE THE CONVENTIONAL CHOICE AFTER THE PARTICIPATION IN 2017, FILTEC COMES BACK TO FAKUMA PRESENTING ITSELF AS A LEADING PRODUCER OF A COMPLETE RANGE OF CUTTING SYSTEMS AND CONFIRMING ITS GLOBAL VOCATION. AS WITNESSED BY MORE THAN 1500 PELLETIZERS AND MANY OTHER MACHINES INSTALLED IN 25 YEARS OF ACTIVITY, MOST WORKING OUTSIDE ITALY
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t Fakuma 2018 (stand 6422, hall A6) Filtec wants to confirm its presence as global benchmark company in the world of plastics pelletizing. The company has roots and headquarters in Badia Polesine (North-East of Italy), almost in the centre of a triangle made by Venice, Verona and Bologna, the country’s most industrialized area world-renowned for top quality products in various fields, from mechanics to food and fashion. While its roots are local, the Filtec vocation and outlook are global. In its 25 years of experience Filtec produced more than 1500 pelletizers aside from other machines, and most of them are working outside Italy. After the positive experience of 2017, at Fakuma 2018 Filtec presents itself as leading producer of the complete series of cutting systems ranging from the WRP vertical to the horizontal type, in air, eccentric and UW underwater type. With them it is possible to process every kind of polymer, even the most critical one. In
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addition, screen changers for melt polymers, systems for the filtration of the process water, vertical centrifugal dryers for pellets and flakes, horizontal centrifuges to wash and dry flakes of plastic material, vented vibrating screens to cool and classify the pellets are developed and produced.
FLAGSHIPS The GRO WRP and the underwater UW pelletizers are the Filtec flagships. As each and every other Filtec product, they are continuously improved by the help of customers and end users. The GRO watering pelletizers represent the perfect balance between quality and economy and they are the correct approach to the cutting systems from 20 to more than 3000 kg/h. Its new automatic blades-adjusting device proved to be very reliable, providing a better control and huge reduction in the wearing of blades and die plates. This new technology allows the user to schedule the blades-replacing time and foresee
the operating costs. While the UW underwater pelletizers are ideal for high MFI polymers and are used to shape pellets worldwide. This system offers many different advantages as no faults in the cooling system, no stinking gases and perfectly spherical pellets, optimal setting of the spaces, positive producA detail of the GRO500 watering pelletizer model
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Are you R? is an initiative aimed at sensitizing the public awareness on the benefits and the advantages coming from plastics use and on its non-culpability for the world pollution
or plants producer, but a reliable partner able to develop and make real ideas and plans together with customers and final users. In this way the customers turn into partners and co-workers. Fakuma 2018 is the perfect chance to meet and share experiences and programs with customers, agents and partners in the very strategic European market and overseas.
25 YEARS
Gianfranco Baracco, founder of Filtec, which in 2018 celebrates 25 years of activity
tion-energy deployed ratio, fully automatic control system and high attention to the operators thanks to the extremely low level of noise. All the machines have a high technological level and their list is long. Anyway in Filtec, technology is a very important aspect but never predominant because service and human factor are key factors more important than that. Therefore Filtec considers itself not only a simple machines
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In 2018 Filtec celebrates its 25th birthday and its presence at the Fakuma is a good way to continue with the celebrations. At the fair, Giovanni Baracco, Flavio Dall’Aglio and the whole Filtec staff take the opportunity to explain the meaning of “turn a new leaf, don’t make the conventional choice”. According to many social media, plastic is accused of being the main responsible of the world pollution. This is a well-spread conventional misperception because plastic is a very important and precious achievement of the human being. In order to fight against such a wrong feeling, Filtec recently joined the initiative “Are you R?”, which involves four Italian companies operating in the production of machines for plastics recycling and has the support of the PRE association
(Plastic Recyclers Europe). They aim at sensitizing on social media the public awareness on the benefits, the advantages and the non-culpability in pollution of the plastics. And, on the contrary, to consider this latter a “resource”, as declared by the European Commission. The aim is to spread the recycling procedures and show how the correct procedures may turn plastics waste in precious resources, underlining the sustainability and the profitability of this virtuous circle. For Filtec, Fakuma is the ideal showcase and the strategic place both for confirming its presence as global benchmark company in pelletizing and for boosting the “Are you R?” face to specialists visiting one of the most important plastics event in Europe for 2018. www.filtec.it
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ANCILLARIES AND COMPONENTS
NEWS The Blauwer priority
Innovation and energy efficiency Italian company belonging to Plastic Systems Group, Blauwer was founded to provide to the market innovative thermal machineries for the industrial fields. The company designs, manufactures and installs high efficiency thermal machineries able to handle flows of water and air for industrial processing for: only cooling; only heating; simultaneous heating and cooling; air-dehumidification. The design of equipment gives the priority to energy efficiency following the path of innovation and always looking at the forefront solutions: “Waste - Future� is the inspiring idea from where all the company projects take shape. Technical innovations contribute to increase advantages for a higher environmental sustainability. At Fakuma 2018 (stand 53, Foyer East), Blauwer presents the following machines: - a high temperature CO2 heat pump for preheating plastic granules; - side-machine thermo-chiller with extremely low energy consumption; - a high efficiency pumping group equipped with automatic flow regulation by means of an inverter; - a compact chiller featuring a compressor equipped with inverter and water pump controlled by inverter.
The name itself, Blauwer (bluer) wants to be auspicious, because the company operates in the conviction that the respect for the environment is a non-negotiable ethical priority. Its product lines are: - high efficiency industrial water chillers (series Chillwer); - fluid coolers equipped with extreme high-efficiency adiabatic nebulizers (Drywer); - p umping groups to circulate water to the process with the possibility to adjust water temperature or to control water-flow by the use of an inverter (Hydrower); - thermo-chillers with single or dual thermoregulated outlets (Conwer); - mould temperature control-
lers (Hydrower); - high efficiency air-dehumidifiers working with refrigeration technology and recovery heat exchanger (Recuwer); - high efficiency adsorption air-dehumidifiers with extreme high-efficiency regeneration mode with high-temperature heat pump (Adsower); - high temperature heat pumps type water/water (Aquawer); - high temperature heat pumps type air/water (Heatwer); - heat pumps for residential (Thermower). The new medium (from 70 to 320 kW of cooling capacity) and large lines (from 350 to 1300 kW) are the synthesis of the best that can be found in
the market. Some main features of the chillers are listed following: - high energy efficiency in line with the new European Directives ERP2021; - high efficiency self-adapting compressors to the requested refrigerant load; - low power consumption and high efficiency fans with equipped with flow rectifiers; - pipes, pumps and water tanks in stainless steel; - electronic expansion valves; - low refrigerant charge. The company is able to supply not only machines but turn-key projects thanks to the long experience achieved. www.blauwer.com
Blauwer designs, manufactures and installs high efficiency thermal machineries able to handle flows of water and air for industrial processing
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Eprotech Srl Via Vittorio Veneto 71/73 21050 Lonate Ceppino (Va), Italy Tel. +39. 0331.81 01 86 Fax +39. 0331.86 05 95 www.eprotechsrl.com eprotech@eprotechsrl.com
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ANCILLARIES AND COMPONENTS
NEWS Vision systems
Always looking at the future An Italian manufacturer of automatic sorting systems and customized solutions for the visual control in the rubber, plastic and metallic field, Doss is at the forefront of research and development of new technologies since more than 20 years. Today more than ever, its goal is to continue to create value for customers with increasingly customized and advanced optical inspection solutions. In 2018 Doss participated to many international events, and will continue to be protagonist in the next months: exhibitions in Germany, Japan, Philippines, USA, and a rubber conference in India, where Doss met hundreds of experts and industry enthusiasts from all around the world. For Doss Visual Solution these world renowned fairs represent the ideal opportunity to present its latest solutions, confirm its global presence and commitment to grow, and share
the vast experience and knowhow within the global market. The quality of Doss Visual Solution services is based both on the experience and value of the people who have been part of the company for more than 20 years, and on the integration of new resources. Believing and investing in people is a fundamental value for Doss, and that is how the company evolves its experience and keeps on growing. From 2016 to date, Doss Visual Solution has strengthened all its teams to offer ever better service to their customers. The creation of an R&D team, dedicated to the development of new hardware and software solutions, met the growing demands of customers and the requirements of their industrial sectors. The new plant in Detroit has been completed: it will offer a show room with machines for the customers to view and test
