S A P OLY ME R TE C H N OLOGY
V OL 17 N R 4
VOL 17 NR 4 AUGUST / SEPTEMBER 2019
A U GU S T / S E P TE MB ER 2019
Industry closing the loop toward a circular plastic economy in SA :
DURABLE STAR WHEELS FOR WASTE SORTING
F R O D L E S IC 9 IN DÜS
TOP T O H A Y ONOM C E R A L U CIRC
Cabletech installs 4 Haitian machines at Electrolux
MBT changes name to Meraxis South Africa
CTP Flex, Polyplank develop solution for laminate scrap www.sapt.co.za
The Home of Size Reduction
Cover.indd 1 Classifieds Feb/Mar'18.indd 92
The story gets longer at Inkulu
Zerma at IFAT 18
Coca-Cola in SA recycled more plastic than it produced
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BY THE WAY
Publisher & Managing Editor: Martin Wells (email@example.com) Editor: Tessa O’Hara (firstname.lastname@example.org) Publisher’s assistant: Heather Peplow (email@example.com) Financial manager: Lisa Mulligan (firstname.lastname@example.org) Designers: Jeanette Erasmus Graphic Design (email@example.com) Bronwen Moys Blinc Design (firstname.lastname@example.org) Summit Publishing cc t: +27 (21) 712 1408 f: 086 519 6089 c: +27 (82) 822 8115 e: email@example.com Postnet Suite 42, Private Bag X16, Constantia 7848, Cape Town, South Africa Unit 8, Bergvliet Village Centre, Cnr Hiddingh & Children’s Way Roads, Bergvliet 7945
www.sapt.co.za GAUTENG Lowrie Sharp t: (011) 793 4691 c: 082 344 7870 e: firstname.lastname@example.org KZN Lynne Askew c: (082) 904 9433 e: email@example.com Printed by: Tandym Print, Maitland, Cape Town SA Polymer Technology is published six times a year and focuses on these industries in South and southern Africa. We welcome news, articles, technical reports, information in general and photographs about events and developments related to the plastics industry. The views expressed in the magazine are not necessarily those of the publisher. Views expressed are not necessarily those of the Plastics Converters Association, Institute of Materials or Association of Rotational Moulders either. Copyright: All rights reserved. ISSN number: 1684-2855 (ISDS Centre, Paris) Summit Publishing: CK 9863581/23 VAT reg: 4600187902
Plastics Institute of Southern Africa
Association of Rotational Moulders of South Africa Plastics Converters Association
PET Plastic Recycling South Africa
Institute of Materials
Can do it – In the last issue we suggested that South African convertors can be world leaders in moulding … and many of you probably didn’t take that too seriously. But GPS Plastics of Durban is evidence that this can be and is the case: GPS’s Kevin Govender has won a couple of contracts for parts that were being moulded in China. GPS found they could be competitive, even given that an engineering polymer is used for these bicycle components. Let’s be honest: for most SA moulders, just the cost of shipping the parts over 12,000kms would make a contract unsustainable, but this does not appear to be a problem for the Oriental manufacturers (possibly due to the fact that they have such powerful and effective shipping/exports systems). Operating out of Pinetown, GPS has also built up its assembly abilities and is now able to manufacture and supply parts such as these to local customers very effectively
Don’t start the revolution without us
AS YOU know, a revolution is upon us, the Industry 4.0 revolution. That’s what I hear, but some people say Industry 4.0 hasn’t got to Africa yet. You go to shows and conferences, and learned academics stand up and tell you how incredible it’s all going to be. Previous revolutions were relatively drawn out affairs, like the actual Industrial Revolution, which ran from 1760 to 1840, but this one’s coming at speed. From our point of view, the main feature of Industry 4.0 is hugely improved remote communication/control and massively increased data storage ability. The one plus for Africa is that just about everyone has a mobile phone and is therefore able to participate. For manufacturers, however, probably the most necessary feature will still be for sales personnel to remain well connected with customers – you’ve got little chance otherwise.
Thank you for the compliments
WE HAVE received several compliments on the content and appearance of the mag from readers lately, and many thanks to you for that. This was partly in response to the slight redesign we did, which, actually, we thought you wouldn’t notice. The goal for us is to produce a publication which readers ﬁnd interesting, relevant and useful. To be honest, we believe we are fortunate to be involved in a very creative industry, and it’s therefore not too much to expect that the publication should be interesting. A lot of the info published comes to us via the press or marketing representatives of global material, machinery and – most interestingly – product manufacturers. Plastic and composite products offer fabulous solutions and opportunities to improve life on Earth.
Paper straws not recycled, yet
SUPPLIERS of alternative materials may readily jump on the bandwagon when products made from a rival material draw environmental criticism, you may be aware of this by now. Take the example of the phasing out of plastic straws by McDonalds from its 1300-plus stores in Britain and replacement by paper straws. McDonalds has HAVE had to admit that the paper straws were in fact not … IF YOU G TO SAY IN H ET SOM being recycled and that they had yet to develop a de: if you si ht e brig Look at th isdom to recycling system for them, which info came to light w of e gem us at have som to te ri after an internal memo was intercepted. ease w za impart, pl .co. mmitpub tessa@su
VOLUME 17 NR 4
Contents AUGUST /SEPTEMBER 2019
Find out more at www.sapt.co.za
Industry closing the loop toward a circular plastic economy Cabletech installs 4 Haitian machines at Electrolux IDC funding helps Emalahleni recycling ﬁrm expand CTP Flex, Polyplank solution for laminate scrap MBT changes name to Meraxis South Africa BFG Africa takes off in composites industry Plastics industry mergers & acquisitions New 55-layer Nano Lite stretch ﬁlms from Taigan Ipex gains new agencies AM awards to recognise and inspire SA’s innovators
6 8 10 12 14 16 18 20 23 24
SA’S recycling champions ARMO 2019: Good int’l response SAVA’S newly launched Vinyl-dot
26 28 30
Repi: Satisfying demanding environmental promises Annual Clean-Up and Recycle SA Week Binning the idea that plastic bags are the problem Biocomposites performing great LyondellBasell, production of bio-based plastic Avantium moving forward on bio-based plastics plant
New Zealand plastics industry design awards Winners of Plastics Recycling Awards Europe
Covestro Sonnenwagen: Full throttle with solar power BMW sees potential of 3D printing in new business models Will the EU miss its 2025 plastics recycling target?
Riding the waves with electric surfboards
46 43 50 52 54 55 56 62
72 74 75 92
ON THE COVER
Injection moulding for the medical, transportation, engineering, home appliances & houseware markets Various and vast skill sets, coupled with years of experience in quality and production control, R&D, machine setting, mould designing and procurement. Manufacturing • Injection moulding machines from 100-ton up to 500-ton clamp force • R&D expertise specialising in cradle-to-grave solutions, product design Quality Systems • Effective quality benchmark tool to ensure the precision of all products • Implemented throughout every process in the supply chain Value-Added Services • PAD printing • Product assembly • Re/design consulting • Career development and enhancement
Kevin Govender at GPS Plastics on tel 031 700 6900 or email: firstname.lastname@example.org
Lanxess’s Urethane Systems business unit has developed an alternative to synthetic rubber for producing star wheels for material separation plants and material transport. It is based on polyurethane (PU) elastomers produced from Adiprene Low Free (LF) prepolymers. Read on page 44
GPS ad.indd 90 2-3.indd 3
2019/08/02 09:41 14:33 2019/08/06
Foil to desk – Production clerk, Christopher Davis and assistant, Joseph Cupido, manage the quantities of laminate scrap at CTP Flexibles in Cape Town. Much of this material previously went to landﬁll, but is now supplied to recycler Polyplank from which its proprietary planks are manufactured … and the result is (right) sturdy school desks used in arguably the most important development environment, school education – see page 12
SAPRO’s Plastics Pact is another option
Big positive is that both Plastics|SA and SAPRO have attracted some major partners
AUG / SEPT 2019
O NOW we have not one, but two plans aimed at counteracting the environmental pressure and coming up with new solutions for used plastics..
costs of collection, sorting and cleaning/washing), but it’s our belief that showing faith in recycled material directly implies better respect for the value of virgin polymers. Up until now, businesses have not been queuing up to take responsibility (it’s a difﬁcult and costly problem), so the big positive is that both Plastics|SA and SAPRO have attracted some major partners: SAPRO also has the support of the Ellen MacArthur Foundation; Plastics|SA that of raw material as well as FMCG manufacturers.
First Plastics|SA introduced the South African Initiative to End Plastic Pollution earlier in the year and then, in July, the SA Plastics Recyclers Organisation (SAPRO) put forward its proposal, the South African Plastics Pact (page 6), in collaboration with World-Wide Fund for Nature (WWF-SA). At ﬁrst it looked like the plans were conﬂicting, but are they? At this formative stage it’s got to be Whose problem is it anyway? better to look at various options. The fact that It’s our belief that the main problem is actually Hopefully, a second plan has been tabled (and hats one of littering, and it’s going to be extremely off to Johan Conradie and the SAPRO difﬁcult to change that behaviour, which is a embodying these team for getting their programme off global problem. It’s ironic therefore, that the plans will create the ground) may confuse some people, new programmes are being largely driven but it’s hardly that, there are so many opportunities for all by European and American companies, conﬂicting agendas and priorities around the people involved when plastic litter is hardly even a problem in and solutions are not jumping out at us – their areas. As a result, some of you may be in our industry in fact, it’s proving complex. thinking, ‘Why should we have to deal with this The pressure from environmental groups anyway?’ Well, it’s gone beyond that. Basically, around the world has, if anything, presented if you derive the bulk of your income from polymer an opportunity that recyclers have long been materials or moulded products, then you are part of the waiting for. Recycling is not glitz, but recyclers all over problem – and hopefully also part of the solution. the world (of any material) provide a vital service for both As far as the South African situation is concerned, perhaps convertors (of production scrap) as well as of post-consumer we can see this as an opportunity? Our recyclers are already material. world leaders in some categories: hopefully embodying Now, as you will read in the several environmental these plans will create opportunities for all the people articles in this issue, even the big material and machinery involved in our industry. manufacturers are acknowledging that they have to factor So, read about the alternative material reuse into their strategies. Previously, it was quite proposals here and consider the options. easy for the big material manufacturers to ignore the problem. That’s logical, given that manufacturing virgin material is far easier than recycled material (which incurs the additional Martin Wells Publisher Martin Wells,
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Industry closing the loop toward a circular plastic economy – the South African Plastics Pact Our plastic perils TO reduce the negative environmental impacts of plastics and accelerate the transition from a linear plastic material ﬂow to a closed loop or circular ﬂow situation, the World-Wide Fund for Nature (WWF-SA) and the South African Plastics Recycling Organisation (SAPRO) are spearheading the development of the South African Plastics Pact.
6 AUG / SEPT 2019
The partners also have the support of the Department of Environmental Affairs (DEA), technical support from the Waste and Resources Action Programme (WRAP) and the Ellen MacArthur Foundation’s New Plastics Economy Global Commitment. The SA Plastics Pact brings together all key stakeholders at national level to implement solutions towards a circular economy for plastics. The initiative will be led by a South African organisation, uniting businesses, governments and citizens behind a set of concrete, timebound, ambitious targets, relevant to the local South African context which also compliment statutory requirements. It not
only builds on the transition agendas for plastics and consumer goods as set out in the Waste Act, Waste Phakisa, Good Green Deeds, ‘The New Plastics Economy’ published by the Ellen MacArthur Foundation and the G7 Ocean Plastics Charter, but it will also contribute towards the UN’s Sustainable Development Goals (SDGs), speciﬁcally SDG 12 (ensure sustainable consumption and production patterns), SDG 13 (take urgent action to combat climate change and its impacts) and SDG 14 (conserve and sustainably use the oceans, seas and marine resources for sustainable development). The South African Plastics Pact has evolved since it was unveiled at the Design for Recycling event at Propak Africa and the GreenCape and Sustainable Retailers Forum Circular Economy event in March this year. An intensive scoping and engagement phase has been initiated, driven by WWF, and there has been an overwhelmingly positive response from key stakeholders across the value chain including: national government, NGOs, retailers, brand owners, plastic industry bodies, Producer Responsibility Organisations and waste management companies interested in taking this collaborative initiative forward.
Collaborating towards concrete and measurable goals In a bold move, distinguishing itself from other initiatives, the prospective SA Plastics Pact signatories are supporting the undertaking in a pre-competitive setting and in cooperation with players in the plastics value chain, to collaborate and lead the way in: • addressing problematic single-use plastic products and packaging • increasing the recyclability in practice of plastic products and packaging • enhancing corporate social responsibility • pooling resources for research and innovation, and • improving consistency in communications and messaging to customers and consumers. At this stage, the SA Plastics Pact is mainly focussed on fast-moving consumer goods (i.e. single-use plastic products and packaging as well as plastics recyclate applications in complementary consumer goods industries, such as furniture, electronics, clothes and toys). The work streams to support the achievement of these targets are at the inception stage. However, momentum has already been gained in some instances
To this end they have set concrete and measurable goals up to 2025. The national targets proposed are as follows: • Target 1: Deﬁne a list of problematic/ unnecessary plastic packaging and items and agree to measures to address by 2021 • Target 2: 100% of plastic packaging to be reusable or recyclable or compostable# by 2025 (# applicable only in closed loop and controlled
systems with sufﬁcient infrastructure available or ﬁt-for-purpose applications, eg tea bags) • Target 3: 70% of plastic packaging effectively recycled by 2025 Target 4: 30% average recycled content across all plastic packaging by
2025 (average across all product lines) • Target 5: could include number of jobs created in the plastic waste sector and/or; economic contribution of the plastic waste sector to overall GDP and/or 100% of plastic producers are members of Producer Responsibility Organisations.
SA Initiative to end plastic pollution unites members of value chain Important progress made as role players collaborate to ﬁnd solutions
with the WWF holding the OPRL (On Pack Recycling Label) guidance initiative. Other work streams that have been identiﬁed are guidelines on biodegradable and compostable materials (which ties in to Target 2 ) and the ongoing government and industry driven dialogue on waste collection and the informal waste sector (which impacts Target 3). The SA Plastics Pact will be managed by an independent coordinating body or secretariat. There will be on-going engagement with the organisations that have expressed interest in the role of the SA Plastics Pact. Recruitment and roll out To jointly work towards the vision for a circular economy for plastics and the targets of the SA Plastics Pact, the WWF and the Consumer Goods Council of South Africa (CGCSA, the secretariat of the SA Alliance of Plastic Waste Forum) are in discussions on the synergies between the Pact and the SA Alliance on Plastic Waste Forum. In the coming weeks, WWF plan to release a ‘Signatory Pack‘ which would include information on organisational structure, fee structure, targets, marketing and scope. Potential signatories will be encouraged to sign-up by the end of August 2019 whereafter the steering committee will be formalised in September with a view to launching by October 2019.
AUG / SEPT 2019 7
• For more information on the SA Plastics Pact, or to become a part of this pioneering initiative, please contact Lorren de Kock at the WWF (Lorren manages the Circular Plastics Economy Policy & Futures Unit at the WWF-SA): Tel +27 (0)21 657 6656; email@example.com
PLASTICS|SA has made important afford to wait on them. Instead, it is strides in its efforts to unite the entire up to us to create scalable African plastics industry value chain and solutions that are ﬁt for purpose and other role players around developing will address our own unique set of workable solutions that will end challenges when it comes to waste plastic pollution in our oceans and management infrastructure, education the environment since the launch of and awareness,” he adds. the South African Initiative to End The SA Initiative has identiﬁed the Plastic Pollution. importance of tackling the problematic Executive director Anton Hanekom, ‘single use’ plastic packaging as a says regular meetings have been matter of urgency, closely followed taking place with the Consumer by the need to increase the plastics Goods Council of South recycling rates and Africa (CGCSA), the make more products Chemical and Allied available with It is up to us Industries Association increased recycled (CAIA), Packaging content. Saving to create scalable SA, raw material jobs (and African solutions suppliers, where possible, converters, that will address our creating more brand owners, employment own unique set of international FMCG opportunities) challenges. companies, recyclers whilst relieving and environmental the pressure on organisations to develop the environment, a workable, local plan that is a guiding priority ﬁts the South African context and throughout the dialogues. our particular environmental, socioTo this end, a special board – political and economic realities. comprising of senior decision-makers Plastics|SA is also currently from brand owners, industry and engaged in discussions about government – has been elected the synergies that exist between to drive the rollout of workable members belonging to the South action plans: African Plastics Pact in an attempt “Our next step will be to develop to combine the various activities objectives and targets, identify into a single, uniﬁed movement to products, alternatives or projects avoid duplication of efforts and more founded on evidence-based confusion in the market. conclusions during August. This will “We cannot solve the growing be followed by identifying research to problem of plastic pollution in the determine best solutions and secure environment alone and welcome any funding in September, after which partnership that supports our focus we will begin the rollout, monitoring, of developing inclusive, practical and evaluation and reporting on the scalable solutions that will protect our success of the plans and projects from people, our planet and our industry,” October onwards,” Hanekom states. Hanekom says. “Whilst we continue working with our global counterparts to ensure that • For more info on the South African we are in-step with developments and Initiative to End Plastic Pollution, initiatives taking place in the rest of visit www.plasticsinfo.co.za the world, we realise that we cannot
PHOTO BY LOWRIE SHARP
Marius Hofmeyr, Electrolux area manager, Duane van Zyl of Cabletech and Braam Le Roux, Electrolux engineering manager, with three of the new Haitians that will be used to produce geysers
Cabletech installs 4 Haitian machines at Electrolux
8 AUG / SEPT 2019
Haitian’s ﬂagship series in servo hydraulic toggle driven machines
CABLETECH recently supplied, installed and commissioned four Haitian MAIIS series injection moulding machines at Electrolux in Benoni to manufacture 10-litre to 30 000-litre electric geysers. The two Haitian MA 470 ton injection moulding machines, and the MA 470 ton and a MA 200 ton machines are considered to be Haitian’s ﬂagship series when it comes to servo hydraulic toggle driven machines. This was a high priority job for Cabletech as Electrolux is a key account for Haitian internationally. In South Africa, Electrolux manufactures household appliances for its brands which include Electrolux, Kwikot and AEG. Electrolux is one of the largest geyser manufacturers in the country. As a leading global appliance company, Electrolux, through its brands, including Electrolux, AEG, Anova, Frigidaire, Westinghouse and Zanussi, sell more than 60 million household and professional products in more than 150 markets every year. Electrolux has been doing business since 1919. The headquarters are located in Stockholm, Sweden, and the Electrolux share ELUXb is listed on Nasdaq OMX Stockholm. Braam le Roux, engineering manager at Electrolux explained that after Kwikot geysers were taken over by Electrolux three years ago, innovations had to be implemented. “Electrolux continually strives to better
our production, both in efﬁciency and in our level of quality and commitment to producing the best quality product. We pride ourselves on the fact that basically every part of one of our geysers – from a 10-litre to a 30 000-litre – can be manufactured in our factory in Benoni,” he added. Electrolux’s area manager in the plastics department, Marius Hofmeyr, was tasked with getting the department to run more efﬁciently and requesting options and quotations from machinery suppliers. Cabletech’s Duane van Zyl, sales engineer, was one of the suppliers approached. “Duane took this opportunity and went above and beyond to ensure that Cabletech supplied the best equipment to ensure that our plant will run as efﬁciently and cost-effectively as it possibly can,” said Le Roux. “Duane took our product into consideration and supplied us with, not only our request, but also his suggestion to ensure that the machine was speciﬁed in accordance to our product. It became clear that Duane’s recommendation was the route to go.” The order was placed and Cabletech managed to deliver a month before Electrolux’s deadline. Duane and the Cabletech technical department installed and commissioned the machines the same day they were delivered to Electrolux. “There were some obstacles, but Cabletech was constantly there to support us. We are completely satisﬁed www.cabletech.co.za
with both the sales and aftersales service we receive from Cabletech. Duane’s understanding and knowledge helped us with different channels and methods that are of great advantage. We are looking forward to the journey ahead and reaching our end goal – a plant consisting of only Haitian machines,” Le Roux added. Cabletech’s Van Zyl said that when he met with Electrolux’s Marius Hofmeyr it was clear that Hofmeyr’s knowledge regarding plastic injection moulding was extensive. “I knew I would need to step up to the plate with this one. Coming from a technical background, I always feel much more comfortable discussing projects after seeing the client’s plant. This is exactly how it went at Electrolux. Marius took me through their plant and explained to me what they were looking for and shared all the relevant information regarding the new venture,” Van Zyl added. Van Zyl said that after installing and commissioning the ﬁrst two Haitian machines, Electrolux gave him the opportunity to incorporate a few additional functions in the next two machines to give them faster cycle times and increase their efﬁciency. “I am very proud of this project and I am very enthusiastic for our future journey ahead. I get along really well with Electrolux and would like to thank Braam and Marius for trusting in me and the opportunity to play a part in Electrolux’s success,” he added.