and a spare parts stock. This will enable Doss to be closer to customers overseas and offer them a punctual technical and logistic support. The countdown for the release of new Doss solutions has begun. Its product family is about to grow even more. 2019 will be a very special year, with some innovative new entries designed to meet all the needs of customers. During 2019 the company will organize special open house events at its headquarters in Italy, Taiwan and the United States, during which its specialists will present the new products and all their unique characteristics. Doss is carrying out a complete rebranding of logo and website which will be soon available for all customers: brand new colours and lines for a company vision which combines passion and experience in all its products and will always do. A 25 years old story. A future that be-
gins now. While waiting for all these novelties, Doss invested a lot of energies and know how in the optimization of products models that belong to its present line. Amongst all, the new dSort7, a system for the full inspection of very large o-rings: a compact solution, with a dragging roll system and a vision core composed of 5 cameras for the dimensions and surface check of o-rings with a cross section of 20 mm. The new design allows the operator to manually load the parts, measure the length, the cross section and the inside diameter. The system carries out a complete surface inspection to find defects such as flash, lack of material, tears, porosity, cuts. Concentrated in a small space, a brilliant solution to inspect articles that are not easy to handle. www.doss.it
A detail of a Doss system in action
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ANCILLARIES AND COMPONENTS
NEWS Moulding and welding
Automating small production volumes cost-efficiently From the injection-moulding machine straight to ultrasonic welding: a space-saving robot solution combines several production steps in one flow. Herrmann Ultraschall (stand 4108, hall A4 at Fakuma 2108), in cooperation with Arburg and robomotion, set a modular automation cell producing a toy spinning tops. Due to the cell’s flexibility, a variety of products, small batch sizes and short life cycles can be automated. As a result, nonvalue-adding processes, in particular, such as transport, storage, and repeated sorting and supplying are eliminated, and production times are thus shortened. This means that the investment is economical even for a
small company. Due to its space-saving design and the possibility of moving the robot cell on air sleds, the flexobot cell from robomotion can be quickly and simply deployed to different injection moulding machines. Different applications can be realized using changeable plug-in units. The 6-axis robot is versatile in use, from simple removal to complex assembly tasks, which finish up the components immediately after the injectionmoulding process. “Automated ultrasonic welding supported by robots increases the advantages of our technology: speed and reproducibility”, said product manager Volker
Aust. “We have successfully carried out the first projects with robomotion”. www.herrmannultraschall.com
Modular robot cell with integrated ultrasonic welding system
New drying system
Pure efficiency This is precisely what Dega set out to offer when developing its new FJH drying system, which, according to the manufacturer (this year celebrating 40 years in business), should be regarded not as the best product of its kind, but rather as a superior product. Following the application of new concepts and new technological solutions, perfection is here taken to equate with level of efficiency, and this has been found to be 99%. FJH is a drying system that can be readily converted into a dehumidification system, and both processes are managed completely autonomously by software which acts on air flows (the heart of the
entire process), regulating and optimising them. Furthermore, the presence of an internal boiler means that it is no longer necessary to wait for the system to heat up after being started up, and this, in turn, translates into energy savings. Every component has been designed to work and, above all, interact optimally with the others, thereby eliminating unnecessary parts of the system, boosting the efficiency of the entire process, and cutting waste and maintenance. This has made it possible to reduce the system installed power and achieve a significant reduction in kW consumption. www.dega-plastics.com
A rendering of the functioning of the new Dega system
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The 2018 end fairs of Star Automation
Four months around Europe
The last months of 2018 are full of international appointments for Star Automation Europe (hall A7, stand 7113 at Fakuma 2018), who do not miss any of the most important plastics-related events on the European territory until the end of the year. Activities have started at full speed after the summer closure and much of the effort, aside from the one always dedicated to the completion of machinery and automations for the customers who are waiting for their deliveries, are dedicated to the participation to exhibitions. The first event of the autumnal exhibition season was Expo Plast Exhibition in Romania (Sibiu, September 18-21), where on the agent Almitech booth an automated system for the extraction of plastic cups, with a Stec-510-controller-managed Fx-1000 high-speed Cartesian robot, was exhibited. The second one was held in the Netherlands, where the historical distributor Koot Automation, who has been representing Star Automation Europe for a long time on the German market as well, took part to Kunststoffen exhibition (Veldhoven, September 26-27). The following appointment was Plastex exhibition in Czech Republic (Brno, October 1-5), a market which demonstrated itself to be more and more interesting for the producer and their agent Selex, given the presence in the area of many
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Eins is the Star Automation brand and division devoted to the EOAT component
European seats of Japanese groups, whose relationship with Star Automation Europe has always been tight and highly satisfying. The last of this year exhibitions is the important appointment with the Turkish exhibition of Plast Eurasia (Istanbul, December 5-8): the penetration in the Turkish market is highly successful, also thanks to the notable effort of the distributor Moritech Robot Teknolojileri Otomasyon, who is being particularly appreciated by customers also for the extraordinary services of installation, maintenance and after-sales assistance. Star Automation Europe takes directly part with its own booth to Fakuma exhibition (Friedrichshafen, October 16-20) where an important space is dedicated to Eins, Star brand for EOAT components. During the latter months the important step of constituting Eins Division has been made, with the raising of its dedicated personnel and the participation on the first Eins-only event, Automatica exhibition in Munich, from June 19 to 22. The publication of Eins E-Commerce website has also proven successful: in fact, it is possible to purchase online all the components of the catalogue, with a special 10% discount on the end user pricelist. www.star-europe.com
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ANCILLARIES AND COMPONENTS
NEWS Novelties from Maklaus
Three in one With almost 25 years of experience, Maklaus is an Italian company which manufactures machinery for stretch film processing and hole punching on moving web. After consolidating its international market position in these two segments, in recent years it has chosen to expand its range of machines with the creation of the Smart printing machine. Reliability, high efficiency and quick return on investment are the pillars of the Florentine company industrial philosophy. The Smart printing machine was projected respecting the Maklaus design philosophy: to put the customer at the center of the project and its possibility to realize margins. The “logo” of the film allows to sell
a product valued compared to the cost of the reel, ensuring the processor an economic advantage that allows to quickly recuperate investment costs. From this starting idea a machine was built with the capacity to print up to four colors with a speed up to 300 metres per minute on stretch film. The advantages are two: logos are often monochromatic or at most have two colours. With a four-colour machine it is possible to prepare the cliché of a second print/ logo to be made later. The first advantage is the very fast pro-
cessing change that practically eliminates machine downtime. The second advantage consists in the fact that a rewinding machine is combined with the printing machine, which for example, in the 1000-mm version, produces two 500-mm reels even with different prints, thus increasing the flexibility of use. Moreover, the magnetic coupling system of cliché on the roller, allows changing the print quickly and safely, without requiring further calibrations. The printing machine is easy to operate and can be managed by
The new RES 08 is one of the two rewinders manufactured by Maklaus
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a single technician, even if this is not specialized: a further advantage is in the evaluation of the required time for the amortization. Furthermore, Maklaus produces two rewinder models: the new base version is the RES 08, that is even more efficient and performing, and the advanced version of the RES UNI. The latest models allow producing several finished products in complete automation, making pre-cuts on the material and creating minirolls; all in a production space of 4 square metres. The RES UNI works with an Industry 4.0 perspective, allows the use of Italian super-amortization and, thanks to a high level of electronics, can be managed with a very low number of operators. The main advantage of RES UNI is the ability to create various products, capturing market trends and dedicating investment not only to seasonal work, but to a continuous medium and long-term activity. The process changes are very simple: just change the supply chain and start a new process. The punching units are the third type of machines in the Maklaus range. Supplied in numerous versions with compressed air or laser technology, they are built ad hoc according to customer needs to be integrated on existing production lines or as standalone machines. Thanks to the internal design office, Maklaus is able to guarantee customization of the product. This machines can process different types of film and are used in many different sectors including agriculture, packaging, construction and clothing. www.maklaus.com
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promaplast srl
A M A P L A S T ITALIAN PLASTICS AND RUBBER PROCESSING MACHINERY AND MOULDS MANUFACTURERS’ ASSOCIATION
www.amaplast.org
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ANCILLARIES AND COMPONENTS
NEWS Since 1992
High-end screws and barrels Since 1992, Superior Machinery has been a leading manufacturer of high-end barrels and screws for plastic processing equipment and machineries, providing professional and customized solutions to clients all over the world. ISO 9000 certified, the company is headquartered in Zhoushan (China). The 10,000 square metres plant is equipped with cutting-edge precision facilities to produce high-end screws and barrels based on resistance to abrasion, corrosion, high pressure, high-speed. The screws and the barrels are also suitable for several kind of materials, such as halogen-free material, high fibre-reinforced material, ceramic, powder alloy, magnetic material, high corrosive material, high temperature material, thermosetting material, liquids, high abrasion materials and many more. The company R&D department is able to recommend the most suitable solutions for
different applications, which helps customers to save costs and improve the production efficiency. This is all thanks to the international team, comprised of professionals both from China and from Europe, all of whom have years of experience and an in-depth understanding of the product processing. Superior Machinery has always been at the forefront of technology research and development. The company has taken the lead in developing and manufacturing iron-based alloy barrels in the industry. In 2009, Superior Machinery adopted advanced vacuum sintering technology and successfully developed nickel-base alloy barrels and nickel-alloy-coated screws. Thanks to the precise expertise and the high-quality service provided, Superior Machinery has become a point of reference in the international market and is entrusted by customers all over the world. The company recent-
ly updated its corporate image, releasing their new company logo and in combination with the launch of their new website, they have set expectations high for a continued successful growth. To meet the needs of European clients, Superior Machinery will open a sales and service branch in Milan, Italy, soon. The company technical department is able to advise customers about the most suitable product for the specific application based on the physical characteristics of different material and product requirements. The main application areas of Superior Machinery products include IT connectors, automotive parts, optical products, precision gears and special products. The raw materials for Superior Machinery screws and barrels are imported from the United States, Germany, Austria, Sweden, Switzerland and
Japan, assuring the highest quality possible for clients. The wide range of products for the plastics and rubber industry includes: bimetallic barrel series; fully hardened screw series; screws and barrels for rubber machines; single screws and barrels for extruders; parallel twin screws and barrels (counter-rotating and co-rotating); conical twin screws and barrels (counter-rotating and co-rotating). In order to meet customers different requirements, Superior Machinery is able to apply on the surface of the screws different kind of surface treatment, using technologies like PVD coating, HVOF supersonic flame spraying, PST titanium-nitrogen diffusion technology and traditional salt-bath style heat treatment. www.superrare.net www.superior-machinery.com
For over 25 years Superior Machinery has manufactured high-end barrels and screws for plastics processing equipment and machineries
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High quality moulds for caps and closures
Provide processors with innovation, flexibility and service To anticipate market needs and keep up with the times, Giurgola Stampi (hall A5, stand 5117) has continually worked to provide processors with innovation, expertise, flexibility, service and, of course, high quality moulds. Primary emphasis has been placed on the moulders’ production requirements. Although it remains a mouldmaker, the company feels it is necessary to expand its competence from the co-design of the processor product to the complete quality control of the moulded part, through the whole testing phase and pre-production, with the aim to provide processors with an answer to any need and a solution to any problem. The company takes part in several 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 Giurgola to expand its commercial presence in Europe and around the world, looking for continuous growth opportunities in a changing socio-economic re-
A multi-cavity mould from Giurgola Stampi
ality. 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
www.marfranmed.it
A VERY PARTICULAR KIND. is our innovative solution for the development of new products for biocompatible medical devices. MARFRAN.MED®... your partner for high-tech compounds !
Beware of imitations. FRIEDRICHSHAFEN (GERMANY) OCTOBER 16 - 20, 2018 STAND: BOOTH B5/5212 - HALL B5
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DÜSSELDORF (GERMANY) NOVEMBER 12 - 15, 2018 STAND: 8B P16 - HALL 8B
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ANCILLARIES AND COMPONENTS
NEWS Screen changers for extrusion lines
Turnkey package for continuous flow With an output rate up to 1,200 screen changers per year, BD Plast confirms itself as the favourite partner of extrusion line manufacturers in Italy, Europe, North America and Asia. 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. On this path, the manufacturer has recently introduced three novelties. 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
BDOx3 BF triple-plate continuous flow back flushing screen changer
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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 replace-
ment 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 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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A die and calibrator sections by Eprotech
Extrusion equipment
The advantage of being “small” The advantage of being a small-medium enterprise is that it is helpful when it comes to moving around with more agility and flexibility and doing so relatively quickly. A company that knows this well is Eprotech, based in Lonate Ceppino near Varese (Italy), which 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. Eprotech produces tools and accessories for extrusion lines used for the most diverse applications in PVC production. The company has made the upgrade of extrusion tools a strategic and practical service, a choice that has met with approval in the form of market demand, to the point that company revenue
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is generated more or less equally at the rate of new tool sales and upgrades of used tools. One of its projects involves combining reclaimed and virgin materials through a process of co-extrusion. The company supplies tools for producing profiles using different percentages of virgin and recycled material without distinction, reducing the cost of manufacturing by 28%. The use of reclaimed material in combination with virgin materials is strategic and practical to cut costs and find new niche markets. The plastic 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 pos-
itive aspects, all synonyms for a business approach that boosts a company 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. The Italian company has developed a specific technology for producing extrusion tools for socalled “plasmix”, and establishes itself amongst the few industrial realities that can supply everything needed to process this material. Given Eprotech’s confidence on foreign markets, participation at international fairs is now consolidated practice for the company. In fact, it is present at Fakuma 2018 (hall A2, stand 2115), where visitors can find out more about the company’s latest innovations. www.eprotechsrl.com
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ANCILLARIES AND COMPONENTS
NEWS Helios Quartz at Fakuma 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, hall A4, stand 4201, at Fakuma 2018) 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 IR unit produced by Helios Quartz
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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 for 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 developing 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 includes: - quartz IR lamps (in single or two-row tubes) either in short, medium or medium-fast wave; - IR units; - tubes, sheets and discs of quartz glass; - quartz glass articles according to drawings; - UV lamps and equipment for the curing of glues, inks, var-
nishes 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 be 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 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 the best solution for each application and product. www.heliosquartz.com
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State-of-the-art machining centres
A life for screws and barrels Often it is said that the manufacturers of plastic processing components have a double commercial soul, which, because of the nature of their product, will meet the needs of both system manufacturers and processors. The former use the component to integrate their production systems destined for plastics processors, while the latter install the component directly on their processing machinery. This double soul belongs to Mast, based in Como (Italy), which in 2017 celebrated 50 years in operation in the production of screws and barrels for the plastics extrusion sector. The years of work spanning two generations have brought experience that has had to adapt to the use of new techniques and materials. It is now widespread practice to process highly filled and reinforced materials, with decreasing resin content