News Packaging World buys SOMA printer, kit from Cibapac PACKAGING World of Durban has completed the purchase of the Soma printer from Cibapac, along with a laminator and slitter, in a highvalue transaction. The Czech-built ‘Optima2’ system is reputed to be one of the most sophisticated printers in Southern Africa: printing an 820mm web width and is capable of printing both sides of the web at high speeds, which is, well, radical. The equipment is in the process of being installed at Packaging World’s plant in Westmead, seeing Dean Gianni’s company going up a gear: it now operates four presses (its other large line, a Windmöller and Hölscher Miraﬂex S ﬂexographic system, went into operation in May last year). The Soma line was installed at Cibapac in Cape Town in July 2017.
10 AUG / SEPT 2019
• Greg Petzer signs on at Packaging World – see page 66
Aberdare opens R135m power cable plant in PE ABERDARE Cables opened its new R135-million high-voltage power cable plant in Port Elizabeth on 25 July. The plant forms part of Aberdare’s expansion strategy and increases its manufacturing capability of cables from a current level of 33kV to a new product offering of up to 132kV. A further 58 jobs were created, in addition to the 429 employed at the Aberdare site in Port Elizabeth to date. Aberdare Cables chief executive Dr Haiyan Song said the investment would create opportunities for local young people. Opening the plant, Trade & Industry Minister Ebrahim Patel said: “Wealth and jobs are created by expanding productive capacity. The government will deploy industrial policy measures to support manufacturers as that opens economic opportunities for the industry and for the country at large.”
Mihula grew from lifting nine tons of waste a month to 20 tons over a short period of time
IDC funding helps
Emalahleni recycling ﬁrm expand THE dream of becoming a leading recycler with a network of branches around Mpumalanga province, while also setting an example to young people, is closer to reality for Amilia Mkhonza and Hercules Moosa who secured ﬁnancing from the Industrial Development Corporation (IDC). Funding from the IDC for equipment and working capital, as well as business support, has had an immediate impact on Mihula’s supply capacity. Mihula grew from lifting nine tons of waste a month to 20 tons over a short period of time. Mkhonza and Moosa own Mihula Holdings, a 100% black youth and woman-owned waste recycling company based in Emalahleni that has used the ﬁnancing from the IDC to signiﬁcantly accelerate its growth. The duo, who are former colleagues at a defunct recycling business, decided to go into business together after being retrenched. They started out recycling glass using their respective back yards to keep their collectibles. “As business partners we have complementary skills sets that have helped the business grow, using my background in accounting and administration and those of my
partner in recycling and operations has put us at a great advantage to move our business forward,” says Mkhonza. “After getting advice that glass was unsafe to keep at a residential site, the National Youth Development Agency helped us to ﬁnd premises to keep our recyclables. Moving to a place that had big enough space provided more options for us to add paper, cardboard and plastics to the streams of waste we collect,” she adds. The business was registered in February 2018 and has made strides as a new player in the circular economy of waste recycling. The duo has already secured signiﬁcant off-take agreements from established companies in the paper and packaging sectors. IDC regional manager in Mpumalanga, Mashweu Matsiela, says the corporation identiﬁed great potential in the Mihula business model. “A key element of our mandate is to invest in young black-owned companies, promoting entrepreneurship through building competitive industries and enterprises based on sound business principles.”
CTP Flex, Polyplank solution for laminate scrap
Talking the plank – Jakes Wallage with the ultimate product, the Polyplank™ proﬁles which are used in a variety of end products, including desks, pallets, furniture and others
12 AUG / SEPT 2019
Laminate ﬁlm is one of the products where beneﬁciation has proved most elusive … till now BENEFICIATION is a term usually applied to the mining sector, a process that involves improving the economic value of ores, but there’s no reason for convertors to not look at a similar scenario for production scrap. These polymer materials are, after all, commodities and in some cases production scrap – including start-up scrap, edge trim
and off-spec print run – forms a higher than desired ratio of material cost. CTP Flexibles in Cape Town has come up with a solution for the quantities of laminate ﬁlm scrap it produces, much of which previously went to landﬁll – which incidentally also incurred additional costs for both transport and landﬁll dump fees. CTP Flexibles, a ﬁlm extrusion/printing/ bag making business in the Caxton media and print group, now supplies the laminate scrap to recycler Polyplank, including
polyethylene, BOPP (biaxially orientated polypropylene) and metallised PET (polyester). Polyplank manufactures its proprietary Polyplank™ range of planks from a combination of polyoleﬁns, polyester and polyamide. Polyplank MD Jakes Wallage, who established the company in 2006, has developed the ratio formula for the extruded proﬁles that are manufactured in a process developed by Polyplank, operating out of Epping Industria, Cape Town.
No foiling around – The Polyplank process involves shredding the laminate ﬁlms. The material, mainly polyester (PET) is then blended with other polyoleﬁns as well as PA from which the Polyplank proﬁles are eventually manufactured CTP Flexibles’ facilities manager Allison Horton with some of the laminate edge trim scrap, in this case bagged direct from slitter-rewinder before supply to the recycler, Polyplank
In a case of adding value to a material previously seen as high-cost scrap and diverting it from landﬁll, the partners CTP Flexibles and Polyplank have come up with a solution that is assisting the drive to improve the environmental image of plastic ﬁlm materials. Even on landﬁlls, these ﬁlms can still pose an environmental hazard by being blown into surrounding areas, ending up littering the environment and entering rivers and hence the ocean. Eliminating this source of plastic litter is just one step in the industry’s drive to clean up its image. “Polyplank has made it its business to design a solution to this complex multi-lam waste. We did this with our own funding and initiative,” said Wallage, who has been working for some time with CTP. CTP Flex general manager Alan Booth said “we realized how important it is for us to reduce the amount of scrap going to landﬁll and this needs to be done as much as possible. “One of the key objectives is to limit our factory scrap rate wherever possible. Getting this project underway has been a positive venture for us and our partners,” added Booth.
that was previously seen as an environmental contaminant. One of the obvious advantages is that the Polyplank desk is somewhat heavier than the pine solution and hence sturdier. The Polyplank proﬁles are supplied as ready-to-assemble ‘ﬂatpack’ kits (similar to the concept pioneered by IKEA of Sweden over 70 years ago, with wood) and assembled on site. Post-consumer next? Using factory scrap for the production of the proﬁles is obviously far easier than working with post-consumer material, which would involve the additional steps of collecting, sorting and cleaning, but the partners see the initiative as a step towards the goal of fully resolving the problem posed by laminates in the environment. These ﬁlms have proved difﬁcult to recycle and if anything could possibly be one of the plastic materials least likely to degrade and therefore remain in the environment for years after disposal. Developing the technology to reprocess these ﬁlms (thanks to Polyplank) and gain market traction for resultant products is thus a step towards the somewhat fanciful but not unattainable ‘zero plastics to landﬁll’ goal.
Profiles are supplied as ready-toassemble kits
Gained popularity The Polyplank proﬁles have recently gained popularity in the manufacture of school desks, where they offer some advantages over the wood used traditionally. Besides the fact that timber has become increasingly expensive, the Polyplank alternative provides a solution for a material
The Polyplank desk offers some advantages, one of which is that it is sturdy – it weighs in the region of 40kg – and which is hence also a useful market for recycled polymer AUG / SEPT 2019 13
MBT changes name to Meraxis South Africa Meraxis combines the polymer purchasing power and versatility of Rehau Procurement and MB Barter & Trading
14 AUG / SEPT 2019
A NEW global materials distributor entered the international polymers market in July in the form of Meraxis Group, following the merger between the Swiss businesses MB Barter & Trading and Rehau GmbH. Meraxis made its ofﬁcial debut in the market on 1 July and will be promoting itself as a new player in the market at the K Show in Düsseldorf in October. The merger involves the combination of the purchasing arm of Rehau and all global ofﬁces of MB Barter & Trading, which now all operate under the new common name of Meraxis. The goal of the merged and substantially larger entity is to become one of the world’s largest polymer distributors in just a few years, The Meraxis Group said in a statement. As a result, MBT South Africa, a subsidiary of MB Barter & Trading, formed by Dick Coates in 1996 in partnership with the Endres Family, changed its name to Meraxis South Africa. “Only our name is changing,” said Meraxis South Africa Managing Director, Ivan Horowitz. “Our contact details, registration number, VAT number, bank details etc. remain the same.” “What does change is that we are now part of a bigger organisation with considerable buying power and our challenge is to use this to the advantage of our customers and grow the business accordingly,” added Horowitz. Sales of more than €2-billion With sales of more than €2-billion, the merged group’s product portfolio includes classic polymers (including PE, PP, PET, PVC), engineering plastics, masterbatches (colour granulates) and recycled materials. In addition, Meraxis procures purchased parts (such as metal, foils, electrical) as well as machines, systems and tools for various plastics processing technologies. “Meraxis combines a global distribution and logistics network with decades of experience in the development and processing of polymers,” said Dr Stefan Girschik, CEO of Meraxis. “The merger now enables us to support customers around the world in the strategic sourcing of plastics and industry-speciﬁc solutions.” Meraxis works with a global portfolio of supply partners and, said Girschik, “this enables us to provide our customers the products they desire in an agile manner, especially in times that continue to be very volatile and ever-changing”. It supplies customers in the automotive, chemical, construction, furniture and packaging as well as many other sectors. In addition to trading in classic polymers, the Swiss polymer distributor likewise develops bespoke solutions to make customer production more efﬁcient. “As a full-service provider, we not only provide advice about the selection of suitable materials for a wide variety of production processes,” said Meraxis deputy CEO Philipp Endres. “We actively take up the ideas of our customers and, working together, are constantly striving to further develop them into innovative polymer solutions.”
The members of the board of Meraxis, headquartered in Muri bei Bern, Switzerland, include Dr Stefan Girschik (CEO), Philipp Endres (deputy CEO) and Marco Zahnd (CFO)
Ivan Horowitz and Dick Coates
In future, Meraxis’ partners will also beneﬁt from digital and forward-looking service offerings: “Digitalisation offers a multitude of opportunities to make the polymer trade more efﬁcient and to establish new business models,” said Girschik. “As a ﬁrst step, we will soon be providing our customers with helpful services via a customer portal. Additional ideas are already in the design phase.” In future, however, Meraxis not only wants to be a digital pioneer, but also wants to be a driving force in the continued development of sustainable applications. For example, recycling solutions are also an important thrust of the Meraxis strategy. The Board of Directors of the new company consists of Dr Stefan Girschik as CEO (formerly deputy CEO of Rehau Group), Philipp Endres as deputy CEO (formerly CEO of MB Barter & Trading) and Marco Zahnd as CFO (formerly CFO of Rehau Switzerland).
The merger is completed. MBT is now Meraxis South Africa.
Meraxis South Africa (Pty) Ltd Johannesburg +27 114552889 Cape Town +27 215567787 Durban +27 827755344
Together into the future. meraxis-group.com
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Two traditional Swiss companies have merged to create a new global player: The REHAU Group's procurement company and the global commodity trading business of MB Barter&Trading are now Meraxis.
Our commitments for working together: Trade. We supply the right product reliably. Create. We think in tailor-made solutions. Elevate. We redefine boundaries. Our vision. We operate and deliver reliably, tailor our solutions to your needs, and constantly redefine the limits of what is possible.
16 AUG / SEPT 2019
Backlash stalls ‘Litter Trace’ marine research project A NOVEL project aimed at monitoring the ﬂow and incidence of plastics litter in the marine environment, involving the experimental release of marked plastic blocks into Table Bay and False Bay, was halted in June after environmental groups obtained a legal interdict preventing the study from going ahead. The aim of the Litter Trace project, undertaken by the FitzPatrick Institute of African Ornithology at UCT, was to estimate the proportion that wash ashore. Two types of polymer blocks were to be released, and the Institute requested that fellow beach cleaners keep an eye out for them and spread the word. The white plastic blocks to be used in the project measure 12x8cm and come in two types, hard plastic sheets 3mm thick with stickers on them bearing a unique item number and information on how to report them; and polystyrene blocks 30mm thick that are only labelled with a unique code (as the labels the researchers had did not stick to EPS). According to Prof Peter Ryan of the FitzPatrick Institute, it is widely assumed that 80% of the plastic litter found in the sea comes from landbased sources. And certainly most of the litter close to urban areas in South Africa comes from local sources. “However, there is a massive mismatch between the estimates of how much plastic is ﬂoating at sea (about 250,000 tons) and how much ‘leaks’ from land into the sea each year (anything from 5-12 million tons). Even allowing for plastics that sink, either one (or both) of these estimates is wrong, or a lot of the plastic litter coming out of rivers and storm drains is not actually ending up at sea,” said Ryan, adding that the experiment was intended to estimate the proportion of litter coming out of urban catchment areas that washes up on beaches. For the time being, however, the project is on hold. The researchers had advised a group of beach cleaners in the Western Cape, estimated at about 500 individuals, of the project. Ryan said the vast majority of feedback on the experiment had been positive.
The new BFG Africa plant in Elandsfontein was ofﬁcially opened by Doctor Xhakaza, MMC for Finance and Economic Development of Ekhurleni, who cut the ribbon, and Mohamad Usman, group CEO of BFG International (out from Bahrain)
BFG Africa: Black industrialist company takes oﬀ in composites industry New venture involving SA’s Mergence and Bahrain’s BFG set to manufacture large composites parts in Joburg BFG Africa Rail, a joint venture by global composites group BFG International of Bahrain and local black industrialist group Mergence, opened its South African moulding plant in Johannesburg on 18 July. Mergence, a diversiﬁed ﬁnancial services group based in Cape Town. acquired a 51% stake in the R50million venture, set up in June 2018, with BFG (Bahrain Fibre Glass) International owning the remainder. The 9,500m² factory, in the Tunney Industrial Area in Elandsfontein, is producing a range of composite components for applications across the infrastructure, mining, automotive, transport and architectural sectors. Production at the plant commenced earlier this year. “We were delighted to provide BFG International with a local partner that can assist with unlocking further opportunities in the composites space,” said Mergence managing director Masimo Magerman. “Our
objective is job creation and skills development and to grow the black industrialist sector in South Africa and Sub-Saharan Africa.” Dr Samer Aljishi, group president of BFG International, said: “Currently 27 people are employed by BFG Africa, 18 of whom underwent extensive training in Bahrain. The company is well positioned to beneﬁt from the roll-out of transport infrastructure and rolling-stock (interiors and claddings) renewable energy projects (composite-based wind turbines), and automotive projects.” As an initial contract, entered into with the Gibela Rail Transport Consortium, BFG Africa will clad the interiors of a ﬂeet of 600 commuter trains that will be supplied to the Passenger Rail Agency of SA (PRASA) over a 10-year period. The ﬁrst delivery on this project was met in May 2019. BFG Africa is also working on an affordable emergency housing
Masimo Magerman, MD of Mergence Group, at the plant opening in July
Arshad Gove, MD of BFG Africa, has been deployed at a number of BFG’s plants internationally – including France (La Rochelle), USA (Plattsburg), Philippines and India, besides Bahrain – prior to his appointment to head up the African business. He has been in Johannesburg since November 2017; the plant started production in June last year
solution product, whereby lightweight collapsible structures can be transported and erected within hours to disaster areas. Arshad Gove, MD of BFG Africa, said: “The factory is regarded as one of the best of its kind in the world, with state-of-the-art equipment, including several specialised presses. The manufacturing processes include tooling, open contact moulding, resin transfer moulding, painting, SMC material production, SMC press moulding, vacuum infusion, assembly and product integration.
“Composites ﬁbreglass has replaced conventional materials in locomotive, buildings and specialised applications. Fibreglass as a ‘material of the future’ has an imprint in many developed nations and we are excited to be leading the charge with applications in Africa in areas of architecture, rail & transport, wind energy, housing and many other areas by using this advanced material,” added Gove, whose previous experience includes that of setting up a ‘lean factory’ dedicated for the rail business in Bahrain.