Barrel and screw profiles for co-rotating twin screw extruders
and an increasing high abrasive component. Today, sintering materials are used not only for the construction of milling inserts, but also for the complex mechanical parts which may include plasticisation screws. Traditional steels lose validity and this is why screw manufacturers have a new problem to face, namely identifying processing parameters and technical solutions for processing increasingly less conventional steel, with respect for specifications from the extrusion line manufacturer, in this case the client. The machining centres installed at Mast are state-of-theart: Weingartner, particularly well suited for milling screws, which represent the true added value of the finished product. While historic technical know-how and continual innovation in the methods used to process materials are vital factors for the present and the future of the compa-
ny, communication is essential in today world. Breaking out of the mould means getting on the Internet and marketing the company brand online. These concepts are very clear at Mast. Communication also means attending the largest trade shows. Mast regularly participates at Plast in Milan and at K in DĂźsseldorf. Expansion on foreign markets is another objective on the company agenda, as well as the collaboration and synergy with other Italian companies. Following true to the best Italian tradition, quality is a brand. The “tailor-madeâ€? approach at Mast entails a greater sacrifice, a warehouse that is virtually non-existent, but the reward is customer loyalty, confirming the importance that the client attributes to the relationship with a supplier of essential components. www.mastsrl.it
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 capa-
bilities. The filtration materials used in the FM products take advantage of media such as resin filter paper, polyesters 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, pres-
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ent 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.com
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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The press conference of RadiciGroup at the Plast 2018 international exhibition
MATERIALS AND APPLICATIONS
RADICIGROUP’S VISION OF POLYAMIDE-BASED ENGINEERING POLYMERS
DEMAND IS SET TO GROW IN THE COMING YEARS THE NEW OPPORTUNITIES ARISING FROM THE ELECTRIC AND HYBRID VEHICLE MARKET ARE THE REASON BEHIND THE MAJOR INCREASE IN DEMAND FOR POLYAMIDES ENVISAGED BY RADICIGROUP FOR THE NEXT FIVE YEARS, WITH THE TREND SEEMING TO BE MORE RAPID FOR THE SPECIAL GRADES, INCLUDING THE HIGH PERFORMANCE TYPES DESTINED FOR HIGH-TEMPERATURE APPLICATIONS BY ANGELO GRASSI AND RICCARDO AMPOLLINI
E
lectric vehicles are one of the sectors in which car manufacturing industries are investing to the greatest degree in terms of research, production and marketing. We have only to think of Toyota, first of all, to which have gradually been added Renault, FCA, Volkswagen… to mention but a few. These vehicles are powered by an electric engine that uses the chemical energy generated by one or more rechargeable batteries and then released in the form of electricity for the engine. From the point of view of energy efficiency, electric vehicles offer higher performance as compared to those powered by internal combustion engines, but on the down side there are still problems in terms of mileage and recharging times. However researchers are busy working to rectify these problems.
ELECTRIC VEHICLES: AN INSIGHT INTO THE HISTORY, DATA AND FUTURE POTENTIAL Perhaps it is not generally known that electricity MACPLAS INTERNATIONAL AT FAKUMA 2018
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was among the favoured means of power cars between the late XIX and early XX century, as it offered a degree of reliability and comfort that could not be matched by the internal combustion engines of the time. Manufactured by companies such as Anthony Electric, Baker Electric, Detroit Electric etc., these battery-powered vehicles (BEV) in fact sold more than carse with internal combustion engines for a certain period. In addition, it also seems that these BEV vehicles were very popular with women. If we flash forward to the current day, the high purchase cost tends to limit the popularity of modern electric cars, binding it to the economic policies of the individual countries, that often provide customized incentives in order to promote the sector. The 2016 figures show that sales of electric vehicles are greatest in Northern Europe, with Norway clearly in the lead, ahead of Holland and Sweden, followed by Denmark. In Italy the popularity of this type of car remains fairly low, although numbers are growing. A report by the
For a certain period during the early XX century, it would appear that more battery electric vehicles were sold than those with internal-combustion engines. It also seems that they were very popular with women, as confirmed by this Baker Electric advertising poster
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MATERIALS AND APPLICATIONS
Cesare Clausi, global sales director (on the left), together with Enrico Spini, marketing and applicative development director of RadiciGroup Performance Plastics
Milan Politechnic in fact outlines that as compared to the 5,000 electric powered cars sold in Italy in 2016, by 2020 the registration of today’s BEV vehicles will reach a level of between 70,000 and 130,000 vehicles a year. This trend forecast by the Milan Politechnic is the first concrete fact!
THE ISSUE OF VEHICLE WEIGHT: AGAIN A BRIEF INSIGHT To the question: “What impact does the weight of a car have on consumption?”, the answer lies in another basic physical principle: “The heavier the vehicle the more fuel it consumes”. This being the case both for internal combustion and electric vehicles. This unavoidable physical principle being the second concrete fact! A study made by American analysts of IHS Markit indicate the greater use of plastics and the adoption of new generation compounds as being an excellent way to reduce the weight of a vehicle. They also estimate that in 2020 a single vehicle will have an average of 350 kg of plastic components as compared to the 200 kg used in 2014. A trend which, according to IHS Markit, will also result in lower production costs and greater efficiency in industrial cycles. As a result, the combination of “e-mobility and plastics” already appears to have great potential, an aspect which is very favourable for the Italian chemical giant RadiciGroup.
A MARKET VISION, SHARED BY RADICIGROUP “We have been strongly focused on applications in the e-mobility field and we offer to carmakers a selection of innovative materials for battery coverings, charging sockets and plugs (such as for example, the flame retardant engineering polymers of the Radiflam range), as well as materials for battery cooling circuits (Radilon RG, D, DT, or Aestus and Raditeck)
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and for high-voltage connectors”, explained Erico Spini, marketing and application development director of RadiciGroup Performance Plastics, before the press conference held on May 31 at the exhibition Plast 2018, primarily focused on the most innovative engineering polymers developed by the R&D department at Radici. It was in fact the same Spini to give the talk on the technical-applicative specifications of PA66 based Radilon HHR in particular, and on the PA6 or PA66 based Radistrong, that are already well-known products, moving on to illustrate the features of the more recent PPA based Radilon Aestus T, and Raditeck P (PPS)… amongst others. It must be said that aside from the purely technical issues, the conference at Plast provided the backdrop for the presentation of the state-ofthe-art of RadiciGroup Performance Plastics… in its capacity as a global player in the field. “The upstream and downstream integration of our polyamides and the corporate presence over three continents with eight compounding sites means that we are ready to take advantage of the opportunities that the current trend is offering, and that we are able to place a truly sophisticated and far-reaching service at the
disposal of our clients, not only in terms of the extent of the range, but also in terms of specialist consultancy in design, alongside various forms of external technology, for each individual order”, said Cesare Clausi, global sales director of RadiciGroup Performance Plastics. On this last point Spini went on to further explain: “We are solution providers, in the sense that we are committed to acting as a partner for our clients in their most innovative projects, through the identification of the most suitable materials, and by developing, new solutions as necessary, whilst providing adequate support in the mould filling simulations, and in the sophisticated structural calculation phases”. This approach being the third fact that officially proves the commitment of RadiciGroup in the field of polyamide based engineering polymers… above all, in metal replacement applications.
SUMMARY OF THE FIRST TEN YEARS IN METAL REPLACEMENT OPERATIONS Erico Spini made a public proclamation in his talk at the recent Plast in Milan as follows: “At RadiciGroup Performance Plastics we can already boast a long-standing history in operations that have given rise to the increased use of plastics to reduce car weight”. A history that chronologically, we would add, encompasses a period of ten years, in which the driving ambitions of the R&D division has led, in several cases, to the much coveted replacement of metal parts in cars, thanks to the development of materials with increased chemical resistance, with greater resilience to high temperatures, in a word offering improved performance. Once again at the press conference held on May 31, Spini made use of table 1, which provides a synthetic summary of the technical/performance results achieved from 2008 to today by the Italian group.