BFG International (Bahrain Fibre Glass Int’l)has been a global leader and pioneer in composite design, engineering and manufacturing for over 40 years, with over 2,500 employees and 15 production facilities worldwide. BFG supplies customers in various sectors, including such global leaders as Bombardier, Alstom, Siemens and Gamesa. BFG also works alongside leading architects and developers of the world executing landmark projects.
www.mergence.co.za www.bfginternational.com AUG / SEPT 2019 17
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Mergers, acquisitions, restructuring, recruitment
The Prea technical consultancy team with global CEO, Pravin S Mistry (second from right)
– Africa has enormous potential China and India are no longer competitive
18 AUG / SEPT 2019
PREA Ltd of England, a global consultancy focussed on mergers & acquisitions (M&A), business restructuring, technical and recruitment in the plastics, rubber, composites, chemicals and engineering business, is currently involved in a number of projects in Africa. We speak with Prea’s global CEO Pravin S Mistry who gives a brief overview about this important background to business operation. According to Mistry, Prea is “quite unique in that we as a team are from this industry and have worked previously for both small and multinational companies in the industry in various roles, from operations and technical, to directors running the businesses”. We hear of some major purchases in the industry internationally, speciﬁcally that of RPC by Berry Int’l of the USA: is there much merger and acquisition activity besides? We operate globally and have completed several cross-border deals in buying and selling companies, working with strategic acquirers and private equity companies. The appetite just seems to be growing globally year on year. The scope is widespread, not just multinationals but also small to medium-sized business. If anything, family-run companies, from ﬁrst to subsequent generations, are more in demand and more attractive and carry a premium. Potential acquirers want a global
presence and also a foot in the market geographically, and to reduce their carbon footprint. As well as international deals, there are local deals within each country. We have seen strategic manufacturing companies compete with individual private investors, and private equity companies. Due to the supply and demand of companies, this has led to businesses increasing in value. A prime example of the increase in prices is that of political changes: in the USA prior to Trump, we had several manufacturing companies for sale, with empty warehouses. A simple change in policy of “let’s make America great again and let’s make it in America” saw manufacturing companies, distribution businesses, land and warehouses increase in price overnight. Now, due to the inﬂated prices of companies in the USA and as a result, strategic and private investors having ‘dry powder’ (surplus funds), we are seeing more American acquirers looking outside the USA, mainly in South America, Europe, Nordic countries, Asia and Australia. Note, this has always been active but has become more prominent. Africa is on the radar, but low-key. We have been recommending the African continent and some of the major players are in Tunisia, Algeria, but South Africa could challenge them. We have seen an explosion of Chinese investments in the African continent. European acquirers are still looking within Europe and the aforementioned
areas, but also more and more in Africa. At the time of going to press we had a request to search for a plastic medical manufacturing company in SA and also to acquire and set up a plastics recycling company. Plastic recycling is becoming more prominent globally and we are receiving increasing requests to acquire or set up recycling plants locally within each continent due to the recent global events. As a result, we have employed technical recycling experts from the industry, again people who have run recycling plants. What is the state of M&A activity in Britain and Europe at present? Still very active, mainland Europe is very active in Western and Eastern Europe. Countries like Poland, Hungary, Slovenia, Slovakia and Romania have seen rapid activity and where again, we are very active. We have two scenarios in Britain; we have companies looking to buy and sell from within the UK and from outside the UK. Those that are looking to sell are holding on and, if Brexit goes ahead successfully, will sell their companies at a higher value. Then we have the vultures hovering around hoping that Brexit will fail and/or the pound devalues further against the US dollar and Euro so they can acquire companies at a lower price. Remember, when the UK announced in 2016, it was leaving the EU the pound devalued by 20%! www.prea.co.uk
The story gets longer at Inkulu It’s soooo long – Gabriel Reddy of Inkulu Plastic Pipes is dwarfed by the 24m lengths of 560mm butt and ﬂanged pipes ready for shipment from the company’s Hammarsdale, KZN, plant. Moving such lengths of pipe is no simple matter, with skilled driving and careful route selection being essential
Habitat A4 Advert_Final_3mm Bleed_expanded Text.pdf 1 2019/08/02 9:15:30 AM
New 55-layer Nano Lite stretch ﬁlms from Taigan
20 AUG / SEPT 2019
‘Incredibly thin and incredibly tough’ TAIGAN M-Stretch is beginning to stretch the imagination somewhat, to put it mildly. The dedicated stretch ﬁlms supplier has recently introduced a 55-layer Nano Stretch ﬁlm which offers real advantages for the transportation of goods. Taigan was most recently in the news when it introduced a 33-layer ﬁlm in 2017, but it’s gone even further ahead now. “It is our intention to be a supplier that looks at the safest and most economical way to wrap a pallet,” said Taigan MD Pete McCullough, who has been involved in stretch ﬁlm production and supply for at least the past two decades. “This does not mean that we must be the cheapest per roll or per kilogram. Rather, we want to offer a package whereby the full value of packaging is achieved.” Through its technical development process, Taigan has been able to offer innovation through the fact that it has moved from offering a three-layer cast stretch ﬁlm to now offering 33 and 55-layer Nano stretch ﬁlm to the SA market, a feat that no other manufacturer can match. “This development was made in order to look at reducing the amount of plastic required to wrap a pallet without detracting from the importance of why wrapping is being used. It is not a case of downgauging to protect manufacturers’ margins, it’s done to improve packaging by using high-tech raw materials that allow for Nano technology to be successful worldwide.
“Sustainability is a key inﬂuence for any market. The understanding that, if we did not look at improving efﬁciencies in extrusion and the correct use of raw materials, it would leave us in a stagnate situation. It is for this reason and the belief that for us to succeed, new equipment such as two more 55-layer nano cast lines are being installed, thus offering a monthly extrusion tonnage of 10 000 tons,” said McCullough, referring to a current capex project by Taigan’s principal. “Traceability also has developed with Nano extrusion. We are able to track the exact extrusion conditions of each roll by checking the barcode on each roll core. This information gives the ‘DNA’ of each roll supplied to our customers. “Nano ﬁlm is 100% recyclable. The ﬁlm is oxo-degradable, which means it is not bio-degradable. Nano ﬁlm is envirofriendly as it is manufactured to offer thinner ﬁlm which means less plastic is needed to contain a pallet of goods. The correct use of raw material in extrusion by adding layers such as 33 or 55 allows for the strength and puncture resistance to be maintained and the integrity of the ﬁlm to not be compromised,” he added. The importance of correct wrapping needs to be understood. Stretch ﬁlm has been developed to hold goods on a pallet in the safest way, but overstretching the ﬁlm can result in unstable pallets of goods being transported. Using the correct settings on wrappers is the key to offering
The difference between rolls of 5 and 9 micron ﬁlm, for the same length of ﬁlm, is noticeable here. The 9-micron roll, behind, is considerably thicker, but the 5-micron ﬁlm achieves the same performance. Taigan’s hand wrap cores are manufactured in green for easier identiﬁcation; it takes the cores back for recycling or reuse, offering a saving for customers
Load stabilisation has got a lot more certain with Nano Stretch 55, using less material. In this case, the 5 micron Nana Stretch Lite ﬁlm is used to achieve very effective stabilisation
Stretch ﬁlms expert Pete McCullough with Taigan M-Stretch’s transport manager Bongani Zulu and ﬁnancial director Ethel McCullough at the company’s premises in Aeroport, Johannesburg
effective cost savings. McCullough says the new stretch ﬁlms offer other new features too, one of the most pioneering being pre-stretched folded edge technology. The result of the edge modiﬁcation is even further resistance to tearing. It is now virtually impossible to tear these ﬁlms. “We’re yielding savings for customers and guaranteeing load stability to an even higher level. These new ﬁlms are incredibly thin and yet incredibly tough,” said the Taigan MD. Another new development is due from Taigan, namely perforated stretch ﬁlms. Perforation, almost by deﬁnition, counteracts a ﬁlm’s stretch and puncture resistance capability, but the 55-layer technology together with the use of hightech polymers are now making this possible.
THE NEXT GENERATION OF STRETCH FILM
THE t-nano RANGE OF 33 AND 55 LAYER STRETCH FILM IS THE NUMBER ONE CHOICE FOR SUSTAINABILITY, LOAD STABILITY AND SAFETY. Contact us today and we’ll show you how the innovative technology behind t-nano stretch film can help your business increase load stability and save costs without sacrificing your consideration for the environment.
TAIGAN.CO.ZA • JHB: +27 11 974 1811 • CPT: +27 21 948 8215
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22 AUG / SEPT 2019
Bunting Magnetics celebrates th 60 annniversary BUNTING Magnetics Co celebrated its 60th anniversary on 3 August. Founded in 1959 by Walter F. Bunting in Chicago, Illinois, the company has remained family-owned and family-operated ever since. Walterâ€™s son, Bob Bunting, serves as the current president of the company, and Bobâ€™s son, Robert Bunting Jr, serves as the GM of the magnet materials division. Represented by Eder Design in South Africa, Bunting Magnetics Co is an industry leader in the design, manufacture, and sales of cuttingedge magnetic equipment used in applications such as magnetic separation, metal detection, conveyor systems, and magnetic printing cylinders.
Tel: 031 403 8152 Bruce: 083 788 8152 Rennie: (KZN)(W Cape) 074 328 1550 Raymond Somiah: (Gauteng) 062 035 0241
Currently, Bunting Magnetics Co is headquartered in Newton, Kansas with manufacturing and distribution facilities in the UK and USA. Bunting Magnetics Co. products address unique challenges across a variety of different industries. For plastics companies, Bunting Magnetics Co worked to develop the FF350 hightemp drawer magnet, which allows for metal separation in extremely high temperature plastics manufacturing. â€˘ Represented in South Africa by Eder Design Tel: 012 253 1025
Bob Bunting visits a customer
109 Lakeview Drive Silverglen, Chatsworth, KZN firstname.lastname@example.org www.skyland.co.za
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Blue Air Systems’ dry mould dehumidiﬁer systems
Hasco offers system components for moulds, injection moulding machines and hot runners
Ipex gains new agencies Hasco, Blue Air and M-Systems join the fold IPEX Machinery has added several new agencies to its already impressive portfolio. Based in Selby, Johannesburg, Ipex has ofﬁces in all major SA cities that supply technological advanced equipment and solutions from leading global brands for the printing, packaging and converting sectors. Among the new agencies Ipex has landed is Hasco (www.hasco. com), a Belgian tooling accessories manufacturer. Mitco of Vanderbijlpark previously represented Hasco. Hasco’s complete range of equipment includes ready-to-install system components for moulds and injection moulding machines and hot runners. With more than 100 inventions and patents over 90 years, Hasco are true innovators in mouldmaking. Another new agency that Ipex has recently acquired is Austrian Blue Air Systems GmbH (www.blue-air.at),
manufacturer of dry mould dehumidiﬁer systems that provide dehumidiﬁcation with the lowest energy consumption down to 0,0007 kW/m³ The third new agency is German M-Systems (www.m-systems-innovation. com) which manufactures material bin covers made from nylon, PU and PVC. The TOP-tex cover is intended for use on 120-litre and 240-litre mobile waste containers to prevent their contents from contamination if used as a pellet container. Ipex have also recently acquired the agency for Nova-Sys (www.main-deprehension.com), which is an end-of-arm tooling manufacturer. Ipex also manages agencies for the following companies: • Wittmann Battenfeld which supplies processing machines, automation and auxiliary equipment for injection moulding
• Garant Maschinen Windmöller & Hölscher (W&H), manufacturer of extrusion, printing and converting machinery for the ﬂexible packaging industry. • Ashe converting equipment, an independent manufacturer of slitter rewinders and customised applications. Roll-o-Matic is a worldwide supplier of roll-bag machinery and plastic converting equipment for the production of plastic ﬁlm and bags on roll. • Achburg, supplier of ﬂexible indoor silos (SFLEX) and silo ﬁlling and discharging equipment, as well as level measuring and silo control equipment. • MB Conveyors, Italian manufacturer of conveyors, separators, mixers and packaging systems for the plastics industry. www.ipex.co.za AUG / SEPT 2019 23
IPEX Holdings (Pty) Ltd. Tel: +27 (0) 11 493 7816 | Fax: +27 (0) 11 493 2389 email@example.com | firstname.lastname@example.org | www.ipex.co.za
Advanced manufacturing awards to recognise & inspire SA’s innovators Will play key role in advancing SA’s advanced manufacturing agenda LEADING lights in the ﬁeld of advanced technology, including 4IR, will be acknowledged at South Africa’s ofﬁcial National Advanced Manufacturing Innovation Awards on November 27. The National Advanced Manufacturing Innovation Awards, co-hosted by South Africa’s Department of DTI and the national Composites Cluster, showcases
South Africa’s capabilities and promote advanced manufacturing innovation in industry and research. According to the organisers, all companies, entrepreneurs and researchers operating in the advanced manufacturing ﬁeld, including engineering, 3D printing, robotics, automation, AI, laser cutting and etching, CNC machining,
software, big data, IOT and composites, are eligible for national recognition. Companies or organisations may make submissions in six categories, including: Scholarly impact in advanced manufacturing, industry advancement in advanced manufacturing, export proﬁciency, contribution to import replacement, composites innovation and
24 AUG / SEPT 2019
SAPRO Best Recycled Plastic Product of Year Awards IT’S THAT time of the year again, when SAPRO hosts the Best Recycled Plastic Product of the Year Awards, on this occasion in partnership with Business Day newspaper and Cold Press Media. The awards presentation takes place on 6 November. The awards are aimed at raising awareness and highlighting the wide variety of ingenious products that are locally designed and manufactured using recycled plastic materials. The event is a cornerstone
of SAPRO’s strategy to grow demand for plastic recyclate and help improve market acceptance of locally manufactured recycled plastic products, inspire innovation and encourage new entrants into the market place. In a bold move, SAPRO has partnered with Business Day and Cold Press Media to increase the reach of the awards, to access a much wider audience and create vastly greater visibility for the work of the
CONSULTING (Pty) Ltd. FdB Consulting (Pty) Ltd. the sole representative for
Feeding, Drying and Slio systems
Supplied by FdB Consulting (Pty) Ltd. Bulk Bag Discharge Station with 2 Ton Electric Hoist Regrind Material Bin
industry. As a value add, the awards are being supplemented by a digital and print publication, ensuring extensive coverage and access to a captive audience of 40,000+ business owners and executives, government ofﬁcials, key industry stakeholders, investors and stakeholders.
• For more information, to enter your product, sponsor a category or attend the awards night, contact Lisa Parkes, 083 406 3298; email@example.com
Representative in Africa
Frank Blues Engineering Design +27 (0)82-651 3315 firstname.lastname@example.org
Agents for Rapid Granulator FdB Consulting (Pty) Ltd. based in Johannesburg has been appointed the sole distributors for the South Africa and Sub-Sahara Market for Rapid Granulator AB, the Swedish-based world leader in plastics granulation technology.
“As we push to consolidate and develop our manufacturing strategy, it is essential that as a collective - government and private sector stakeholders identify, promote and reward innovation in the advanced manufacturing and composites industry,” says Andy Radford, Composites Cluster MD
most promising start- up or newcomer. Composites Cluster MD, Andy Radford, said up to three nominees per category would receive speciﬁc acknowledgment, signiﬁcant exposure and, in identiﬁed categories, ﬁnancial support to commercialise and grow promising concepts. The awards function will take place as part of the African Advanced Manufacturing and Composites Show which will include a dynamic, interactive exhibition, conferences and factory tours at the Nelson Mandela Bay Stadium in Port Elizabeth from 27-28 November. Radford, said the awards would play a key role in advancing the country’s advanced manufacturing agenda. “As we push to consolidate and develop our manufacturing strategy, it is essential that as a collective - government and private sector stakeholders identify, promote and reward innovation in the advanced manufacturing and composites industry.”
The awards will be made annually at the African Advanced Manufacturing and Composites Show which will rotate across South Africa’s major manufacturing hubs. “While manufacturing remains an essential part of South Africa’s economy – contributing around 19% of GDP, our efforts towards advanced manufacturing in South Africa are highly fragmented, but we do have signiﬁcant pockets of excellence,’’ Radford said. “The African Advanced Manufacturing and Composites Show will not only bring all the key role-players and technology partners together towards a common vision and trade, but it will also inspire emerging engineers. “Three-dimensional printing, lasers, automation, drone technology and artiﬁcial intelligence are exciting tools to encourage a new generation of engineers and scientists but we need to expose them and industry to these technologies and there is no time to waste,” Radford said.
Coca-Cola in SA recycled more plastic than it produced
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AUG / SEPT 2019 25
The Coca-Cola Company in South Africa has attained a noteworthy milestone - collecting and recycling more PET plastic than it produced in the South African market in 2018. It collected the equivalent of 113% of the PET plastic bottles it put into the South African market last year, according to Luis Avellar, GM for the South African franchise of Coca-Cola Southern & East Africa. The company has committed to reshape its approach to packaging, with a global goal of helping to collect and recycle the equivalent of 100% of its packaging by 2030. The company is backing this vision with multiyear investments across Africa. It has also committed to ensuring that its packaging is 100% recyclable, and aim to make bottles with an average of 50% recycled content.
Eco warriors champion the underprivileged and the environment ON the back of its recent announcement of a 6% year-on-year increase in the recycling of PET plastic bottles, PETCO has unveiled its 2019 recycling champions – people and organisations making strides in sustainability at grassroots level across South Africa. The annual awards were made across
11 categories, with Western Cape winners scooping nine awards, followed by Gauteng with two, and one each from the Northern Cape, Eastern Cape and Limpopo. Recipients varied from a nineyear-old eco warrior to a recycler who overcame three ﬁres on her premises, and an award-winning consumer journalist.
Waste Reduction Youth Warrior
Woman in Recycling
PETCO chief executive ofﬁcer, Cheri Scholtz, said the organisation’s greatest asset was “the remarkable network of partners we work with every day.” Scholtz said the 98 649 tons of PET plastic bottles recycled in 2018 had only been achieved through their collective dedication and efforts.
Wendy Knowler (Cape Town, Western Cape) – Award-winning consumer journalist Wendy Knowler has been recognised for her role in helping to shed light on the importance of conscious consumption and recycling, while taking a balanced approach to the plastics issue. Rocco Antonio Da Silva, The Future Kids Club (Cape Town, Western Cape) – Nine-year-old Rocco started the club to create awareness and get the youth in his area to participate in monthly beach and community clean-ups. Over the last 14 months, members have collected over 950kg of rubbish off a local 400m stretch of beach.
Jocelyn van der Ross, Green Spot Recycling (Franschhoek, Western Cape) – Buy-back centre Green Spot Recycling has overcome the odds, with owner Jocelyn van der Ross starting from scratch three times. Van der Ross started the business with two employees in 2005 and today has 15 staff collecting and sorting over six tons of PET plastic bottles a month.
26 AUG / SEPT 2019
Waste Reduction Youth Warrior
Recycled Product of the Year Corruseal (Cape Town, Western Cape) – As a national manufacturer and supplier of packaging to a wide range of industries, Corruseal made the decision to use only locally sourced and recycled PET strapping. Corruseal sources the strapping from Cape Townbased supplier Propet, which uses locally sourced post-consumer PET bottles in its manufacturing process.
Rotondwa Musitha, Trash Converters (Limpopo) – Musitha, 24, is a business school graduate who started her recycling business after her research showed that just 2% of all recyclable material in Limpopo was being recycled, creating a gap in the market for waste buy-back centres. Working on foot, she and her three employees collect approximately 8 to 11 tons of waste per month.
PET-trepreneur of the Year
Excellence in Academia
Takunda Chitaka, University of Cape Town (Cape Town, Western Cape) – Chitaka is in the fourth year of her PhD studies and was nominated for her work on the nature of the plastics found on Cape Town beaches, published in an international scientiﬁc journal this year. Her studies are dedicated to better understanding the nature of the problem of plastics in our coastal environment, and how solutions based on the principles of life-cycle management could be developed for moving the plastics economy forward.
Melanie Samson, University of the Witwatersrand (Johannesburg, Gauteng) – An academic, Samson works closely with informal reclaimers who see themselves as the last line of defense before the rubbish hits landﬁlls, extracting recyclables from waste and redirecting them into the recycling value chain. Samson is completing the three-year ‘Lessons from Waste Picker Integration’ research project, which includes facilitating a participatory stakeholder process to develop the DEA’s forthcoming Guideline on Waste Picker Integration for South Africa.
Makhabisi Recycling and Trading Co (Boksburg, Gauteng) – The Boksburg-based Makhabisi Recycling and Trading is a 100% black female-owned business, founded by Anna Hartebeest in 2007. The business employs 60 people who sort and grind 200 tons of plastic preforms and 60 tons of sorting bales such as PET, HDPP and PVC per month. Makhabisi collects 18 to 20 tons of PET every month.
AUG / SEPT 2019 27
new possibilities to turn product ideas into reality new possibilities to turn product ideas into reality Don’t delay....... get in touch with us today and see how Exxon Mobils performance polymers can help with your product applications.
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ARMO 2019: Good int’l response to SA presentation of global roto event
28 AUG / SEPT 2019
Some regulars and some newcomers for event in Sun City THE presentation of the rotational moulding sector’s annual global event, ARMO2019, in Sun City in September appears to be attracting considerable interest from abroad. By mid-July over 140 delegates had already registered, with more than half being international guests – which translates to a major breakthrough for ARMSA, the Southern African roto association. “This is truly going to be an international event,” said ARMSA chairman Wayne Wiid. It is the ﬁrst ofﬁcial ARMO event to be hosted in South Africa, so it’s a big step for the SA roto industry. The programme for the two-and-a-half day event features a number of speakers who have presented at the Rotation conferences in South Africa over the years as well as some interesting newcomers.
Rotation regulars include Dhanu Patell (Reinhardt Teknik, India), Oliver Wandres (Maus GmbH, Germany) and Ronny Ervik (Ultrapolymers, Belgium); Mark Kearns of Queen’s University, Belfast; Leisa Donlan, CEO of ARMA (Australia); Dr Gareth McDowell of 493K (Northern Ireland); Dick Coates of Meraxis South Africa, Gary Lategan of RotoSolutions; Martin Spencer of Unique Roto (England) and Bill Spenceley of Flexahopper Plastics of Canada. New international speakers include Katia Zoppetti (ARMO chairman), who will give an update on the latest global industry projects for the beneﬁt of rotational moulding globally; Konstantia Asteriadou of Lysis Technologies on ‘Label-Free Marking, Branding and Decoration of Polyoleﬁns’; and Filip Claus of Plastigi Belgium who will talk about ‘Different machines for different
120 plus turn out for KZN shootout 21 JUNE saw the KZN plastic industry converge on the lush fairways of the Royal Durban Golf Club for the annual PISA KZN golf day. Players travelled from as far aﬁeld as Ladysmith, Newcastle and Isithebe to play in this much anticipated event. Durban’s clear skies and warm weather was ordered for the day and the 120 players enjoyed all ﬁve hours of it, give or take a little. As it is customary in KZN, each player walks away with a prize and the branch committee worked tirelessly to ensure this tradition was upheld. PISA KZN express sincere appreciation to their sponsors for the day, Associated Additives, Busch Pumps, Continental Compounders, Emond Auto, GPS Plastics, Safripol, Standard Bank, Skyland Masterbatch and Subtech. Congratulations to the winning Skyland team (bottom left), with Lenny Naidoo, Pramesh Ramday, and Dhiren Singh (of Pacpro) in ﬁne form. They received their prizes from KZN chairman Rani Appalsamy. Ex-chairman Garth Taylor, showing impressive health since his ‘retirement’ due to health reasons, presented a ‘50 Years Service’ award to Peter Rose (bottom right), also an ex-KZN chairman, in recognition of his contribution to PISA in KZN over the past half-century.
applications: Robot vs Traditional vs Rock & Roll’. Professional adventurer Peter van Kets will give a presentation titled ‘How do we achieve and sustain true success and how do we fulﬁll our purpose?’ … which should provide food for thought, and then RMB chief economist Ettienne le Roux, who has spoken at several ARMSA events, will give an ‘Economic Update with Macro Forecasts’ There will also be presentations by ACD Rotoﬂo, Persico, Sasol Base Chemicals, Reinhardt Teknik and Wenling Rising Sun Rotomoulding Technology. The nominated fund-raising beneﬁciary is the Zululand Rhino Orphanage. A portion of every registration and funds raised during the event will be contributed to the rhino orphanage in KZN. www.armo2019.com
Caroline Reid Award for Clean-Up Champion PLASTICS|SA has launched a new annual award, which aims to recognise and reward excellence in South Africa by an individual in the ﬁeld of marine and coastal clean-ups, called the Caroline Reid Award for Clean-Up Champion of the Year. “Caroline Reid was an ocean conservation warrior who sadly passed away in 2018 after a tragic accident. The entire South African conservation community lost a dynamic champion who coordinated hundreds of beach and diving clean-ups and who was central in the work done with the loss of the plastic pellets (nurdles) in the Durban harbour in 2017 and helped to increase the awareness of plastics pollution on the KwaZulu-Natal Coastline,” explains Douw Steyn, sustainability director at Plastics│SA. “In honour of this wonderful person and the many other individuals who altruistically give up their time to make our marine and coastal areas cleaner, safer environments, we will be awarding a R10 000 cash prize, a ﬂoating trophy and exposure in local and international media as role models and winners of the Caroline Reid Award for the Clean-up Champion of the Year,” he says.
How to enter Download the entry form from the
Plastics|SA website at www.plasticsinfo.co.za. The closing date is Friday, 1 November 2019. No late submissions will be accepted and the winner will be announced in Cape Town on 23 January 2020 during the National Conference of the Marine and Coastal Educators Network.
Keep food safe and secure Our performance polymers enable high-integrity, cost-effective packaging to protect and preserve food from production to consumption.
Attend our K2019 TechTalk presentations Visit us at Hall 10 / 10.1
© 2019 ExxonMobil. All trademarks used herein are trademarks or registered trademarks of Exxon Mobil Corporation or one of its subsidiaries. X0419-052E49
Bud’s Ian Forbes likes to keep it simple … which is surprising when you’re employing 3 700 IAN Forbes of Bud Chemicals & Minerals group has a disarmingly pleasant and simple way of dealing with industrial matters, which comes as a bit of surprise since the Bud group employs over 3 700 people and supplies some 300 product categories. South African people are friendly by nature and tend to have friendly relations at the workplace, although this is not always that easy … but it’s worked for Ian, who spoke at a SAVA lunch time event in Johannesburg recently. A man who likes quotes, Ian came up with several gems on the day, including ‘A desk is a dangerous place from which to watch the world’ (by British writer John le Carré). Anyone who knows the Bud CEO will agree: Ian frequently attends company events, gets involved
and knows the company’s staff. Originally MD of Sappi group, Ian left corporate life in 2000 and started a private equity business. He got back into manufacturing when he and business parter Bert Davids bought Ferro group in Brakpan in 2004. After Davids passed away in 2006, Forbes forged ahead and expanded the group’s activities through acquisitions of NCS Resins, Cray Valley SA and others. Outside of our industry, Bud’s reach has been far and wide. The group has gone from a turnover of R80-million in 2004 to a projected R10-billion for this year. Many of Bud’s operations are conducted through CJP Chemicals. His four ‘F’s’ of working life are be ﬁrm (with the rules), be fair (everyone is treated the same), have a friendly culture and be frugal … and set your expectations high!
Ian Forbes of Bud Chem group was introduced at the SAVA event, at the Johannesburg Country Club in Woodmead, by George Dimond of Continental Compounders
SAVA’S newly launched Vinyl-dot
30 AUG / SEPT 2019
Lead-free, additives approved for high human contact, recyclable THE Southern African Vinyls Association’s (SAVA) newly launched Vinyl-dot (vinyl.) offers consumers and end-users the assurance that PVC products carrying this quality mark, adhere to SAVA’s Product Stewardship Commitment (PSC) in that they are lead-free, only use additives that have been approved for high human contact applications and are recyclable. “PVC is frequently criticised for posing potential health risks and being a difﬁcult-to-recycle plastic,” says SAVA chief executive ofﬁcer, Adri Spangenberg. To counter these attacks, SAVA’s vinyl-dot has been developed
speciﬁcally for the South African market – a quality guarantee which is awarded exclusively to members who are able to prove that their products meet international safety and quality standards. “The vinyl-dot is awarded free of charge, but has to be renewed annually. It is only issued once the SAVA Executive has conﬁrmed that the member speciﬁes sustainable manufacturing, uses additives in a way that is responsible and sustainable, subscribes to a closed loop management system and is committed to recycling and sustainability
awareness that is in line with our PSC,” Adri says. Since ofﬁcially launching the vinyl-dot at their AGM in April this year, more than 21 SAVA members have been granted the rights to display the logo on their products, websites and other marketing material. These include raw material suppliers, converters and importers of vinyl products that are sold on the local market. www.savinyls.co.za
PVC products carrying the mark comply with SAVA's Product Stewardship Commitment in that they are lead-free, use additives approved for high human contact applications and are recyclable. Safe, responsible and sustainable. When buying shoes, wellies, gumboots, rain coats, umbrellas, or belts made from PVC look for the mark!
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K 2019 in Düsseldorf: Circular economy the hot topic
32 AUGUST / SEPTEMBER 2019
Demand for plastics continues to rise – despite poor image THE image of plastics has never been as negative as it is today and discussions about the use of plastics have rarely been so emotionally charged. However, the fact is that, with perhaps the exception of a few indigenous peoples, not one of the 7.5 billion inhabitants of this planet could live a normal life without plastic, irrespective of whether they are conscious of this or not. So, what are the ramiﬁcations of the present situation for the plastics industry? K2019 promises to offer tangible and future solutions to the question.
Unsurprising, therefore, that the circular economy is one of the leading issues at this year’s international K 2019 trade fair. Visitors to this event will be greeted by a variety of proposals and solutions relating to this topic. The demand for plastics continues to rise – despite, it would seem, their poor image. In its report ‘Plastics – The Facts’, Plastics Europe pointed out that the production of plastics worldwide was 348 million tons in 2017, around 4% higher than in 2016. In Europe, the output of the 28 EU countries plus Norway and Switzerland rose from 60 to 64.4 million tons (up 7%). Europe accounts for around a ﬁfth of global production, placing it second among producers, after China (29%) and just
Black pigment extends service life of plastic components – Lanxess has developed a black pigment that reﬂects 20% more of the sun’s near-infrared radiation (NIR) than conventional products. Plastic roofs and façade elements that are coloured with Bayferrox 303 T heat up much less due to solar radiation, meaning that the building’s inside temperature can be reduced. The temperature in a polymer matrix coloured with Bayferrox 303 T is as much as 8°C lower than when a conventional black pigment is used. Using the Bayferrox 303 T black pigment can also extend the service life of a plastic component considerably as the thermal decomposition of a polymer matrix is reduced due to lower heat absorption. In addition to outdoor applications, Bayferrox 303 T’s characteristics make it suitable for use in the automotive industry, e.g. to colour the dashboard, which is exposed to high and sustained solar radiation. Visit Lanxess at Hall 6, stalls C76 – C78
ahead of the NAFTA region (18%). Although a degree of consolidation has led to a reduction in the number of companies in the European plastics industry to around 60 000 since the last K event in 2016, ﬁgures for those employed in the sector have increased, with 1.5 million working in the plastics industry and generating stable sales of about €350bn in 2017. More than 3 000 businesses from the global plastics and rubber industry will again present products, processes and practical solutions for a productive and responsible future at K2019.
Ultradur®,one fits all – BASF will launch and present its new product Ultradur® B6551 LNI for extrusion and the worldwide ﬁrst thermoformable PBT Ultradur® B6560 M2 FC TF. Both new grades combine all the well-known characteristics of the Ultradur® family like high melting point, low water uptake, high dimensional stability and good barrier properties. By connecting and branching the polymer chains via tailor-made additives the experts of BASF gained a very high melt strength. This makes Ultradur B6551 LNI the perfect material for pipes, proﬁles and mandrels – and Ultradur B6560 M2 FC TF the material of choice for extrusion of ﬁlms and thermoforming of packaging or technical parts. Both grades offer good mechanical properties and are easy to colour – even foaming is possible. Visit us at K 2019 at Hall 5, stall C21/D21
Concept car from Asahi Kasei Showcases wide array of automotive-related materials & technologies ASAHI Kasei and GLM Co Ltd, an electric vehicle manufacturer, have developed a concept car called AKXY™. The car showcases a wide array of automotiverelated materials and technologies from various Asahi Kasei businesses, focused on contribution to safety, comfort, and the environment. Asahi Kasei and GLM began discussions and planning for development of the concept car in 2015. The car uses the GLM electric vehicle platform to achieve a drivable design. The design is based on an SUV. The name AKXY™ comes from Asahi Kasei X (multiplied by) You (the customer). AKXY™ is equipped with 27 of Asahi Kasei’s materials, components and systems. Most of them are available for adoption in mass-produced vehicles, including engineering plastics to replace metal and enable vehicle weight reduction, artiﬁcial suede for seats with superior comfort, and an in-car communication system using various speech-processing technology. The car is additionally equipped with cutting-edge technology that has potential for commercialisation in line with automotive industry trends for safe driving and accident prevention. AKXY™ will be displayed at K2019. Visit Asahi Kasei at Hall 8a, stall J15 www.asahi-kasei.co.jp/amm/en/
BASF’s flame-retardant plastics – BASF has a portfolio of various polyamide 6 and 66 grades available to ensure dependable microelectronics in control equipment and sensors that help prevent electric corrosion damage to circuits. The various Ultramid® EQ grades (EQ: electronic quality) that BASF has been marketing for years are extremely pure and contain almost no electrically active or corrosive substances, such as halides. This material also has excellent heat aging resistance properties. The increasing level of automation will also see a range of new sensors, such as radar, lidar, IR, and ultrasonic sensors ﬁnd their way into our cars. Implementing these solutions into large-scale production can only be guaranteed using plastics. BASF offers radar-optimized plastics used for radar transmission and absorption that increase the accuracy of the radar sensors, thereby improving the functionality of the automated vehicle with greater cost efﬁciency. Visit us at K 2019 at Hall 5, stall C21/D21
KRAUSSMAFFEI and NETSTAL are combining their expertise in injection moulding machinery under the new KraussMaffei umbrella brand. The medical technology and packaging industries are the ﬁrst and foremost common target. The familiar machine series (PX, CX, GX, MX from KraussMaffei and ELION, ELIOS, PET-LINE from NETSTAL) and the production locations will remain as they are. KraussMaffei envisage opportunities for growth in the packaging and medical technology industries. In the packaging area, KraussMaffei offer customers a range from the NETSTAL high-performance, fast-running ELIOS and ELION machines for thin-walled packaging, all the way to solutions for large logistics items such as transport boxes or pallets. The GX and MX series from KraussMaffei will be at K in Düsseldorf. A GX 1100, which expands the clamping force range of the GX series upwards, will produce buckets with a capacity of 20 litres and decoration by in-mould-labeling (IML). With a shot weight of approximately 1 500g (in two cavities) and a cycle time of 14 seconds. The NETSTAL ELIOS 4500 will produce six round dishes with IML decoration (each weighing 250g) in less than 3.5 seconds. Visit KraussMaffei at Hall 15, stalls C24 – C27 www.kraussmaffei.com
Chen Hsong Germany GmbH launched HONG Kong-based injection moulding machine manufacturer Chen Hsong has established a new German subsidiary, Chen Hsong Germany GmbH, in Kempen on the Lower Rhine, to better serve the German market. Chen Hsong Germany GmbH is a wholly-owned subsidiary of Chen Hsong Europe BV in The Netherlands. Chen Hsong is one of the world’s largest manufacturers of plastic injection moulding machines, with clamping forces ranging from 20 to 6500 tons. Chen Hsong Germany GmbH is headed by managing director Andreas Bexte who has more than 30 years’ experience in the ﬁeld of plastic injection moulding. Chen Hsong Germany GmbH in Kempen will stock fully functional injection moulding machines for demonstrations, tests and training. Visit Chen Hsong at Hall 13, stall B43 www.chenhsong.com AUGUST / SEPTEMBER 2019 33
The AKXY™ concept car can carry three passengers, is 4,6m long, 1,8m wide and 1,5m high. The motor output is 225kW (302hp)
KraussMaffei even more effective as a team!
Retroﬁt instead of new purchases BUY new or retroﬁt? Users in plastics extrusion are faced with this question when looking at the performance of their lines in terms of energy consumption or the use of alternative raw materials. And this is where Reifenhäuser comes in with its latest business unit: Reifenhäuser Extrusion Systems (RES), which was founded in May, specialises in components for demanding applications in extrusion, and focuses on sustainability. The Reifenhäuser Group’s new business unit covers the following product areas: screws and barrels, extruders, ﬂat dies, and extrusion tools. In setting up this new business unit, the Troisdorf-based family company has brought all the expertise of the Reiloy, Extruders, Enka Tecnica and Extrusion Dies divisions under a single roof. RES will be presenting its products at K 2019 under the slogan ‘Replace’. “Why exchange your extruder or die for a new one if it’s cheaper not to?” says Philip Neumann, sales director at Reifenhäuser. What’s new is that Reifenhäuser is selling its valuable extrusion components independently of a extrusion line. As of now, the product portfolio will be available on the free market to all customers – both processors and plant construction ﬁrms – and not only to Reifenhäuser’s afﬁliates, as previously. Visit Reifenhauser at Hall 11, B22 (srews&barrels, extruders) and Hall 1, E40 (ﬂat dies). www.reifenhauser.com
Maag enhances systems expertise THE Maag Group, comprising Maag Pump Systems, Automatik, Gala Industries, Reduction Engineering Scheer and, since 2018, Ettlinger Kunststoffmaschinen, is enhancing its systems expertise by focusing on Centres of Excellence. For the ﬁrst time in its history, all the Maag Group’s companies will be showing together at the K show, featuring all their system solutions together. Maag’s portfolio extends from small machines and systems for throughputs up to 100 kg/h to machine and plant components capable of handling more than 100 t/h (centrifugal dryers, polymer pumps and custom solutions in industrial applications). At K-2019, trade visitors to the Maag stand will be served by an international team from all over the world, presenting new and upgraded machinery in pump, ﬁltration, pelletization and pulverizing technology. Visit Maag atHall 9, stall A04 www.maag.com
BASF showcases prototypes made from chemically recycled material BASF’s partners in ChemCycling project: Jaguar Land Rover, Storopack, Südpack and Schneider Electric MORE and more companies from the plastics industry are working on improving the recyclability of plastics and thus helping to create a circular economy. One way that BASF is contributing is the ChemCycling project: At the end of 2018, the company ﬁrst used pilot volumes of a pyrolysis oil derived from plastic waste as a feedstock in its own production. One example of this material in action is at Jaguar Land Rover, a leading automotive manufacturer, which developed a plastic front-end carrier prototype for its ﬁrst electric SUV, the I-Pace, out of Ultramid® B3WG6 Ccycled Black 00564. Another is Storopack, a supplier of protective packaging and technical moulded parts, which used Styropor® P Ccycled to make insulation
packaging for temperature-sensitive pharmaceutical products as well as boxes for transporting fresh ﬁsh and protective packaging for electronic devices. “We were particularly impressed by the fact that Styropor P Ccycled can be used in food packaging. There are already various recycling options for Styropor, and ChemCycling helps raise the recycling share even further,” said Storopack’s chairman of the management board, Hermann Reichenecker. “ChemCycling, which uses a mass balance approach to mathematically allocate a share of the recycled material to the ﬁnal product, can help our customers to achieve their sustainability goals,” said Jürgen Becky, senior vice president BASF Performance Materials.