Tab. 1 - The experience of RadiciGroup, from 2008 to today, in the field of increasingly innovative material development Metal replacement TODAY
Improved chemical resistance
High temperature
High performance
Raditeck P - PPS, greater chemical resistance, highest level of dimensional stability, intrinsically fire-proof Radilon Aestus T - PPA, excellent resistance against hydrolysis, highest degree of chemical resistance, great rigidity, reduced impact of moisture absorption on the mechanical properties Radistrong A - A special PA66-GF grade, minimal mechanical property variation in the event of moisture absorption, excellent aesthetics Radilon DT - PA612, excellent chemical resistance, improved thermal resistance as compared to PA12 Radistrong LGF - Long glassfibre PA6 & PA66, high resistance to creep and fatigue Radilon D - PA610, high degree of chemical resistance, partially of biological origin Radilon A HHR family - PA66-GF high temperature, continuous contact to air up to 210°C Radilon A RV500RW, A RV350RW - A special PA66-GF grade for structural parts Radilon S URV500W, S URV600W - PA6-GF, excellent productivity, rigidity and aesthetics
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Tab. 2 - New applications of RadiciGroup materials on plug-in-hybrid (PHEV) vehicles and on full electric vehicles (EV)
“Table 1 shows that in an initial stage we introduced a whole series of materials, produced mainly on a PA6 and PA66 base, suited to greater efficiency in metal replacement”, commented Erico Spini. “In general they are polyamides with a higher mechanical performance level for structural applications, such as engine brackets and supports (Radilon A RV350RW and Radilon A RV500RW, both on a PA66 base), as well as PA6 based products with a high filler content, whilst also being very fluid and suited to structural parts thanks to their pleasing aesthetic appearance (Radilon S URV500W and Radilon S URV600W). We subsequently introduced the Radistrong A range of special PA66 grades reinforced with fibreglass, also conceived for metal replacement. As compared to other polyamides they are less sensitive to moisture absorption, which means less variation in properties such as rigidity and mechanical performance - a feature that is highly appreciated by designers in all industries. In addition it also assures a pleasing appearance”. Then, Spini continued: “Talking of high temperature applications, we have worked very hard to improved thermal resistance in the event of prolonged exposure to high temperatures as requested by the automotive industries, and in the introduction of new, smaller and more high performance engines. We have introduced two product categories both again polyamide based. While the first we in fact inherited from the Invista Engineering Polymers company, that we acquired in 2016, and in relation to the Torzen Marathon brand, which stands for fibreglass reinforced PA66, featuring good flowability and excellent thermal resistance in continuous use up to 190°C. Then there is the Radilon HHR brand, again polyamide 66 based in which the HHR stands for “High Heat Resistance”. In this case work was primarily done on the additives, during the formulation stage in order to assure greater resistance to prolonged thermal ageing. As concerns the high-performance products, I like to mention those with a long-molecular chain, both PA610 and PA612 based, which are today mainly used in applications related to the transportation of both diesel and petrol. These materials are homologated following lengthy tests, as they are used in the manufacture of automotive parts classified as safety devices. Last in chronological development order, but certainly not in terms of importance, are two truly high-performance specialties; the already cited Radilon Aestus T with a polyphtalammide base (a polymer that actually assures improved performance in damp conditions MACPLAS INTERNATIONAL AT FAKUMA 2018
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Components
Charging socket (Radiflam)
RadiciGroup’s products
Recharging plugs and sockets
•R adilon and Radiflam halogen and red phosphorous free, suitable for external use
EE system high-voltage components; electric parts housing and supports (inverters, converters), battery charger, battery disconnection unit, control boxes, connectors, cable guidests
•R adiflam halogen and red phosphorous free, PA6 and PA66 based •R adiflam A RV250HF 3003 BK (PA66, optimized product for improved protection of circuit against corrosion) •R adilon A RV250KN … A RV500KN: new electrically “neutral” PA grades • Raditeck PPS • Special thermally conductive products
and an excellent chemical resistance in contact with many fluids used in the automotive industry) e and the PPS based Raditeck P”. At this point we asked Spini about the type of companies to which RadiciGroup offers these last materials to, and with a view to the latest technological production trends, whether they can be used in 3D printing. “We recommend Radilon Aestus T or Raditeck P when a high degree of hydrolysis resistance is required, as in the case of cooling circuits and/or car air conditioning circuits” was the reply of Spini, who then went on to say: “We have also recently developed the Radiflam Aestus T2 RV300HF product: which is a flame retardant PPA, free of halogens or red phosphorous. It is in fact a polymer suited to many applications, including connectors for electric and hybrid cars. While Raditeck P is a PPS based material boasting a chemical resistance superior to that of all the other products in our range and gives a low degree of swelling in the presence of petrol, oils, solvents or brake fluid. It also features excellent preservation of mechanical properties even in case of thermal ageing, a high degree of dimensional stability in contact with various substances, and it is also intrinsically self-extinguishing. To be honest, I must say that Raditeck P has certain features that are not particularly favourable, as for example less than excellent impact resistance. However it remains a truly unique product for certain applications, such as in car air-conditioning pump rotors, where despite the continuous contact with water/glycol mixtures, it is the only material to grant total dimensional stability. As regards 3D printing, this is a sector that is certainly appealing and interesting for us. So that it is no surprise that we have already identified several ad hoc materials to be used in the automotive field, and not only, always polyamide based, which accounts for our main business. I am also pleased to add, that up to date some of these materials, that are already in an advanced evaluation stage, could prove to be of great interest in the 3D printing sphere”. At this stage it is obvious that the electric car
is opening various application opportunities for RadiciGroup engineering polymers. We shall end by examining a few.
EXISTING PRODUCTS FOR THE ELECTRIC AND HYBRID VEHICLE MARKET “It is clear that the growing introduction of electric and hybrid car models is creating new and interesting opportunities in terms of markets and products”, confirmed Erico Spini, on introducing tables 2 and 3. “Firstly there is the novelty of the recharging points. Here it is obvious that it is useless proposing electric vehicles on the market if the necessary recharging infrastructure is not in place. In fact it is precisely in the sphere of recharging plugs and sockets that we have developed, and sold, flame retardant polyamides 6 and 6.6, that are also halogen and red phosphorous, and suited to even extreme weather conditions”.
“We have been strongly focused on applications in the e-mobility field and we offer to carmakers a selection of innovative materials for battery coverings, charging sockets and plugs (such as for example, the Radiflam range), as well as materials for battery cooling circuits (Radilon RG, D, DT, or Aestus and Raditeck) and for high-voltage connectors”, explained Erico Spini
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MATERIALS AND APPLICATIONS
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The marketing and applicative development director of RadiciGroup Performance Plastics then went on to examine certain high-voltage components of the electric/electronic control system of an electric engine. “I am not talking about ‘mild hybrid engines’, where the voltage is still quite low, usually around 48 volts, but rather of fairly powerful hybrid plug-in or full electric top performance engines, in which the operating voltage reaches 350-400 volts. In fact, it would seem that Porsche has actually announced the arrival of a vehicle with voltage of 800 V and in such a case there is an enormous challenge to plastics”, declared Spini. “Whatever happens, for the standard electric engine currently on the market we have developed ad hoc materials ideal for the production of: inverter parts, battery charger components, battery disconnection units, control boxes, connectors etc. Tab. 3 - Further application examples of RadiciGroup materials in plug-in-hybrid electric vehicles (PHEV) and in full electric vehicles (EV) Components
RadiciGroup’s products
Battery covers, Battery pack support
•H alogen and red phosphorous free Radiflam, PA6 and PA66 based • Radiflam Aestus T2 PPA
Battery housing support
• Radilon and Radistrong PA for hybrid solutions
Cooling/conditioning system components: cooling ducts, water pump components, valve housing, HVAC components etc.