Spunbond with REICOFIL technology – As a material for hygiene and packaging products, spunbonded fabric can help save up to 50% of the semiﬁnished material previously used, while simultaneously improving product properties. This is made possible thanks to Reifenhäuser Reicoﬁl spunbond technology. Reifenhäuser’s systems and components can also process postconsumer waste. The company’s latest machine generation RF5 can produce nonwoven with attained quality. Reifenhäuser Reicoﬁl supplies spunbond lines predominantly for the hygiene market can produce spunbonded fabrics and SMSs with minimum grammage, extraordinarily high homogeneity, and a very low, speciﬁc energy consumption. In the Reicoﬁl spunbond process, the conversion of granulate into nonwoven takes place in a single production step. Using a higher proportion of recycled materials in the product perfectly combines cost efﬁciency and ecological sustainability. Visit Reifenhauser at Hall 17, stall C22.
34 AUG / SEPT 2019
K 2019 Düsseldorf – When & where? K 2019 takes place at the Messe Düsseldorf Fair ground in Düsseldorf, Germany from 16-23 Oc tober, daily from 10:00am to 6:30pm.
Jaguar Land Rover developed a plastic front-end carrier prototype for its ﬁrst electric SUV, the I-Pace, out of Ultramid® B3WG6 Ccycled Black 00564
The certiﬁed products are indicated with the addition of “Ccycled” to their name. “With the ChemCycling project, BASF is aiming to process pyrolysis oil derived from plastic waste that currently cannot be recycled, such as mixed or contaminated plastics. If we are successful in developing the project to market readiness, ChemCycling will be an innovative complement to existing processes
for recycling and recovery to solve the plastic waste problem,” said Stefan Gräter, head of the ChemCycling project at BASF. Visit us at K 2019 at Hall 5, stall C21/D21
As always, K 2019 exh ibitors will be presenting their produc ts and services in all of the venue’s 18 hal ls with a total area of almost 175 000 m2. Products and services, grouped by topic, will be located in the foll owing halls: • Machines and equipm ent: Halls 1, 3-4 as well as 9-17 • Raw materials, auxilia ries: Halls 5, 6, 7, 7a, 8a, 8b • Semi-ﬁnished produc ts, industrial components and reinfor ced plastics products: Halls 5, 6, 7, 7a, 8a, 8b • Entrances: North A (do wnstairs), North B (upstairs 1st ﬂoor), No rth D, East, South
AUGUST / SEPTEMBER 2019 35
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SABIC present leading edge sustainable solutions SABIC will highlight its commitment to circular solutions and reducing plastics waste under the theme of ‘Making a world of difference together’. SABIC will be addressing global trends by inspiring processes for using bio-renewable and recycled feedstock and designing product solutions for its customers in diverse industries which supports recyclability, durability and optimal reuse, helping build a better world. From making electric vehicles more efﬁcient and contributing to energyefﬁcient buildings, to reducing waste packaging and improvements in healthcare, SABIC is committed to developing pioneering solutions to advance key industry sectors. SABIC has come one step closer to creating a circular economy by becoming the ﬁrst in industry to scale up an innovative chemical recycling process of mixed plastic waste back to the original polymer, enabling downstream customers to develop high quality, recyclable product design solutions. It has also created leading polymer solutions for the manufacture of pure, lightweight packaging to extend shelf life of food and other perishable goods. The company has also developed solutions to encourage the re-use and recycling of industrial packaging through innovative processes and partner collaborations. Visit SABIC at Hall 6, stall D42 www.sabic.com
Maguire’s vacuum resin dryer with significantly lower energy consumption Uses less than a tenth of the energy needed by a new desiccant dryer THE world’s only vacuum resin dryer designed for plastics processors has a new brand name that reﬂects its proven capability to pay for itself through substantial savings in energy costs. Now called ULTRA®, the dryer uses energy to dry resin at such a drastically lower rate than a comparable new desiccant dryer that its manufacturer, Maguire Products, says, “with costs so low, it’s almost free”. The energy savings with the ULTRA dryer are even greater in comparison with the many low-efﬁciency old dryers still operating around the world. Maguire will formally introduce the brand at K 2019. Frank Kavanagh, vice president of marketing and sales cites a typical material-drying example for a process running at 100kg per hour, for 6 000 operation hours per year. An average desiccant dryer might run at 60 watts per kg of material, versus the ULTRA Low Energy Dryer that would run at 19 watts per kg. Each system uses the same amount of energy to bring the material up to temperature from ambient temperature – around 15 watts. This is the energy
used to HEAT. However, the energy used to DRY is dramatically different: the desiccant dryer would use a further 45 watts to DRY the material so it can be processed, whereas to the same level the ULTRA would only use 4 watts – 10 times difference in energy usage. Visit Maguire at Hall 10, stall A26 www.maguire.com Hestico represents Maguire in SA
Measurement of hose & tubes up to 1 600mm diameter – Sikora will present the Centerwave 6000 that measures big pipes by millimetre wave technology. The system was developed especially for quality control of plastic tubes and pipes during extrusion. The system offers a precise measurement of tubes with a diameter from 630 to 1 600mm. The Centerwave 6000 measures wall thickness, the diameter, the ovality, the inner proﬁle and sagging, continuously and completely over 360 degrees of the circumference of the pipe. Visit Sikora at Hall 10, stall H21
36 AUG / SEPT 2019
Ecovio contributes to closing the nutrient cycle – With the certiﬁed compostable plastic ecovio®, BASF has developed a material portfolio for a variety of applications which can be used throughout the entire food cycle and thus support the circular economy – from production via packaging and transport to the waste collection of food. Numerous studies by independent research institutions conﬁrm the advantages of ecovio for the production, packaging and transport as well as waste collection of food, based on the material’s certiﬁed biodegradability in industrial and home composting as well as in soil. The studies show: food waste is reduced, nutrients are returned to the soil by means of greater volumes of compost generated and the accumulation of plastics in soil is avoided. Visit us at K 2019 at Hall 5, stall C21/D21
AMI to launch new data services offering GLOBAL plastics market intelligence group AMI, will launch new data subscription services and demonstrate a suite of interactive tools to support online analysis of critical market information on its stand. The launch is the latest stage in the development of the company’s unique market intelligence reports and data services. These include AMI’s unrivalled database of global plastics processors, which has been assembled over 30 years and includes veriﬁed information for more than 20 000 named production sites. Information extends from contact details and ultimate holding company to machinery and type and volume of polymers consumed. All clients need is internet access. “This is the ﬁrst important step in the development of our data services,” said Richard Walker, head of market intelligence at AMI. “The demand for plastics continues to rise but there is increased uncertainty as the circular economy becomes a primary issue affecting the industry. It is our intention for AMI’s data subscription package to offer a suite of commercially valuable information including detailed end use application tonnage data with historic, current and future forecasts of polymer, providing our clients with the tools to easily identify opportunities associated with the circular economy in a visually effective way,” he added. With advanced mapping capabilities and online access, a number of AMI’s larger clients are already taking advantage of the new, visually engaging
web-based search and analysis tool. A range of options is also available for smaller clients that may require more targeted access to data. All subscribers will beneﬁt from access to continued enhancements to the new subscription
service in real time, including updated information and new site additions. Aside from demonstrations of the new data tools, visitors to the AMI stand will also be able to join daily speaker sessions, where some of the company’s many polymer
industry experts will cover topics including plastics recycling, compounding and masterbatch. Vist AMI at Hall 7, stall C11
AUGUST / SEPTEMBER 2019 37
The World’s No. 1 Trade Fair for Plastics and Rubber
T h i n k i n g . R e t h i n k i n g . L a t e r a l t h i n k i n g . T h i n k i n g o u t o f t h e b o x . K 2 0 1 9
approaches from industry to help trigger the paradigm shift for our planet with solutions f i t f o r t h e f u t u r e . Ta k i n g u p t h e s e c h a l l e n g e s , around 3,200 international exhibitors at K 2019 will be showing you the latest developments and gr o u n db r ea ki n g i n n ova t i o n s i n th e p l a st i cs a n d r u b b e r i n d u s t r y . K 2 019 : T h e i n d u s t r y ’ s m o s t important business platform. Be a part of it. www.k -online.com/ticketing
Southern African – German Chamber of Commerce and Industry NPC 47 Oxford Road _ Forest Town, Johannesburg P.O. Box 87078 _ Houghton 2041 Tel. +27 (0)11 486 2775 _ Fax +27 (0)86 675 21 75 firstname.lastname@example.org
Elastic textile ﬁbres made from CO2 Covestro and RWTH Aachen University develop industrial process TWO research projects have succeeded in making elastic textile ﬁbres based on CO2 and so partly replacing crude oil as a raw material. Covestro and its partners, foremost the Institute of Textile Technology at RWTH Aachen University and various textile manufacturers, are developing the production process on an industrial scale and aim to make the innovative ﬁbres ready for the market. They can be used for stockings and medical textiles, for example, and might The elastic ﬁbres are made with a chemical component that consists in part of CO2 instead of oil. This precursor called cardyon® is already used for foam in mattresses and sports ﬂoorings. And now it is being applied to the textile industry. Sustainable production process The ﬁbres are made from CO2-based thermoplastic polyurethane (TPU) using a technique called melt spinning, in which the TPU is melted, pressed into very ﬁne
threads and ﬁnally processed into a yarn of endless ﬁbres. Unlike dry spinning, which is used to produce conventional elastic synthetic ﬁbres such as Elastane or Spandex, melt spinning eliminates the need for environmentally harmful solvents. A new chemical method enables carbon dioxide to be incorporated in the base material, which also has a better CO2 footprint than traditional elastic ﬁbres. Development of the method of producing ﬁbres from CO2-based thermoplastic polyurethane has been funded by the European Institute of Innovation and Technology (EIT). It will now be optimized as part of the CO2Tex project, which is to be funded by the German Federal Ministry of Education and Research (BMBF) so as to enable industrial production in the future. “CO2Tex” is part of BioTex Future, a project initiative of RWTH Aachen University. The initiative is devoted to developing production and processing
Scientist Pavan Manvi from RWTH Aachen University (right) and Covestro researcher Dr Jochen Norwig holding a synthetic ﬁbre prototype made from CO2
technologies to facilitate the future market launch of textile systems from bio-based polymeric materials. What makes the CO2-based TPU ﬁbres so special is their properties: They are elastic and tear-proof and so can be used in textile fabrics. Initial companies from the textile and medical engineering sectors have already tested the CO2-based ﬁbres and processed them into yarns, socks, compression tubes and tapes. The aim of launching CO2-based textiles on the market is to promote a material cycle in the textile and clothing industry based on sustainable resources. Visit Covestro at Hall 6, stall A75 www.covestro.com
WACKER introduces high-performance additive for thermoplastic elastomers – Sold under the name GENIOPLAST® Pellet 345, the additive lowers the hardness of TPUs, while boosting their elasticity and enhancing their properties. The surfaces of moulded parts modiﬁed with the additive are pleasantly soft to the touch and more resistant to scratches, abrasion and contamination. The new additive is readily incorporated into thermoplastic polyurethanes and has fewer undesirable secondary effects than conventional silicone products. Pictured here is a surface test of a thermoplastic polyurethane (TPU) part modiﬁed with GENIOPLAST Pellet 345. The new silicone additive boosts the surface smoothness of TPUs, thereby enhancing their scratch and abrasion resistance. Moreover, surfaces become more resistant to contamination by foodstuffs and cosmetics.
Visit Lanxess at Hall 6, stalls C76 – C78
Visit Wacker at Hall 6, stall A10
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Online-paintable fuel filler flap made from PBT – Customised compounds based on polybutylene terephthalate (PBT) can be a cost-effective alternative to high-performance thermoplastics in the production of fuel ﬁller ﬂaps. This can be seen in the new Skoda Scala, for example, whose fuel ﬁller ﬂap is made from Lanxess’s Pocan B5221XF. The PBT compound was given preference over a blend of polyphenylene ether and polyamide (PPE+PA). The material is less expensive and exhibits comparable performance when it comes to surface quality, paintability and mechanical properties. In addition, it is suitable for electrostatic painting. It is also paintable online, which means that it can pass through all painting steps together with the vehicle body without any further outlay. This also contributes to cost-effective production.
‘Zero cooling’ provides revolutionary increase in quality, productivity & eﬃciency Increases visual, physical quality & productivity 1.5 to 3 times NISSEI ASB’s K2019 exhibit will focus around ﬁve ASB Series models demonstrating its patented ‘Zero Cooling moulding technology designed to increase visual and physical quality and productivity by 1.5 to 3 times, depending on the container speciﬁcation, while using standard or recycled PET resins. Taking advantage of their proprietary 4-station, 1-step moulding method, virtually all the required preform cooling is shifted from the injection station into the second, conditioning station to dramatically reduce injection cycle times. Crucially, Zero Cooling enables these short cycle times to be achieved while avoiding the need for thin, compromised design preforms that are susceptible to visual and physical quality related problems. Instead, the preform designer can focus on a
quality optimised preform design that improves stretch ratios, resulting in vastly improved quality and increased productivity. Each machine will be displayed with a full set of matched moulding ancillary equipment that the company is able to supply, such as resin dryer, chiller, mould dehumidiﬁer and mould temperature controllers, take-out units, etc. ASB’s booth will also be exhibiting an exciting range of developments and packaging technologies including two-layer bottles, canted/tilted neck bottles, polycarbonate 5-gallon with blown handle, double wall cup, HDPE bottles by ISBM, thick wall/base cosmetic bottles, etc. Visit Nissei ASB at Hall 14, stall B38
K2019 Dusseldorf Rubberstreet & the ‘Rubber & TPE Pocket Guilde’ One of the rubber hot spots at K 2019 will once again be the Rubberstreet in hall 6. The ‘Rubber & TPE Pocket Guide’ for visitors helps to ide ntify relevant partners at the exhibit ion that deal with rubber and elastomers, including TPE. It compromises the com plete value chain from raw material and machinery suppliers to processor s.
www.nisseiasb.co.jp AUGUST / SEPTEMBER 2019 39
Evonik to present additives for recycling waste rubber at K Recycled material mixed into road construction bitumen to extend service life
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EVONIK Industries AG is highlighting the role of a rubber process additive in turning scrap tyres into road construction materials during the K show. The company’s Vestenamer-branded additive makes it feasible to process rubber powder from scrap tyres for incorporation into asphalt, according to Evonik. The recycled material is mixed into road construction bitumen or asphalt to improve the quality of the mixtures and to extend the service life of road surfaces. The use of the additive in producing rubber-modiﬁed bitumen has developed amid concerns about road quality and durability in Europe. “As a process additive Vestenamer improves the ﬂowability of the rubber compound, as a result of which the material can be processed much more efﬁciently,” explained Dr Peter Hannen, market development manager for Vestenamer. The reactivity and polymer structure of the additive are also important here: Both lead to a good network density between the rubber particles. “This in turn positively impacts the mechanical properties,” says explained Hannen, adding: “Evonik’s process additive improves both the cost effectiveness of processing and the quality of the rubber parts when rubber is recycled.” The use of higher levels of rubber powder in road surfaces can also cut trafﬁc noise by up to 2dB: Evonik noting that a reduction by 3dB is comparable to cutting the trafﬁc volume in half. According to Evonik, each ton of recycled rubber power saves some 2.7 tons of CO2 which would otherwise be produced if
The use of the additive in producing rubber-modiﬁed bitumen has developed amid concerns about road quality and durability in Europe
scrap tyres were burnt. Evonik also claims that VOC emissions are also much lower in road surfaces containing rubber than in conventional, polymer-modiﬁed asphalt types. Figures presented by Evonik suggest that some 19.3 million tons of scrap tyres are generated worldwide annually, including over 3.6 million ton in Europe. Visit Evonik at Hall 6, stall B28
Save materials and energy with RRIcofeed-PRO from Reifenhäuser – Every saving in terms of ﬁlm thickness helps to reduce fossil energy, raw materials, and costs. Of course, the focus remains on functionality, which must always be retained in spite of the reduced use of materials. Over the past few years, the team at Reifenhauser has constantly worked on improving the cast ﬁlm and sheet extrusion line technology, so that optimum tolerances in multi-layer ﬁlms can also be measured on the ﬂy. Their patented REIcofeed-PRO achieves this even for hightech products. Single-layer thicknesses can be set across the width in the feedblock – even during ongoing production. As a result, line stops for product changes become unneccesary. Through the integration of innovative measuring systems, the line itself can continuously and reproducibly measure the thickness of the functional layers during production. Deviations from the target value are detected in real time and trigger an immediate modiﬁcation of the parameters, which the REIcofeed feedblock then implements without delay. The line is in a closed loop, optimizing itself. Visit Reifenhauser at Hall 17, stall C22.
Black pigment extends service life of plastic components – Among the new orange-coloured polyamide compounds from Lanxess, Durethan BKV45FN04 stands out. The polyamide 6 exhibits high stiffness and strength and is very ﬂame retardant. The use of the colour orange to identify live, plastic-sheathed components is becoming well-established in electric vehicles, but it is a challenge to develop orange compounds that exhibit high colour stability over the long term. Lanxess has now succeeded in doing just this. The specialty chemicals company offers a wide range of orange-coloured polyamide and polybutylene terephthalate (PBT) compounds for precisely these kinds of high-voltage applications. The products will be coloured in the highly vivid RAL 2003 (Lanxess colour code 200849) tone. Another colour variant is almost ready to be introduced. The compounds will be available both in a standard formulation and with thermal stabilisation, which will help to improve colour stability when the component is exposed to heat. Visit Lanxess at Hall 6, stalls C76 – C78
Borealis recycling technology & new rPO compound rPO with over 80% recycled content for use in visible appliance parts BOREALIS will introduce a new plastics recycling technology, Borcycle™. This evolving technology will be used to produce high-quality compounds made of recycled polyoleﬁns (rPO) such as the newly-launched Borcycle™ MF1981SY, an rPO with over 80% recycled content intended for use in visible appliance parts. Borealis is developing and implementing novel polyoleﬁns-based solutions that enable plastics reuse, recycling and recovery, by designing for circularity. These wideranging activities are gathered under the symbolic roof of EverMinds™, the Borealis platform dedicated to
promoting a more circular mind-set in the industry. The new technology, Borcycle, transforms polyoleﬁn-based waste streams into recyclate material such as pellets. Borcycle MF1981SY is the ﬁrst of several upcoming launches of rPO solutions made under the umbrella of the Borcycle technology. The compound is a 10% talc-ﬁlled compound that contains over 80% recycled material. It offers an ideal balance between stiffness and impact. The compound is especially suited for use in visible black parts, for example in small appliances. Visit Borealis at Hall 6, stall A43
K 2019 Düsseldorf – Central issues Scientists and experts of the K Innovation Circle expect certain top ics to dominate the global polymer ind ustry in the next years and have deﬁned the following issues as central for K 2019: 1. Plastics for Sustaina ble Development & Circular Economy, fea turing water management, renewabl e energy and the circular economy. 2. Digitisation of the val ue added chain and Industry 4.0, featur ing the aspect of platform economy and the value added network. 3. System integration: Functionality through material, proces s and design, featuring new materials and additive manufacturing, lightwe ight engineering, mobility (e-mobility) and biopolymers. 4. Strategic promotion of young professionals for the pla stics industry AUGUST / SEPTEMBER 2019 41
Smart, speedy and sustainable Fastest, most energy efﬁcient, sustainable, data driven integrated machine line-up SUMITOMO (SHI) Demag Plastics Machinery GmbH will unveil its fastest, most energy efﬁcient, sustainable, data driven integrated machine line-up at K-2019. Sumitomo (SHI) Demag will unveil ﬁve energy efﬁcient machines. The company will also launch a new eMultiPlug innovation, showcase its technical prowess in Liquid Silicone Rubber (LSR) moulding, plus provide an interactive area where customers can test out the latest smart diagnostic and support services using myConnect. Consuming up to 20% less energy than its predecessors, Sumitomo (SHI) Demag is bringing two energy-enhanced El-Exis SP machines to K2019 - a large and a smaller version. Catering speciﬁcally to the packaging moulding markets, the ultra-high speed range ensures manufacturers never need to compromise on quality, production efﬁciency or sustainability. Central to the machine’s fast cycle time is the hydraulic accumulator, which achieves injection speeds of up to 1000 mm/s. This enables moulders to produce even thinner packaging items. Visit Sumitomo at Hall 15, stall D22. www.sumitomo-shi-demag.eu
K 2019 Düsseldorf – Smart online services
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al The K show has its own web port app the via lable avai also , com k-online. nt for iOS and Android OS, a convenie g ssin acce of and readily available way stry indu e entir the from s interesting new oand helpful tips to keep visitors up-t is date on all things trade fair. K 2019 and book Face also present on Twitter, LinkedIn. such as Featuring personalised services ors visit s help al MyOrganizer, the K port on, mati infor el Trav da. agen organise their to do s thing and n datio mmo acco including e hotel in Düsseldorf – including an onlin on lable avai also reservation option are k-online.com.
Sumitomo (SHI) Demag will demonstrate the moulding of an LSR matrix light on an IntElect 130
Non post-cure LSR WACKER, the Munich-based chemical group, will present its Elastosil® LR 5040 product series at the K show. Even without post-cure, this liquid silicone rubber shows excellent mechanical properties and meets strict regulatory requirements for sensitive applications in the baby-care, food and medical technology sectors. Post-curing is obsolete for articles made from Elastosil LR 5040. Elastosil LR 5040 cures to translucent elastomers whose volatiles content – without thermal post-treatment – usually ranges from 0.2 to 0.3 weight percent. So, even in the nonpost-cured state, they are already far below the limit value of 0.5 weight percent that applies to the volatiles content of silicone articles intended for food contact and baby-care applications. This compares with the ﬁgure of more than one percent usually attained by commercial standard products that have not been thermally post-treated. Wacker has managed to slash the content of volatile Dx siloxanes in its liquid silicone rubber by at least 90%. In many applications, manufacturers will have the option to shorten the post-curing times. And, in some cases, they can actually dispense with post-curing altogether. Visit Wacker at Hall 6, stall A10 www.wacker.com
Wacker’s low volatile LSR initiative is setting standards around the world
Going further with Passion. At ENGEL, we embrace responsibility – both for our own products and for those made using our machines. We are committed to working with plastics responsibly and to increase the use of recycled materials. We support our customers in developing their production processes with the expertise gained over the course of seventy-plus years in the plastics industry. Together we strive to use plastics sustainably, meeting the requirements of the circular economy. Along with over 350 companies, universities and organisations, we have signed the Ellen MacArthur Foundation’s New Plastics Economy Global Commitment – helping to show that together, we can achieve greater things.
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Durable star wheels for waste sorting PU elastomers based on low free (LF) prepolymers as an alternative to rubber LANXESS’s Urethane Systems business unit has developed an alternative to synthetic rubber for producing star wheels for material separation plants and material transport. It is based on polyurethane (PU) elastomers produced from Adiprene Low Free (LF) prepolymers. The PU star wheels are not only characterized by a longer service life and excellent mechanical performance, but are also resistant to heat and moisture. In addition to the material, the constructive design of the star wheels also comes from Lanxess. It was developed based on product requirements, technical application and optimization algorithms using the CAD software Solidworks. The design is licensed. Doubled service life While the beginnings of the star wheel can be traced back to the reprocessing of old newspapers, they can now be used to separate paper from various household mixed waste (single-stream recycling). The plants used for the single-stream recycling process must be able to handle waste streams at speeds of up to 50 tons per hour. The star screen machines
used in single stream material recycling facilitys (MRFs) each consist of several steel axles on which the star wheels are mounted. Each deck has its own star wheel arrangement depending on the screen size. In particular, the star wheels of the ﬁrst screening decks are extremely subject to abrasion because they have to sort out heavier waste components at high running speeds. A wheel version based on Adiprene LF TDI prepolymer is used in the plants, which is twice as durable as a component made of rubber. The wheels can therefore be replaced less frequently, which saves material costs and extends the maintenance intervals of the plants. The extreme wear resistance of the wheels is due to the high abrasion, tear and cut resistance of the PU elastomer. Optimal health, occupational safety and environmental protection Adiprene LF TDI is based on LF technology, which reduces the content of free TDI isocyanate (toluene diisocyanate) in the prepolymer to below 0.1%. It meets the highest ecological and industrial hygiene standards, allowing the processor to use the minimum amount of protective measures. Advantages also arise during processing. The long pot life and low viscosities of the Adiprene LF prepolymer
The star screen machines used in single stream material recycling facilitys (MRFs) each consist of several steel axles on which the star wheels are mounted. Each deck has its own star wheel arrangement depending on the screen size. In particular, the star wheels of the ﬁrst screening decks are extremely subject to abrasion because they have to sort out heavier waste components at high running speeds
system allow controlled processing without the use of solvents. The viscosity can be controlled and speciﬁcally adapted to the application. In addition, the PU components are easy to demould, beneﬁting high productivity with minimal waste. The use of Adiprene LF TDI is not limited to star wheels for waste recovery and recycling facilities. The PU star wheels can also be used in agriculture, for example, in harvesting systems or for handling mulch, peat, humus and compost. Further application opportunities arise in the construction industry, including in the demolition of buildings, in forestry and in extremely fast production processes for food, beverages and health products. Visit Lanxess at Hall 6, stalls C76 – C78 www.lanxess.com
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K 2019 Düsseldorf – Special: Science Campus The Science Campus at K2019 encourages the discourse between re research and industry. A forum whe ange exch can ies businesses and universit s bitor exhi K ides prov also information, it ve ensi preh com a with ors and visit results overview of scientiﬁc activities and . arch rese lated in plastics and rubber-re
New line concept for single-origin packaging solutions
Brückner Maschinenbau high performance stretching lines
Innovations for the demands of a circular economy between a working width of 6.6m and an output of 3t/h, or a working width of 8.7m and an output of 5t/h. These are 5-layer concepts for an extended range of ﬁlms. The new lines also have the ﬂexibility to produce BOPP ﬁlms: Specialities such as UHB ﬁlms and coated ﬁlms for high-barrier uses alongside conventional packaging ﬁlm. As the demand for innovative BOPE ﬁlms is only now starting to develop, ﬁlm producers will be able to react swiftly and ﬂexibly to market trends. Brückner has also developed a new inline coater for all BOPP and BOPE lines, installed in the line before the transversal
Digital pioneers present world ﬁrst from KraussMaffei CAN operators make injection moulding machines ﬁt for Industry 4.0 if they are decades-old, yet still reliable? Yes! KraussMaffei is presenting a world ﬁrst at the K show – ‘bundles’ that enable the networking and use of data for all injection moulding machine generations and makes. Soon, reaction process machinery and extrusion technology will also be integrated into the common data ecosystem. With its new retroﬁt programme, KraussMaffei also creates the technical prerequisite
for connectivity across processes, generations and going forward, even across manufacturers. These, as well as the IIoT, form the basis for the use of cloud-based products and services. Wherever data arises, it also needs to be stored. This can take place entirely in the cloud via a gateway computer, or near-network by means of Edge computing, depending on the existing IT environment, the volume of data that accrues and personal preference. Visit KraussMaffei at Hall 15, stalls C24 – C27
stretching, it makes the production of extremely thin functional layers within the nano-range possible. Due to the extreme thinness, the layers don’t disrupt the sorting and recycling, but cater, for example, for an improved adherence during metallising and excellent barriers in combination with the equally thin but effective aluminium oxide coating. Visit Bruckner at Hall 3, stall C90 www.brueckner.com
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BRŰCKNER Maschinenbau is working on a means to make ﬁlms with the highest possible recycling capabilities producible on ﬁlm stretching lines. The focus is on mono-material ﬁlm with superior mechanical and optical properties, which will be able to substitute previous multi-layer ﬁlms made from different materials. These are ideal for the use in new, single-origin packaging and guarantee good sortibility in waste separation and optimal recycling. For K2019, Brückner will introduce two completely new line concepts for the production of BOPE ﬁlms (biaxially oriented polyethylene). Film producers can chose
K 2019 Düsseldorf – Promoting young professionals At K2019, there is a spe cial focus on the promotion of young professionals for the industry, both in science and in practical training. Partic ipating universities, institutes, associations and promotion agencies will present the central topics with discussions, speeches and demonstration of select ed exhibits. The strategic promotion of young professionals is crucia l for the plastics industry. The German training and qualiﬁcation initiative KA I, aims at promoting the versatility and prospects of career options in the plastics industry among the younger gen eration. Activities ranging from exhibition s and moderated discussions through to experiments are provided to attract you ng professionals to the industry.
Enviro This photo shows what a bottle made from 100% r-PET looks like (left), the same bottle using AY 00015 at 0.03% (centre), and with AY 00201 with optical brightener 0.03% (right)
while keeping feet on the ground!
AUG / SEPT 2019
When colours and additives come to the rescue
MORE and more customers are demanding the optimum percentage of r-PET in their bottles, and if they are not yet on the market with 100% recycled packaging, they are already planning it. REPI’s global network develops and produces colours and additives in liquid form for plastics. The colour of r-PET varies a lot from supplier to supplier (and even from one batch to the next) and depending on the ratio of virgin and recycled PET used, the result can be anything from grey or pale yellow, to blue or greenish. The more recycled content the bottle has, the darker the end colour will appear. Mechanical challenges when using r-PET include a drop in the Intrinsic Viscosity (IV) and wall thickness distribution, one the cause of the other. This happens because PET has already passed through several production processes that impact on its chemical composition and shortens its molecular chain. A drop in the IV is responsible for inconsistencies in the moulding machine pressure, leading to uneven wall thickness REPI’s IV enhancer additive boosts the mechanical performance of an r-PET bottle by increasing the IV level from 0,05dl/g to over 0,10dl/g One single shade starting from two different r-PET
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and therefore to insubstantial packaging. REPI has been studying and specialising in additives for PET recycling for many years and is today able to offer broad-spectrum support in the form of their range of ‘Anti Yellow’ (AY) additives and IV-enhancers. REPI’s prototyping research and development laboratories mould preforms and bottles and experiment with colours and additives using r-PET pellets and ﬂakes mixed in different percentages. The AY range comprises different liquid additives able to balance the appearance of inconsistent material and makes it possible to regain brightness, as well as to correct a greenish or greyish tone. REPI’s IV Enhancer attracts and binds to the free oligomers in recycled PET, extending its molecular chain and therefore increasing the IV to the level of a virgin material. Besides additives, colours can be of help Currently the trend is to reduce colour, or even to go transparent, but many brands are not ready to sacriﬁce the aesthetics of their packaging and their brand recognition. When a very dark r-PET is used, an Anti-Yellow additive may not be enough. For this, REPI has developed the Smoky or Fumè colour range that can give the packaging a premium and elegant look, masking the effect on colour caused by the r-PET. The Smoky or Fumè colour range is used at very low dosages (as low as 0,05%) so it does not impact the recycling stream because it is detected as a transparent light colour. The range goes from light amber to light blues, greys, aquamarine shades and even antique rose. “Moving towards a circular economy is not simple, but solutions are already in place to help as much as possible to ﬁnd how to be sustainable from a branding and aesthetic point of view as well as from a technical perspective,” says REPI. “Colourants and dedicated additives are available to make r-PET look and work even better. Take advantage of this opportunity, because after all… how would the world look without colour?” www.repi.com
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Enviro Recycled rPE facestock oﬀers an industry-ﬁrst
THE labelling industry’s ﬁrst-ever facestock made from recycled polyethylene (rPE) has been introduced by Avery Dennison and successful print and dispensing trials are complete. With growing demand for recycled materials among consumers, Jenny Wassenaar, Avery Dennison Label and graphic materials sustainability director EU, said that the new material is an important step towards meeting brand owners’ sustainability goals and complying with emerging regulations: “Polyethylene labels are a very widely used component of packaging, so improving sustainability is important. The technical challenges we faced when developing this rPE product were signiﬁcant in terms of matching technical performance, and development work is ongoing. Our expectation is that ﬁlms with recycled content will improve still further as we pursue new lines of research.” Recycled PE contains more impurities than virgin PE ﬁlm, which gives the ﬁlm a unique aesthetic, without compromising printing, dispensing or application. www.averydennison.com
Graham sets 100% recyclable, compostable target
GRAHAM Packaging Co has pledged to make all of its plastics packaging reusable, recyclable or compostable by 2025. The American based company announced the sustainability commitment as it joined the Ellen MacArthur Foundation New Plastics Economy in May. Graham is No. 2 in the most recent Plastics News ranking of North American blow moulders, with $2.1 billion in annual sales in the region. The blow moulder currently uses more than 45 kilotonnes of postconsumer recyclates in its products annually. At its recycling centre in York, Pennsylvania, the company processes over 22 kilotonnes plastic packaging waste, from curbside recycling programmes each year. www.grahampackaging.com 48 AUG / SEPT 2019
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Annual Clean-Up and Recycle SA Week will see plastics industry tackle waste in the environment Clean up events throughout the week
The SA plastics industry will once again demonstrate its commitment to cleaning up the environment and removing plastics litter from our rivers, streams, oceans and neighbourhoods when the annual Clean-up and Recycle SA Week takes place from 16-21 September. According to Douw Steyn, sustainability director of Plastics|SA, this is the 23rd year that they will be involved in this initiative. “Clean-up and Recycle SA Week began as a project of the plastics industry and Ezemvelo/KwaZulu-Natal Wildlife, in 1996. Since then, it has grown to include the participation of all the packaging streams as well as the support of major plastic raw material suppliers, converters, brand owners and retailers, PRO’s (Product Responsibility Organisations), recycling bodies, and conservationists and government. During this week, we all unite our actions around the common goal of removing as much litter as we possibly can from our environment. We also aim to teach South Africans how to dispose of their waste in a responsible way by highlighting the importance of recycling materials that can be used to create new products, generate employment and reduce our impact on the environment,” he says. Where possible, Plastics|SA will support these activities by donating branded garbage disposal bags as well as offering advice on how to organise a clean-up, where and how to recycle. “This week will culminate in Recycling Day (Friday, 20 September) and South Africa’s participation in the International Coastal Clean-Up and the Let’s Do It! World Clean-Up (Saturday, 21 September). Last year, this clean-up event attracted 17 million volunteers from 158 countries, who participated in clean-ups that took place around the globe on the same day. Despite six tropical cyclones, ongoing wars, conﬂicts and unrest, this was the largest organised clean-up that has ever taken place in a timespan of 36 hours,” Steyn says. www.cleanupandrecycle.co.za
Binning the idea that plastic
Biodegradable plastic bags may not be the alternative to solve environmental woes PLASTIC bags are touted as one of the biggest causes of environmental pollution, with many nations banning the bag in an effort to solve the problem. Globally, single-use plastic bags are banned in over 32 countries, 18 of which are in Africa, with New York City in the USA becoming one of the most recent cities to do this in April 2019. “I fear that, when looking at the alternatives on the table, Back home, leading retailers are as well as human behaviour, in the process of either phasing the symptom rather than the out the bag, banning it altogether, cause is being addressed,” or looking at alternatives, such as says Michelene Locke, biodegradable bags, as a direct sales director ITB Flexible Packing Solutions (ITB), one response to rising consumer of South Africa’s leading awareness of the problem. commercial printers and “The effort from retailers and manufacturers policymakers to address the problem of single-use plastics is admirable, as it shows the commitment from both business and government to prioritise the preservation of natural resources,” says Michelene Locke, sales director ITB Flexible Packing Solutions (ITB), a division
of Novus Holdings, one of South Africa’s leading commercial printers and manufacturers. “However, I fear that, when looking at the alternatives on the table, as well as human behaviour, the symptom rather than the cause is being addressed,” she added. New study challenges assumptions about biodegradable plastics A new study published recently by the University of Plymouth’s International Marine Litter Research Unit and published in the journal of ‘Environmental Science and Technology’, challenges assumptions that switching to biodegradable plastics could reduce ocean-plastic pollution. It found that ‘biodegradable’ plastic bags aren’t all that biodegradable, as after three years, they are still able to act as grocery bags. Furthermore, it found that adding these ‘biodegradable’ bags to recycling bins can destroy efforts to collect plastic bags for the remanufacture into new bags, as chemical additives in these bags can contaminate the mixture, rendering it unusable. “The study’s ﬁndings show that we must exercise caution in thinking that biodegradable bags are a viable alternative to solving the plastic bag problem,” says Locke. The UN, in a report published in 2016, also stated that
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Plastic innovations in cannabis packaging THERE are plenty of similarities between pharmaceuticals and cannabis, both in the strict regulations that guide controlled substances and for the packaging requirements that include child resistance closures, among others. PlasticsToday.com was able to get an in-person look at three of the supplier’s latest packaging innovations in the marijuana market in June during PackEx Toronto. The ﬁrst breakthrough was for injection-moulded brownpigmented jars and lids by Canadian company, Cannasupplies, both made with 20% hemp; the balance
of the material in the packaging is polypropylene. A parallel line of greenpigmented jars and caps is made with an even higher amount, 33% hemp. The mandatory child-resistant lids perform similarly as the ubiquitous amber-coloured pharmaceutical bottles, requiring downward pressure while twisting to release them. Cannasupplies’ second plastic packaging introduction was a childresistant top for cannabis-infused beverages in aluminium cans. For one thing, cannabis in drinkable form can deliver a precisely measured dose of the narcotic for consumer Simply snap this cap onto any #202 aluminium can to transform it into a childresistant container for cannabis infused beverages! This one-time use cap is made from a minimal amount of biodegradable material to keep the cost down, while providing lab tested, CPSC-certiﬁed childresistance safety. CAN’+ features a patent pending design
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assuredness. For another, it enables brands to market an alternative product in form and function to help grow sales. Injection-moulded PP with a biodegradable additive, the intricatelooking plastic ring requires that an equal amount of ﬁnger pressure be applied to opposite sides of the ring. That releases the ﬁnger-sized ringtab that can be pulled upward and removed so the user can access the can’s standard aluminium pull-tab ring. The ringed top can be applied in-line on canning lines. www.cannasupplies.ca The latest packaging innovations in the marijuana market – injection-moulded brownpigmented jars and lids both made with 20% hemp; the balance of the material in the packaging is polypropylene
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in for responsible recycling. It can also carry frozen and wet
AUG / SEPT 2019
biodegradable plastics are not the answer findings show to marine plastic pollution. It found that that we must exercise biodegradable plastics rarely break caution in thinking that down fully in marine environments, and labelling them as such could even biodegradable bags are encourage people to be more casual a viable alternative to about littering. “We tend to blame plastic for the solving the plastic problem, when it is our behaviour that bag problem. needs to change. It is up to us to use plastic bags responsibly rather than discarding it where it will end up as pollution. Using a plastic bag as a products without disintegrating. It is also cheaper than cloth bags bin liner is one way that will allow it to enter the waste and can be cleaned, to ensure it remains hygienic. stream, where it is easily retrieved by recyclers,” says Locke, citing research that suggests waste pickers are key to the local “Ordinary woven bags that are sold as alternatives to plastic economy as they collect as much as 80% of post-consumer bags at retailers can be hazardous as they carry a huge risk packaging, increasing the country’s recycling rate to rival that of of added bacteria if food leaks, and are not easy to clean. some European countries. Therefore, a healthier choice would be to consider recyclable LLD plastic bags,” said Locke. Reusable plastic bags “To really look after our planet, our behaviour needs to ITB has produced a 100% recyclable LLD plastic bag (made with change. Making better choices through not discarding singlerecycled material); is thicker than an ordinary plastic grocery bag use plastic, choosing multiple use plastic bags, recycling and (a sturdier product with added strength – robust for carrying up using plastic responsibly all play a part,” she added. to 20kg) and it can be used up to 200 times before being handed
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LaPlastecnica 2019/01/29 17:35 12:46 2019/08/05
Biocomposites performing great – not only for lightweight construction! Additive manufacturing might change way cars or components are produced BIOCOMPOSITES have begun to penetrate several additional markets beyond the main sales market of decking. With the latest advances in injection moulding and 3D printing, both Wood-Plastic Composites (WPC) and Natural Fibre Composites (NFC) are of high interest for a multitude of applications and fruitful new options for product differentiation. The 8th Biocomposites Conference Cologne from 14-15 November in Cologne offers a comprehensive overview of current developments, product diversity and application areas (www.biocompositescc.com). With an average of 250 participants and 30 exhibitors, the conference has established itself as the leading international conference in the sector of biocomposites.