• Hydrolysis resistant Radilon A (PA66) • Radilon Aestus T1 (PPA) • LCPA Radilon D PA610 and Radilon DT PA612 • Raditeck (PPS)
It is blatantly obvious that the automotive market is fast evolving, towards a context that is closely connected to electric and electronic components, but with a great need/restriction/ demand for materials with higher performance than those currently on offer. Spini went on to accurately point out: “For example the latest cars require materials capable of assuring a very high degree of protection of electric/electronic circuits. This is why we have developed self-extinguishing materials, free of halogens and red phosphorous, which are already used by certain car manufacturers, and it has been proven that during operation they release few chemical substances, and therefore assure added safety. I am referring to the power control boxes in particular”. Just as the car manufacturers are working intensively on e-mobility, the work of the RadiciGroup R&D department also never stops. Erico Spini concluded by saying: “We are currently working on thermally conductive products, and in this sphere - with the housing of the electric engine inverters and converters in mind, that today still use die-cast aluminium as structural support (even though aluminium weighs twice as much as plastic, we editors would say) - our aim is to formulate a material with a good level of thermal conductivity, because the insulation often causes the imperfect function of the appliance itself. We are working on this and we hope to get there “step by step” as they say”. www.radicigroup.com MACPLAS INTERNATIONAL AT FAKUMA 2018
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COMPOSITES EUROPE 13th European Trade Fair & Forum for Composites, Technology and Applications
WE CONNECT – MATERIALS AND EXPERTS
06 – 08 November 2018 Messe Stuttgart, Germany www.composites-europe.com
Partners
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MATERIALS AND APPLICATIONS
NEWS Investments at Sipol
PU foam seal by Sonderhoff
ENSURING STABILITY BY ENHANCING LOGISTICS AND STORAGE CAPACITIES
High tightness due to low water absorption of the closed-cell
An investment program of about 3 million euro was launched on late 2017 and is being implemented during 2018 by the Italian company Sipol. The main aims of this program include: a new 2,400 square meter warehouse dedicated to finished goods and powder-raw material storage increase; six new tanks for liquid monomer storage; dedicated software for the timely and flexible management of inventory and production schedules; packaging quality enhancements to facilitate handling and maximize the finished goods shelf-life. The company creates “tailor made” products designed to match application requirements with an high production flexibility and a close collaboration with the customers, implementing a fast and efficient approach to the development of its brands. A business based on cornerstones such as research and development, process and product quality, price stability, and fast and timely deliveries, Sipol has been able to double its turnover in the last five years. The enhancement of logistics functions as well as the increase of the raw materials and finished goods storage - although financially affecting a company - have proved a necessary, fundamental steps in order to ensure maximum stability to its customers, plants, employees, and shareholders. Located in Mortara (Pavia), Sipol is a chemical company whose core business consists in the polymerisation of co-polyesters and co-polyamides dedicated to both the hotmelt adhesives and the high-performance engineering polymers domains. The company is present in the market of engineering polymers with a family of thermoplastic ether-ester elastomers (TPC-ET) that, with the Sipolprene brand has achieved, in over 15 years of activity, a worldwide visibility in a niche market. Sipolprene engineering polymers have a macromolecular structure that combines rigid blocks of polyester and long-chain polyether blocks, giving the polymer intermediate properties between thermoplastics and elastomers. In addition to engineering polymers, the Italian company also covers the copolyamide and copolyester-based hotmelt adhesives market, where it operates globally with the Technipol and Sipoltex brands in the footwear, leather goods, car filters and textile industries. www.sipol.com
The machine and sealing specialist Sonderhoff, part of Henkel since July 2017, presents a new physical foaming process called FIP CC technology (Formed-In-Place ClosedCell) at the exhibition Fakuma, from October 16 to 20, 2018. Sonderhoff developed for this the predominantly closed-cell foam seal Fermapor CC based on PU, for applications with high demands on water resistance, and the complete new mixing and dosing machine DM 402 CC. The seal cures without oven or moisture and closes the gap between the more expensive silicone foams and the cheaper mixed-cell PU foam seals. At the Sonderhoff booth (5109, hall A5) the metering of the very fine-cell, predominantly closed-cell PU soft foam seals Fermapor CC is demonstrated live on the new mixing and dosing system DM 402 CC. The foam seal makes a very high-quality impression visually with its slightly glossy surface. The low water absorption of the CC foam seal is demonstrated with an endurance test for water resistance at the booth. The predominantly closed-cell foam seals Fermapor CC are room temperature curing 2-component PUbased systems that cure without oven or moisture. They represent a significantly less expensive alternative to 1-component and silicone applications. Unlike comparable mixedcell seals, the very fine-cell CC foam seal requires less compression with the same sealing performance. A robust, mounting-resistant surface of the CC foam seal withstands possible mechanical stresses in the parts’ handling. Even after damage to the surface, such as tears, the water absorption changes only slightly. The polyure-
Sipolprene for thermoplastic hoses
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The Fermapor CC seal made of polyurethane is very robust and also ice water resistant
thane-based Fermapor CC foam seals are very weatherproof and even ice water resistant at water temperatures up to 1°C. Fermapor CC PU foam complies with Reach/ EC regulation 1907/2006 and RoHS and is generally used for sealing components at temperatures from -40 to +80°C, for short periods even up to +160°C. The closed-cell foam is applied with the well-known FIPFG (Formed-InPlace Foam Gasket) process, which is the production standard for component sealing in many industrial sectors. Already with the metering by physical foaming, the CC foam is applied stable to the component contour in an almost complete sealing dimension. As a result, the user can check immediately after applying the seal whether the seal has been applied at the same height over the entire component contour. Thus, Fermapor CC PU foam is especially suitable for three-dimension components and a process-oriented quality control. Due to the increased efficiency of the new FIP CC technology, automated seal foaming opens up new fields of application. www.sonderhoff.com
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TPE compounds
Deleting the build-up of electrostatic charge Plastic materials are electrical insulators by their own nature. This feature is usually desired in most applications but it can generate problems when the final product undergoes rubbing stress. In such conditions, the material accumulates electrostatic charges which are responsible for the “shock” received when touching an electrified object. The problem of the accumulation of electrostatic charges has increasingly become an aspect of legislative relevance thus it is regulated by various sector directives, especially for personal protective equipment for professional use such as safety shoes. Based on SBS or SEBS and manufactured by Francesco Frances-
chetti Elastomeri (stand 5212, hall B5, at Fakuma 2018), Marfran TPE compounds are excellent insulators as well as all plastic materials. Nevertheless, it is possible to exhaust the build-up of electrostatic charge. The main methods for modifying electrical conductivity in a thermoplastic elastomer can be achieved through the addition of: • Unmixable particles of conductive materials. The electrical conductivity occurs thanks to the contact of conductive particles that create a network within the thermoplastic material. Some examples of such particles are conductive carbon black, metal microfibres, carbon nanotubes etc.
Resistivity of different materials
• Migrant ionic and/or hydrophilic additives. These additives migrate on the surface of the material, activating an electrical surface conductivity through time. For this reason they are easily removable so the dissipative effect is destined to decrease over time. These additives are commonly referred to as “non-permanent antistatic additives”. • Intrinsically Conductive Polymers (ICP). The conduction mechanism is activated by a homogeneously dispersed polymer component in the thermoplastic matrix; this mechanism doesn’t depend on mechanical and environmental stresses applied to the material and it guarantees a much more stable electrical conductivity over time (permanent). The conductive properties of the compound strongly depend on the
choice of fillers and how they are dispersed inside the thermoplastic matrix but only if ICP are used, the resistivity of the object is permanent. That is why Francesco Franceschetti Elastomeri has developed three new families of antistatic TPE compounds Marfran E CD. These compounds are based on technologies that make the antistatic material both non-permanent (ionic additives) and permanent (ICP), combining the easy processability, lightness and versatility of TPE with the dissipation properties of the electrical charges. The new Marfran E CD compounds are born as products oriented to the production of work shoes such as, for example, hospital clogs, but they can also be used in other applications by injection moulding technology. www.f-franceschetti.it
Masterbatches and compounds
Colours and effects for engineering polymers Over more than 20 years a wide range of products has been developed by the Italian company Color Tech 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 Color Tech products 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 masterbatch division produces various types of colours and effects for every plastic
material, white, black, coloured according to Ral, 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, extrusion etc. 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
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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 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. 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 interna-
tional standards for food and toys. www.colortech.biz
The ISO 9001 and ISO 14001 certificates guarantee product quality and environmental sustainability of compounds and masterbatches manufactured by Color Tech
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MATERIALS AND APPLICATIONS NEWS
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
Masterbatches
Biodegradable solutions to really safeguard the planet Always focused on environmentally friendly products, in 2015 the Italian company Vanetti has received the certificate “TÜV Austria” which attests to the quality of its Biomasterbatches and ensures their suitability for colouring new-generation biopolymers. Produced exclusively by Vanetti, Biomasterbatches (registered trademark) were designed by analysing the molecular structure of biodegradable materials in the laboratory and verifying their specif-
ic chemical properties, in way to respect the environment while still enjoying attractive, natural colours. Furthermore, when biodegradable polymers are coloured with its Biomasterbatches, the finished product successfully meets all the requirements of the EN 13432 standard. Biomasterbatches with biodegradable “ingredients” are used in a variety of different industries, from shopping bags to packaging and even for more technically demand-
Fluoroelastomers
An exciting target for a young compounding company The expression Industry 4.0 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. In such context it is nowadays necessary that a company that wants to be successful on all fronts, takes action to become a factory 4.0. The challenges 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
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ing products. These second-generation biomasterbatches are designed for application with PLA, Mater-Bi, PHA 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
very sensitive to these aspects and are always looking for technological innovations that can improve, sometimes radically, the performance of finished products. Established in 2009, the Italian company Elastomers Union 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 its finished products - fluoroelastomer compounds - being economically competitive and responding 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.