footprint plays a crucial role in technical applications and in the automotive industry in general. Wood-Plastic Composites are mainly used for rear shelves, trims for trunks, spare wheels as well as for interior trims for doors. Natural Fibre Composites have a clear focus on interior trims for high-value doors and dashboards, that are processed either with thermoset or thermoplastic matrix. Another potential market, which was developed recently, are biocomposites for small electric car manufacturers and racing cars. Such smaller car producers are not part of the established automotive value chain and they are looking for ecological lightweight materials with low carbon footprint.
Market development for biocomposites Recently observed market developments are favourable for biocomposites. The table shows existing application areas and the potential for market growth. The biocomposite markets continue to grow, stable in established markets like construction and automotive and growing strong in the more recently entered markets of consumer goods and packaging, with new players providing opportunities in innovative applications. The biggest increase is expected for traded biocomposite granulates for furniture, toys, consumer goods and cases, primarily in injection moulding and 3D-printing. According to calculations by the nova-Institute, the production of biocomposite granulates in Europe will double over the coming 10 years.
Consumer goods: Biocomposites – the real alternative to plastic Biocomposites contain wood or other natural ﬁbre and a (bio-) polymer as a matrix. Various production methods including extrusion and injection as well as press moulding or 3D printing can be offered. Most producers still use fossil-based polymers for the production of biocomposites. But meanwhile, there are a lot of bio-based polymers on the market to produce partly or fully bio-based composites which allow to use renewable carbon instead of fossil carbon. Some are biodegradable for special applications: in combination with biodegradable plastics, biocomposites are suitable for the use in agriculture, horticulture and also for utilisations such as ﬁlter balls and coffee capsules. Packaging is the leading application for bio-based polymers. Bio-based polymers do not differ optically from petro-based plastics. In combination with wood or natural ﬁbres, they offer excellent opportunities for the ecological marketing of food trays, biocosmetics or detergents.
Biocomposites in the automotive sector One session of the conference focuses on biocomposites in the automotive industry in cooperation with the working group for natural ﬁbres of the AVK – Federation of Reinforced Plastics e.V. In the automotive sector, biocomposites are primarily used for lightweight construction. The resulting lower CO2
The table shows existing application areas and the potential for market growth
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AUG / SEPT 2019
Willard Batteriesâ€™ beach cleanup set for September
AUG / SEPT 2019 53
AS a follow up to the launch of the limitededition Willard BLUE battery, aimed at highlighting the threat that plastic poses to oceans and beaches, Willard Batteries in partnership with The Beach Co-op has scheduled beach clean-ups in the Western Cape, PE and KZN in September. The Beach Co-op is developing a shared data platform that will allow those engaged in beach cleanups to interact and share their ďŹ ndings. This will contribute to the understanding of beach and marine litter at the national level and help provide a robust rationale for national campaigns. In addition to beach clean-ups, The Beach Co-op offers data collation and analysis services for organisations and businesses wanting up-to-date and rigorous quantitative and qualitative studies. People participating in the campaign to purchase a Willard BLUE battery stand a chance to win a Big 5 Sea Safari in Hermanus, with luxury accommodation at the Marine Hotel. To enter the competition, customers must register the purchase of their new BLUE batteries online at /www.willard.co.za before 30 September.
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The LyondellBasell production team in Wesseling, Germany shows off ﬁrst batch of bio-polymer made from renewable materials
LyondellBasell, Neste in commercialscale production of bio-based plastic First time bio-based PP and bio-based LDPE produced simultaneously at commercial scale
LYONDELLBASELL, one of the largest plastics, chemicals and reﬁning companies in the world, and Neste, the world’s largest producer of renewable diesel from waste and residues, have collaborated to produce bio-based polypropylene and biobased low-density polyethylene at a commercial scale. The joint project used Neste’s renewable hydrocarbons derived from sustainable bio-based raw materials, such as waste and residue oils. The project successfully produced several thousand tons of bio-based plastics which are approved for the production of food packaging and being marketed under Circulen and Circulen Plus, the new family of LyondellBasell circular economy product brands. An industry ﬁrst This achievement is extraordinary in that it combined
Neste’s unique renewable feedstock and LyondellBasell’s technical capabilities. LyondellBasell’s cracker ﬂexibility allowed it to introduce a new renewable feedstock at its Wesseling, Germany site, which was converted directly into bio-based PE and bio-based PP. An independent third party tested the polymer products using carbon tracers and conﬁrmed they contained over 30% renewable content. LyondellBasell sold some of the renewable products produced in the trial to multiple customers, one of which is Cofresco, a company of the Melitta Group and with brands like Toppits® and Albal®, Europe’s leading supplier of branded products in the ﬁeld of household ﬁlm. Cofresco plans to use the Circulen Plus bio-based polyethylene to create sustainable food packaging materials. www.LyondellBasell.com
‘Ecophane’ line of sustainable PET ﬁlms
54 AUG / SEPT 2019
Composed of 30% or more of post-consumer recycled, food grade PET
LATIN American company, Terphane, a global player in specialty polyester ﬁlms, has introduced its sustainable Ecophane ﬁlms to the global packaging market. These new PET ﬁlms address a growing demand for ﬁlms that guarantee the production of recyclable packaging with recycled content. “The Ecophane line is the result of extensive research and development and the use of highly advanced technology. We are now able to create a PET ﬁlm with a minimum of 30% post-consumer recycled PET in its composition,” explained Marcos Vieira, global R&D director of Terphane. This technological expertise has resulted in more than 10 different types of Ecophane ﬁlms available for a wide variety of applications. While guaranteeing a lower use of new raw materials, Terphane´s new Ecophane ﬁlms are also aligned with the circular economy concept:
ENVIRO- .indd 54
disposable PET packaging and other products are collected, recycled, and become new packaging. ‘The Perfect Fit’, a document produced by FPE (Flexible Packaging Europe – www.ﬂexpack-europe.org/ en/sustainability/the-perfect-ﬁt.html), states that efﬁciency is a fundamental issue when deﬁning the sustainability of a package, taking into consideration all aspects of the product´s value chain, the packaging itself, consumption, and all other impacts. With ﬂexible packaging, packaging producers and brand owners can achieve the ‘ideal point’ that optimises their functional
and material efﬁciency. This is the perfect relation between product and packaging. ‘The Perfect Fit’ document also emphasises the fact that ﬂexible packaging is highly adaptable. Its intelligent design can guarantee even more sustainable beneﬁts, including correct portion sizes, reclosable packaging systems to minimise waste, printing of information that guarantees correct use and storage, functional and lighter packaging that reduces the impacts of storage, distribution, and transportation. www.terphane.com
While guaranteeing a lower use of new raw materials, Terphane´s new Ecophane ﬁlms are also aligned with the circular economy concept: disposable PET packaging and other products are collected, recycled, and become new packaging
Avantium moving forward on bio-based plastics plant Will produce 100% renewable, fully recyclable PEF polymers
has already started the design of the plant, slated to start production in 2023. The ﬁnal site for the plant will be named later this year, but is expected to be in Northwestern Europe. Avantium expects to make an investment decision for the construction of the plant by the end of 2020. Additionally, Avantium said the Synvina business unit has been renamed Avantium Renewable Polymers and operates under the Avantium brand. www.avantium.com
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The YXY plant-to-plastics–process catalytically converts plant-based sugars into a wide range of chemicals and plastics, such as PEF
AUG / SEPT 2019
DUTCH biotechnology company Avantium NV has unveiled a series of plans to commercialize its YXY technology to produce 100% renewable and fully recyclable polyethylene furanoate (PEF) polymers. The Amsterdam-based company said it had revised its scaleup policy after taking full ownership of the Synvina bioplastics business from joint venture partner BASF SE earlier this year. The YXY plant-to-plastics process catalytically converts plant-based sugars into a wide range of chemicals and plastics, such as PEF. Avantium demonstrated the YXY Technology at its pilot plant in Geleen, the Netherlands. In the future, with increased scale, Avantium expects PEF to compete in high-volume markets, including bottles for carbonated soft drinks and other beverages. Synvina was formed in 2016 to commercialize the YXY technology developed by Avantium to produce PEF-building block FDCA. But BASF terminated its partnership earlier this year, citing disagreements over implementing the terms of the agreement. As part of its new plan, Avantium said it intended to build a cash-ﬂow positive ﬂagship plant with a planned annual capacity of 5 kilotonnes per annum (ktpa) of FDCA and PEF. The plant will produce products for high-value markets and performance applications such as high-barrier ﬁlms and specialty bottles. Avantium said it would maintain control of ﬂagship and licensing business of YXY, while building a network of committed partners throughout the value chain. Engineering company Worley, formerly known as Jacobs Engineering,
Plastics industry More than just businesses, these companies are at the forefront of developing innovative design, processes, technologies and materials in the New Zealand Plastics Industry. They are playing a major role in New Zealand’s continued expansion and success on a global level.
& BEST MANUFACTURING PROCESS & EXECUTION
F15 CHASSIS & HELMET COMPONENTS – AXIAM PLASTICS LTD The supreme winner for the 2019 Awards results from bringing together a range of classic product development considerations: attractive and versatile design which was well researched and future-proofed; a range of carefully selected materials; appropriate manufacturing technologies; high quality, complex precision tooling; and all good commercial and export potential all based largely on New Zealand input. The overall design of this product impressed the judges but also was commendable for its versatility to meet a wide variety of helmet speciﬁcations, while also catering for future requirements. It is obviously the result of considerable design evolution while including signiﬁcant further product development. At its heart is a high quality, well-engineered chassis component which requires a very complex mould. All other components are well designed and moulded to create an impressive complete ﬁnal product. Paciﬁc Helmets are market leaders in design, function and technology offering all levels of speciﬁcation for helmets used by ﬁre ﬁghters in structural and wildﬁre situations, USAR rescue personal and paramedics. With the F15 Fire Helmet they have created a high spec model that can be accessorised to suit any specialist customer demand. A key component being the 1-piece chassis which allows for current and future advances in communication integration, visor function, torches, biometric and even augmented reality www.axiam.co.nz technology related components to be added to the helmet.
BEST INDUSTRIAL PRODUCT
56 AUG / SEPT 2019
GALLAGHER TW SERIES – GALLAGHER GROUP LTD This weigh scale and data collector represents a further evolution in similar controllers from this manufacturer. Aside from the pleasing and practical design, the judges were especially impressed with the overmoulding and enhanced design of the seals throughout the product. The parts require challenging dimensional control during manufacture to function correctly and are thus excellent examples of modern injection moulding technology. Designed to perform in a tough
environment for demanding users, the Gallagher TW Series Weigh Scale is a highly resolved product solution from the design team based at Massey University College of Creative Arts. It encapsulates a complex digital management tool in a rugged, yet simple product design that pushes past the boundaries of mere functionality. Advanced EID compatible weigh scale and data collector. Simple to operate, touch screen weigh scale with the additional functionality www.gallagher.com of life data and trait recording.
design awards BEST ENVIRONMENTAL PRODUCT HIGHLY COMMENDED: ALTO PACKAGING LTD – LIGHTWEIGHT DAIRY CAP The new Alto Packaging Lightweight Dairy Cap has become the standard cap across all the major fresh dairy producers in New Zealand. The new cap design has reduced the cap weight by 41%, this saves the use of 276 tons of plastic resin per annum. The cap was designed and developed in New Zealand by the Alto Packaging team. www.alto.co.nz
HIGHLY COMMENDED: ELASTOMER PRODUCTS LTD – BIODEGRADABLE WINE NET CLIP The renewable, biodegradable net clip developed for the viticulture industry addresses an emerging environmental problem: The accumulation of nondegrading littler of broken net clips in vineyards and generation of microplastic pollution. The solution is a clip made of biodegradable polymers and renewable additives. The short-life, single-use product now has an appropriate end of life – it degrades! A new, additional sustainable practice for an industry that relies on brand proﬁle. www.eplgroup.com
AUG / SEPT 2019 57
BEST CONSUMER PRODUCT DRAPE SUPPORT – VERSATILE STERILE DRAPE MANAGEMENT AND WORK SURFACE – ADEPT LTD This was a complete product with a simple function. The judges were particularly impressed with the clever and elegant design. With its lockable, articulating joints the product is very versatile and easily used. All parts have been well engineered, include good material choices and are high quality mouldings. It is a ﬁne example
of a product conceived, developed and manufactured in New Zealand. Modern interventional radiology and cardiology procedures requiring access to arteries use a sterile drape over the patient exposing only the access site. Keeping the drape off a patient’s face reduces patient anxiety and allows visual communication.
The Adept Drape Support uses unique lockable articulating joints, to provide positioning versatility and a convenient work surface. Designed, tooled and manufactured by Adept to CE certiﬁcation, the drape support was released to market in September 2018. www.adept.co.nz
BEST TOOL MAKING APPLICATION HIGHLY COMMENDED: MASTIP TECHNOLOGY LIMITED – VERISHOT™ SINGLE VALVE GATE SYSTEM Sporting an extremely compact design, the VeriShotᵀᴹ system greatly reduces mould height requirements as it doubles as a locating ring housing the mechanics. This ensures perfect alignment between mould and machine platens. Pre-assembled, VeriShotᵀᴹ features Mastips FlowLoc™ threaded leak proof nozzles with advanced heating technology for optimum control, providing exceptional thermal performance for improved part quality making it ideal for applications requiring a highly cosmetic gate ﬁnish, fast ﬂow rates, large volume parts, and dimensional accuracy. With an excellent thermal proﬁle, VeriShotᵀᴹ ensures a wide moulding window and is capable of processing a wide range of both engineering and commodity polymers. Low mould ﬁlling stress results in superior part quality and consistency. With patent-pending technology that includes hightemperature seals and adjustable valve pins, the system provides a ﬂawless injection moulding process. www.mastip.com 58 AUG / SEPT 2019
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Design ENVIRONMENTAL & ENERGY ACHIEVEMENT NEW ZEALAND RECYCLED PLASTIC CONTAINERS – FLIGHT PLASTICS LTD This was considered to be a major development for the plastics industry and recycling generally in New Zealand. As a consequence, there is now a domestic recycling channel for postconsumer PET, one of the high-use materials used in the industry. It is an initiative which has required bold investment and appears to have been thoroughly researched and carefully executed. Because new PET containers are now able to be produced with high levels of recycled PET content, not only is there less PET going to landﬁlls but less PET resin being imported in the ﬁrst place. The judges considered this development to be a major improvement in all respects. Flight’s Recycled PET containers are the only rPET packaging in NZ guaranteed to be made using our own waste PET. The project is part of a $17 million investment which started in 2013. Flight now operates the ﬁrst and
only plant in NZ that can manufacture rPET food packaging from waste PET and is one of the few facilities in the world where all parts of the process take place on the same site. www.ﬂightplastics.co.nz
60 AUG / SEPT 2019
RESEARCH & NEW INNOVATION AWARD LIGATE™ – BIOBASED ADHESIVE – SCION The concept of a polymeric bioadhesive which is free of petrochemicals and made from 100% renewable plant resources seemed to the judges to be a very signiﬁcant challenge, and yet it is now a reality. This water-based, non-toxic bioadhesive is used for the production of panelboard and is fully compatible with existing panelboard manufacturing equipment. The judges
felt that this product certainly met the criteria for innovation and environmental achievement, and with commercial trials advancing well they felt this was an appropriate inaugural winner in this category. Scion’s LIGATE™ bioadhesive resins are free of petrochemicals and formaldehyde and made from 100% renewable plant resources www.scionresearch.com
including lignin, a by-product of papermaking. The water-based, nontoxic bioadhesives are compatible with existing adhesive and panelboard manufacturing equipment. LIGATETM uses very challenging chemistry in a very simple way to deliver an environmentally friendly performance product. Unlike other biobased adhesives – Scion’s resin does not just replace petro chemically based adhesives but uses bioinspired chemistry to achieve its performance.
Classifieds Apr/May'19.indd 92
PLASTIC RECYCLING AWARDS
Winners of the
Outstanding innovation in recycling THE seven winners of the Plastics Recycling Awards Europe 2019 were announced in April. “Already in their second year the Plastics Recycling Awards Europe have come of age, thanks to the quality and depth of entries we have received,” said Ton Emans, PRE President and awards judge. “Together our seven winners show outstanding innovation in recycling to use plastics in a truly sustainable and circular way. Congratulations to them all!”