production of a finished product, thereby creating a new product with technical characteristics specifically designed to satisfy the processors’ requirements. Development of all these products (masterbatches, Biomasterbatches and additives) and perfecting new formulations represent one of the great strengths of the Italian company, based in Marnate, Varese. www.vanettimaster.com
Quality control is essential for the Italian company Elastomers Union
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
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Poliblend at Fakuma 2018
Growing, innovating, qualifying
Coloured engineering thermoplastics by Poliblend
It was 1999 when Giancarlo D’Ottavio, Filippo Corradini and Italo Bececchi decided to establish Poliblend (stand 5116, hall A5, at Fakuma 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 important commercial agreements, 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 (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 15th 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 in 2017 opened a new office in Germany, to serve better 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 colour masterbatches and additives; • Celloplast GD, which manufactures various thermoplastic elastomers; • 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 TPES in Spain; • Mazzer Grip GD, active in the field of thermal insulation of windows, doors and facades; • Weber Kunststoffe, which has marketed thermoplastics since 1994. www.poliblend.it MACPLAS INTERNATIONAL AT FAKUMA 2018
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Top performance for production change
An imminent revolution in purging Perhaps the most familiar problem encountered when needing to change production, or when switching colours or materials, is that of cleaning the screws, barrels, nozzles, hot runners, extrusion heads, and so on. Well, to solve this problem, the Italian company ErreTi has recently developed a brand new detergent, called P&P Cream, for purging and polishing jobs on any type of injection moulding machine, as well as on extruders, blow moulding machines and rubber processing plants. “P&P Cream is a universal product that can be used at all temperatures, from 70°C to 420°C, and on the following materials: ABS, PA, PET, PS, PMMA, PC, SAN, PVC, EVA, PU, TR, PBT, PPO, PPS, PPA, PP, PE, SBR, EPDM, BMS, FPM and silicone”, explains Canio Baldassarre, managing director of ErreTi. Furthermore, P&P Cream can be used to clean extruders as well as all types of in-
jection moulding, extrusion blow moulding, 3D printing and rubber processing machinery, without needing to dismantle and clean the machine manually. Supplied in small single-dose containers that are easy to use, transport and store, P&P Cream is capable of removing any type of plastic sediment, and residual material or colour left inside extruders, extrusion heads, nozzles, hot runners and moulds. Cleaning is achieved almost instantaneously without gradual colour fading, and this translates into considerable time savings and reduces machine downtimes drastically. Finally, P&P Cream is absolutely safe, both for people and for the environment: it is certified for use in contact with foodstuffs and also carries FDA GRAS certification (Generally Recognized As Safe). It does not give off fumes, it is totally odourless and it does not contain solvents or abrasive substances. www.purgingit.com
Injection screws, untreated (top) and treated with P&P Cream (bottom)
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TRADE FAIRS AND CONFERENCES
Plast Eurasia 2018
A fast growing market Despite the hard context of internal politics and the rapid worsening of international relations, the Turkish economy is growing; increase of the public spending supports investments in manufacturing and infrastructures, and corrective measures to credit improve consumptions. In 2017, Italian exports of plastics and rubber machinery, equipment and moulds towards Turkey reached 89.5 million euros, with a significant share of extruders (14 million euros); in the first six months of 2018, the Italian exports exceeded 52 million euros. The Turkish plastics industry is one of the most successful sectors of the local economy. According to Tüyap (fairs and exhibitions organization), in 2017 the output of raw materials and plastics products reached 9.6 million tons or 36.8 billion dollars, becoming the sixth largest producer in the world and the second one in Europe. Annually organized by Tüyap in cooperation with Pagev (Turkish Plastics Industry Foundation), Plast Eurasia will take place on December 5-8, 2018, in Istanbul, at Tüyap Fair Convention and Congress Center. It will represent an important occasion for exhibitors to show the highest quality of the plastics industry to experts coming from all over the world, thanks to its 28 year experience, and making the best value in the industry, taking this value protection as its principle. Within the scope of the fair, the latest technologies and innovations about plastics machinery, ancillary equipment, moulds, raw materials and recycling will be showcased. The 2017 edition of the Turkish trade show brought together 1,087 companies from 43 countries and 53,919 professional visitors from 101 countries, hosting also several official delegations coming from 31 countries. As regards the 2018 edition, 23 Italian exhibitors have already confirmed their participation, besides tens of Italian companies represented by their local agents. Italy turns out to be, as in every edition of the trade show, one of the most considerable European presence together with Germany, especially because Turkey ranks among the most important destinations for the Italian plastics and rubber machinery exports. www.plasteurasia.com
EXHIBITIONS & TRADE FAIRS 2018 October 16-20 - Fakuma (Friedrichshafen, Germany) October 23-25 - Parts2Clean (Stuttgart, Germany) October 25-27 - Adhesive & Sealant Eurasia Exhibition (Istanbul, Turkey) October 26-29 - India Plast (New Delhi, India) October 31 - November 1 - Advanced Engineering + Composites (Birmingham, United Kingdom) November 1-4 - Plas Print Pack Myanmar (Yangon, Myanmar) 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 - JEC Asia (Seoul, South Korea) 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, Ivory Coast) November 26-29 - All4Pack Paris (Paris, France) November 30 - December 3 - Indplas (Kolkata, India) December 5-8 - Plast Eurasia (Istanbul, Turkey) December 12-15 - Plastpack Packexpo (Casablanca, Morocco) December 16-19 - Plastshow Saurashtra (Gujarat, India)
2019 January 5-8 - Arabplast (Dubai, United Arab Emirates) January 17-19 - India Rubber Expoindia (Mumbai, India) January 17-20 - PlexpoIndia (Mumbai, India) January 27-30 - Saudi Plastics & Petrochem (Jeddah, Saudi Arabia) January 29 - February 1 - Interplastica (Moscow, Russia) February 28 - March 4 - Indiaplast (New Delhi, India) March 5-8 - Plastiworld (New Delhi, India) March 12-16 - Koplas (Seoul, South Korea) March 22-24 - Plasprintpack Pakistan (Lahore, Pakistan) March 25-29 - Plastico Brasil (São Paulo, Brazil) March 26-28 - Plast Print Pack Nigeria (Lagos, Nigeria) March 26-28 - PSE Europe (Monaco, Germany) April 2-5 - Plastimagen (Mexico City, Mexico) April 15-17 - Oman Plast (Muscat, Oman) May 9-11 - Plastprintpack Ethiopia (Addis Ababa, Ethiopia) May 21-24 - Chinaplas (Guangzhou, China)
Last edition of Plast Eurasia, in 2017
May 21-24 - Moulding Expo (Stuttgart, Germany) May 28-31 - Plastpol (Kielce, Poland)
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TRADE FAIRS AND CONFERENCES
MEETINGS & CONGRESSES Austria
Italy
November 6-7 - Wien: Conductive Plastics AMI (www.ami.international/events/) November 14-15 - Wien: Wood-Plastic Composites - AMI (www.ami.international/events/) November 19-21 - Wien: Multilayer Flexible Packaging - AMI (www.ami.international/events/)
Germany November 5-6 - Stuttgart: International Composites Congress (ICC) - AVK-TV (www.composites-germany.org) November 21-22 - Düsseldorf: The European Thermoplastic Compounding Summit - ACI (www.wplgroup.com/aci/event/europeanthermoplastic-compounding-summit) November 28-29 - Hamburg: Polymer Foam AMI (www.ami.international/events/) December 4-5 - Berlin: European Bioplastics Conference - European Bioplastics (www.european-bioplastics.org) December 10-12 - Cologne: Fire Resistance in Plastics - AMI (www.ami.international/events/)
October 25 - Cologno al Serio (BG): Defects due to incorrect settings of operating parameters: causes and solutions Plastinnova (www.plastinnova.it) October 26 - Rivalta Scrivia (AL) Comparing welding technologies - Proplast/ Plastics Academy (www.plasticsacademy.it) November 5 - Monza (MB): Technical documents in the injection moulding Cesap (www.cesap.com) November 6 - Monza (MB): Extrusion process - basic principles - Cesap (www.cesap.com) November 7-8 - Monza (MB): Techniques to colour polymers - Cesap (www.cesap.com) November 8-9 - Cologno al Serio (BG): Costing of products in the injection moulding Plastinnova (www.plastinnova.it) November 9 - Monza (MB): Innovative materials: biodegradable plastics, biopolymers, compounds with natural fibre Cesap (www.cesap.com) November 15 - Cologno al Serio (BG): Safety in the injection moulding department -
Plastinnova (www.plastinnova.it) November 23 - Monza (MB): IR and DSC techniques in detail - Cesap (www.cesap.com) November 27 - Milan: Circular economy/ recycle - PVC Forum Italia (www.pvcforum.it) November 27-28 - Milan Malpensa: Thermoplastic Elastomers & Silicone Elastomers World Summit - Smithers Rapra (www.elastomer-forum.com) December 18 - Monza (MB): Basic course of quality control - Defects in injection moulding - Cesap (www.cesap.com)
United States October 23-25 - Chicago (Illinois): Vinyltec 2018 - PVC Additives Today and Tomorrow SPE (www.4spe.org/Events) October 30 - November 1 - Chicago (Illinois): The Global Plastics Summit (GPS) - IHS Markit (www.globalplasticssummit.com) November 13-14 - Coral Springs (Florida): Stretch & Shrink Film US - AMI (www.ami.international/events/)
Summit in Italy by Smithers Rapra
The “home” for the elastomers industry Over 250 global elastomers professionals will gather at the Silicone Elastomers and TPE World Summits organized by Smithers Rapra at the Sheraton Milan Malpensa Airport Hotel, in Ferno (Varese, Italy), from November 27 to 28. Known as the “home” for the
Opening presentation of Thermoplastic Elastomers World Summit 2017, in Munich
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elastomers industry, the two co-located summits have built a reputation as the key thought leadership forum and are the must-attend events in the elastomers calendar. With two events co-located under one roof, delegates will receive access to each event for the price of just one ticket, meaning double the opportunities for networking and enhancing their knowledge and skills. Described as an excellent opportunity for networking and improvement of market and technology knowledge, the summits will offer delegates the opportunity to gain updates on the latest advancements and trends, build relationships and network with key
players across both industries in a series of dedicated networking breaks, as well as hear from industry thought-leaders delivering expert presentations. Sessions will include material innovation, regulatory updates, use of TPE in medical devices, new trends and technologies, updates in LSR and much more. New for this year, the event will bring both audiences together for a joint session dedicated to the automotive industry, with speakers from Volkswagen, Hexpol TPE and more. The session will assess the latest material trends, requirements for suppliers, the future for autonomous vehicles and the electric car revolution.
Attendees to the conference comprise of industry leaders from across the elastomers value chain ranging from OEMs, manufacturers, processors and compounders, through to tier one and two suppliers, designers and researchers. Just some of the companies confirmed to attend include Teknor Apex, Basf, Saint Gobain, Kraiburg, Dow Silicones, Arburg, Engel, Aptiv, Sigma Engineering, Wittmann Battenfeld, RD Abbott Company, Wacker, Fraunhofer Institute for Silicate Research, Arkema, Dynasol, Nexant, Polyone, Panorama, Evonik, Momentive, Kassel University, Elmet, Decathlon and Holland Colours. www.elastomer-forum.com
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EDITORIAL CONTRIBUTORS
THE FOLLOWING COMPANIES ARE MENTIONED IN THIS ISSUE:
2nd International Exhibition for Polyurethane Solutions 26–28 March 2019 MOC Munich, Germany
nd users: a s t r e p x ll PU e Calling a ative PU v o n n i r e ts Discov ew marke n r o f s n io applicat • • •
ors with al exhibit n o ti a rn Meet inte ns PU solutio innovative s of sentation e live pre c n e ri s e n p o x E cati and appli machines and gain seminars e e fr d n e NEW Att PU topics to current in ts h g si in bility Sustaina Area
The portfolio includes:
Innovative PU solutions for various industries:
www.pse-europe.com
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Organisers: Mack Brooks Exhibitions Ltd
Raw materials +++ PU products and systems +++ Materials and semi-finished products +++ Processing machinery, systems and equipment +++ Services
COMPANY/ASSOCIATION/CORPORATION PAGE AMAPLAST 10; 13 AMI (APPLIED MARKET INFORMATION) 21 BCC RESEARCH 18 BD PLAST 80 BIESSE 36 BINOVA 48 BLAUWER 70 CERESANA 20 COLOR TECH 91 DEGA 74 DOSS 72 ELASTOMERS UNION 92 EPROTECH 81 ERRETI 93 EUROMAP 29 EUROPEAN BIOPLASTICS 27 FAKUMA 16 FILTEC 68 FM FILTER 83 FRANCESCHETTI ELASTOMERI 91 FREEDONIA 18 FRIGEL 55 FRIUL FILIERE 40 GAMMA MECCANICA 50 GIURGOLA STAMPI 79 HAITIAN 33 HELIOS ITALQUARTZ 82 HERRMANN ULTRASCHALLTECHNIK 74 HRSFLOW 58 IMG 33 INGLASS 58 IPM 60 MACPLAS 23 MAGIC MP 43 MAKLAUS 76 MAST 83 NINGBO SUPERIOR MACHINERY 78 NOVA-INSTITUTE 26 PLAST 2018 14 PLAST EURASIA 94 POLIBLEND 93 PRESMA 52 PROMIXON 62 RADICIGROUP 85 SARA 52 SIPOL 90 SMITHERS RAPRA 96 SONDERHOFF 90 STAR AUTOMATION EUROPE 75 ULTRA SYSTEM 7 VANETTI 92 VINYLPLUS 27 WM THERMOFORMINGMACHINES 46 ZAMBELLO 64 MACPLAS INTERNATIONAL AT FAKUMA 2018
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ZAMBELLO
group
Advanced technology for extruders
25
years
in designing and manufacturing high quality gearboxes for corotating and counter-rotating
twin screw extruders
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a Family Company since 1957, made in Italy
Headquarters
Zambello riduttori srl 20020 Magnago, MI - Italy info@zambello.it _IIIcop_Zambello_ADV.indd 99
Zambello riduttori 2 srl www.zambello.com
45026 Lendinara, RO - Italy info@zambello2.it
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