The winners each received a trophy, with a 3D-printed base made from 100% recycled ABS plastic car dashboards and the multi-colour top which is laser cut from compressed HDPE beach clean-up bottle caps. Open to organisations and individuals across Europe who are involved in the recycling of plastic materials, the Plastics Recycling Awards Europe are organised jointly by Plastics Recyclers Europe (PRE) and Crain Communications, organisers of the Plastics Recycling Show Europe.
Automotive, Electrical or Electronic Product
Volvo Recycled Plastics Demo Car, Volvo Cars Volvo’s demonstration vehicle was lauded for its extensive use of recycled plastics. The recycled plastics demo car by Volvo Cars, demonstrates that recycled plastics deﬁnitely have a place in the automotive industry. The jury lauded Volvo’s pioneering work in this area: a total of 170 plastic components in this demo XC60 were replaced by recycled plastics. A unique accomplishment and deserving of this award.
Plastic Packaging Product
Garçon Wines sustainable 100% rPET, ﬂat wine bottle
62 AUG / SEPT 2019
The sustainable, 100% rPET, ﬂat wine bottle by Garçon Wines and RPC M&H Plastics is an innovative mail order wine bottle that ﬁts through letter boxes. This product ﬁts perfectly with the spirit of our times. The packaging combines convenience and cost-effectiveness with a lightweight sustainable design, ticking all the boxes required in packaging today.
The packaging combines convenience and cost-eﬀectiveness with a lightweight sustainable design
Awards Europe Household & Leisure Product
PBD Collection Bag, Cedo Folien- und Haushaltsprodukte GmbH The PBD drawstring collection bag by Cedo Folien- und Haushaltsprodukte GmbH contains more than 90% certiﬁed post-consumer recycled (PCR) plastic of which more than 40% is ﬂexible packaging. As well as successfully recycling post-consumer plastic, the collection bag is designed to actively encourage the collection of plastic packaging, metal packaging and drink cartons for recycling.
Building & Construction Product
MPO Easy Channel, Multiport GmbH The MPO Easy Channel drainage system by Multiport GmbH makes perfect sense: made from HDPE- and PP packaging waste, it is lightweight, easy to handle and easy to lay. The jury liked the fact that the material was an ideal ﬁt for the purpose and as result successful in the market.
Economical Unbreakable Easy & lightweight
Plastics Recycling Ambassador
Gian De Belder, Procter & Gamble
Gian De Belder is the face of Procter & Gamble’s commitment to sustainable development. He has worked tirelessly to develop solutions to problems such as the recyclability of Opaque and Difﬁcult to Recycle (ODR) household and personal care PET bottles. He is the project leader of Procter & Gamble’s Holy Grail project, which is developing industrywide system for watermark and tracer technology. He has put recycling on the map, both for the industry and consumers and was therefore unanimously voted this year’s Plastics Recycling Ambassador by the jury. AUG / SEPT 2019 63
PLASTIC RECYCLING AWARDS Product Technology Innovation
REC-NIR-BLACK, Ampacet Carbon black packaging waste – trays, clamshells and the like – causes problems in recycling streams, as it cannot be detected by the NIR sensors used by most recyclers. Ampacet Corp has developed black masterbatches that contain no carbon black pigment, rendering them near-infrared (NIR) transparent, and therefore detectable and able to be sorted. Ampacet’s NIR (near-infrared) detectable black colourants are part of the company’s sustainable development programme.
Recycling Machinery Innovation
Cascade® Extrusion System COREMA by INTERSEROH Dienstleistungs GmbH & EREMA Engineering Recycling GmbH
64 AUG / SEPT 2019
The COREMA® Cascade Extrusion System, extrusion line for mechanical recycling of post-consumer thermoplastics by INTERSEROH Dienstleistungs GmbH and EREMA Engineering Recycling Maschinen und Anlagen Ges.m.b.H was recognised by the judges as the most innovative combination of processing technologies that delivers cost-effective recycling of post-consumer plastic to produce high quality plastic material.
Save the date!
The Plastics Recycling Show Europe 2020, from 25-26 March 2020, will be held in RAI Amsterdam, the Netherlands. The Plastics Recycling Show Europe was launched by Crain and Plastics Recyclers Europe as the ﬁrst dedicated exhibition for plastics recycling in mainland Europe. The free to attend conference and exhibition
www.prseventeurope.com has ﬁrmly established itself as the focal point of plastics recycling in Europe. The biggest names in recycled materials, recycling machinery and services will be on display, showing the latest innovation from this exciting industry. The informative and inspiring free conference with key industry ﬁgures will address the latest opportunities
and challenges that face the plastic recycling industry in Europe. The event covers the supply chain from design for recyclability, collection, sorting and recycling of industrial, commercial, agricultural, postconsumer and ocean plastic through to the recycled polymer being designed and incorporated into new products and applications.
“We are what we repeatedly do. Excellence, then, is not an act, but a habit.” -Will Durant
Distributors of :
Black Masterbatch PCS JOHANNESBURG:
ADRIAN VAGLIETTI: 084 786 9428 GLENN ROPPA: 082 416 8352 JARED KHOURY: 071 775 5747 LURIKA VAN STADEN: 083 555 2001 THABANG LECHALABA: 067 027 0785 ULENE GOVENDER: 071 410 0679
COLIN GOUNDER: 071 363 1829 TRACEY MCGEE: 082 316 5518
PCS CAPE TOWN
BARRY SHAW: 083 408 9226 BRETT POLLARD: 082 691 3758
www.performance.co.za PCS EAST LONDON
DAVID BOATWRIGHT: 083 893 4131
JARRED SWART: 082 736 5326
+263 430 5613 TERENCE +263 772 602 339
Labels specialist Greg Petzer joins Packaging World … and now all the world’s his stage LABELS fundi Greg Petzer has joined Packaging World, giving the rapidly expanding Durban ﬂexibles business some extra options. Greg has joined the Westmead-based company run by Dean Gianni long-term with the open-ended goal of ‘growing the business’ – which incidentally is already happening, and has been for some time (Packaging World has been in operation since 1995). Greg is one of the most experienced labels specialists in South Africa, having been the founder of DLC (Diverse Labelling Consultants) way back in ’90. Prior to that – in 1979 – he had been working at a ﬂexible packaging manufacturing business, where he observed that there could be opportunities in the labels sector – and there have been, several in fact. He pioneered the production of shrinksleeve labels as a short-run option, which led to this solution becoming increasingly popular. Later he was to be involved in the development of the wraparound and stretch labels in SA too. DLC’s reputation spread as a result, and attracted corporate attention: the company was bought by Astrapak in 1998. Following that Greg and the DLC team were central parts in a number of other takeovers including ﬂexible packaging companies: DLC
Bernhard Mahl, Plastics|SA chair, will retire at the end of December 2019
Delyce Ririe joins Borealis
Astrapak was successively purchased by Afripack (became Afripack Labels Dean Gianni recently welcomed Greg Petzer DLC), then Constantia Flexibles (another to Packaging World in name change) and most recently, in Westmead, Durban; 2017, when it was purchased by the Greg has been involved global Multi-Color Corporation (yet in the development and production of labels for another name change). close to four decades Greg conﬁrms he’s pleased to have exited the corporate culture and be back where he’s happiest, that of unfettered business development. “I was looking for something new, to bring a slightly different structure to Packaging World,” said Dean. Greg’s move was but a short walk, since his last employer operated from literally around the corner in Gillitts Road, but it was quite a journey up till that point. • Arriving simultaneously at Packaging World is George Dufﬁeld (also from MCC), who has been with Greg in production since 1992. George will be working in production in conjuction Chris Burnard under the management of Gianni and Petzer, so expect interesting things from Packaging World.
Helene Barnard joins Plastics/SA
Leslie Kearney retires after 15 years at Plastics|SA
Vernon Ramiah joins Milliken
66 AUG / SEPT 2019
People on the move Bernhard Mahl, Plastics|SA chair, will retire at the end of December 2019. Mahl, who is currently the chief commercial ofﬁcer at Safripol, has served on the Plastics|SA Board since 2001 and as chairman from September 2005 - 2009 and again November 2016 - 2019. Mahl has given many years of service and dedication to the South African plastics industry. His passion, insight and in-depth knowledge of the industry has helped shape it and guided many individuals through important and difﬁcult decisions. We wish him well with his retirement and future endeavours! Dr Vernon Ramiah has been appointed the territory manager – Sub-Saharan Africa at Milliken & Company based in Johannesburg, effective January 2018. He has been active in the plastics industry since 2004. Prior to joining Milliken & Company, Dr Ramiah was with Performance Colour Systems as
export sales manager, and before that, with Mpact Plastics as new business and market development manager where he was awarded several Mpact Limited awards for his commercial role with the most prominent being their ‘All Stars Award’ in 2014 as well as in 2016. He has also held positions with the Mondi Group and Marmoran. Helène Barnard has joined Plastics|SA as accountant at its Midrand head ofﬁce. Helène will replace Leslie Kearney, who will retire at the end of July 2019. Prior to joining the Plastics|SA team, she worked for the DRA Global Group – an engineering, project delivery and operations management ﬁrm in the mining industry. Leslie Kearney has retired after 15 years at the helm of Plastics|SA’s accounts and ﬁnances. Leslie started work at Plastics|SA in 2004 and has seen many interesting changes and events unfold during that time. She plans to spend more
time on her passions – art and travel. Oratile Matsoati has been appointed group compound technologist at Aberdare Cables in Elandsfontein, Johannesburg, responsible for material (PVC, CLPE, EVA) preparation and additives for cable manufacture. Oratile took over from Sipho Khumalo, who left Aberdare earlier this year. Nadia Tesnar has joined material supplier Somochem in Cape Town. Somochem, part of the Mohinani group of India, has been supplying polymers in Africa for close to four decades, including HD, LD, linear, PET, PS, PVC and chemicals. Delyce Ririe has joined Borealis Polymers as sales manager for South Africa and Southern Africa. Delyce has been in the plastics industry for over 15 years with BASF, and spent the last three years in the automotive production industry.
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KITE ‘019 was no flight of fancy Solutions from automation, control and drive systems suppliers KITE 2019, the KZN Industrial Technology show in July, was exactly as its name suggested: industrial technology was clearly to the fore. Anyone involved in manufacturing, in
off arn showed ’s up – WD He incipal, pr w Got their Taili ne its achines from one of the m ossthwaite, with Myles Cr a, in Ch of ili Ta showing the y le el Sh d Brett Dale Otto an n io in operat 150t machine
KZN or further aﬁeld for that matter, could have done worse than attending: exhibitors included a cross-section of automation, control and drive manufacturers and suppliers.
Of the 160-plus exhibitors, a sizeable portion were South African manufacturers. Even if you weren’t planning to buy, interacting with the exhibitors would have been worthwhile.
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AUG / SEPT 2019
Jeddah’s 1st Industrial City was established in 1971, on a fully developed area of 12-million-m². The city has various necessary facilities, residential units, and support services and logistics, in addition to its strategic location and proximity to the city centre and Jeddah’s Islamic Port, which is the largest port in Saudi Arabia.
‘Nitaqat’ compliance is forcing private Saudi companies to become serious about training
In the plastics industry the pool of technically skilled Saudis is small BY NIALL MARSHALL
70 AUG / SEPT 2019
NE of the largest costs for any plastics converter is labour costs. Not just salaries, but all the costs associated with recruiting, training, employing and retaining valuable employees. In the Middle East, where plastics converters rely on being able to recruit skilled operators on contracts from outside the region, these costs are signiﬁcant. In the Middle East all private sector companies, especially manufacturing, rely heavily on foreign workers. In Saudi Arabia more than 70% of employees in the private sector are foreigners. Initially this was driven by the dramatic growth of the petro-economies following the oil price boom of the early 1970’s, when shortages of certain skills could only be addressed by recruiting foreign workers. The increased wealth of the country meant that the menial work in the inhospitable climate could also be outsourced to foreign workers. In Saudi Arabia almost 30% of the population are expats, but what is often overlooked is that a large number of these expats are domestic workers, drivers or construction workers. Over the years, various factors have continued to contribute to a reliance on foreign workers, including an historical preference among local citizens to take up employment in the public sector, a willingness (and the ﬁnances) of the rulers to create government jobs to employ their citizens, and an education system that was not well suited to training students for the workplace. Private companies have also contributed to this situation by hiring foreign workers
for a fraction of what they would need to pay local citizens to do the same job. But with almost 50% of the Saudi population under 24 years of age and youth unemployment over 24%, it is an unsustainable situation. Just to keep up with the demographics, more than 400 000 jobs need to be created every year – beyond what even the oil-rich Saudi state can afford to absorb in the public sector. With growing populations and lower oil prices, Middle Eastern governments have the additional challenge of increasing government revenues without reducing the beneﬁts enjoyed by their populations (such as subsidised water and electricity, healthcare, housing and education). Most of the GCC countries have introduced VAT in the last few years as well as ‘sin taxes’ on sugar and tobacco. This dual goal of increasing the employment of Saudis and of increasing non-oil government income is being addressed by a combination of ‘localization’ policies and imposing additional fees on foreign employees. Localisation is a requirement that a certain percentage of any company’s workforce should be citizens. In Saudi Arabia the system, known as Nitaqat, introduced a layered approach to quotas. Companies are categorised by their business activity as well as their size and this determines the quota which needs to be met. Companies are rated on their compliance, and non-compliant companies are subject to sanctions, including not being allowed to hire new foreign employees or even renew the work permits of existing employees.
In 2017 the requirements were further amended and companies are rated on the percentage of their employees that are Saudi nationals, what the average salaries are for the Saudis (to ensure that numbers aren’t boosted by employing Saudis in artiﬁcially created low-paid positions) and retention rates. In the plastics industry the pool of technically skilled Saudis is small and even in the private sector qualiﬁed Saudis prefer to work for the petrochemical companies or at large multinationals. Therefore, the smaller converters must rely on foreign operators, many from India or the Philippines, but they still need to comply with Nitaqat and this is where the higher costs of hiring expats is negatively affecting these companies. The cost to the company of the various visas and permits is approximately R41 000 per employee per year, regardless of their position or salary. Skilled employees who qualify for family visas pay an additional R20 000 per year for each dependent that stays with them in Saudi Arabia. This has resulted in many longterm expats sending their families back to their home countries. One possible advantage is that companies have had to become serious about training. This will in time create a larger pool of technically skilled Saudis for the plastics converting industry. However, whether there will be sufﬁcient Saudis to meet the needs of the plastics converting industry, or whether there will still be a large enough plastics converting industry for the trained Saudis, is an open question.
Artist’s impression of the massive new project
KraussMaﬀei-Berstorﬀ building massive new extrusion plant
EXTRSUION technology leader KraussMaffei Berstorff is to build a major new plant for extrusion technology in Hanover, Germany, involving the construction of a 55,000m² production hall and ofﬁce complex. The new location, set on an 80,000m² site in the Laatzen/Rethen Ost business park, will have a state-of-the-art TechCenter, production and ofﬁce facilities and provide space for up to 750 employees. Clear commitment to the Hanover location for the KraussMaffei Group “We are delighted that, with this new building project, we have created the basis for further growth. More than ever, we are committing ourselves to innovation and quality – made in Germany – and Industry 4.0,” said Matthias Sieverding, director of the Extrusion Technology segment in the KraussMaffei Group. “We consciously chose the Hanover region as the location in order to be able to shape the future together with our experienced employees,” Sieverding added. The construction work is scheduled to start this year. KraussMaffei Berstorff plans to have completed the transfer to the new location before the end of 2022.
Arlanxeo seeks to extend global R&D network
ARLANXEO has begun the next phase of its growth plans to expand its R&D efforts into the Kingdom of Saudi Arabia by entering into a collaboration framework with Dhahran Techno Valley Company (DTVC), a company wholly owned by KFUPM, the Kingdom’s foremost academic institution for oil and gas. The two will work together to develop products and applications relevant for Arlanxeo’s elastomers businesses. Such collaboration will be centred in a technical R&D centre to be established by Arlanxeo in Dhahran Techno Valley, Saudi Arabia. www.arlanxeo.com
Covestro Full throttle Testing innovative materials for electromobility
A highly motivated team of students from RWTH Aachen University and FH Aachen is currently developing an electric car powered by solar energy that will compete in the world’s toughest solar car race – the Bridgestone World Solar Challenge 2019. Covestro is supporting the new Sonnenwagen project with innovative materials, technical services and as main sponsor. Following the initial successful participation at the race in Australia 2017 as ‘Best Newcomer’ and the third place at the European Solar Challenge 2018, the
Floating wind farms Plastic-concrete hybrid system to improve the buoyancy of wind turbines
THE Flotant project is developing a plastic-concrete hybrid system to improve the buoyancy of wind turbines, as well as materials that are more lightweight and resistant to the marine environment. These developments are expected to reduce installation and maintenance costs by over 50%. When there are no offshore locations far enough from the coast at the right water depth (less than 60 metres) where the wind turbine can be anchored directly to the seabed, more expensive systems must be used such as mooring, anchoring and floating structures. To provide a solution to these problems, Aimplas, the Plastics Technology Centre, is participating in the Flotant project that aims to develop a solution for installing marine wind farms in water depths of 100 to 600 metres, with installation and maintenance costs that are 55% to 60% lower than at present.
Flotant, which began in April 2019, is framed within the European Horizon 2020 programme and will last 36 months. The solutions developed in this project will make it possible to install wind turbines of more than 10 MW thanks to an anchoring system made of high-performance polymers that will reduce platform movements. This solution will consist of a plasticconcrete hybrid floating system, dynamic lightweight wiring and a highperformance power export system. The project has chosen three different environments to install three prototypes: dynamic testing equipment for marine components used in the anchoring and power export systems, a tank that simulates marine conditions for the prototype of the comprehensive system, and the Port of Taliarte (Gran Canaria) for characterization of the new polymeric materials under real marine conditions. Aimplas’s role in the project is
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Sonnenwagen: with solar power team now wants to build on these experiences and challenge the next step at the World Solar Challenge 2019. Covestro shares the students’ enthusiasm and will work with them to push the boundaries of that which is possible and make the project a success. The primary objective is to test new materials under the extreme climatic conditions of the track.
One of Covestro’s forward-looking goals is to support automotive concepts in which vehicles generate energy while in motion. Another objective is to test materials that could later be used in other applications. Covestro is also promoting young talent with this project. www.covestro.com
in deeper water
Erema bosses honoured for recycling innovations
mainly to develop and optimize the anchoring, wiring and floatation system through the development of thermoplastic
THE European Inventor Award 2019 has been presented to Erema of Austria for its development of ‘efﬁcient and high-quality plastic recycling technology’. The award was presented to Manfred Hackl (left) and Klaus Feichtinger of Erema for their development of ‘new technology capable of efﬁciently sorting and separating plastics, meaning less waste and more new plastics available for production’. Their recycling machines move, sort and ﬁlter plastic matter, delivering a high-quality pellet at the end that will be used to create new products. In particular, Erema’s patented Counter Current technology was praised for allowing a wider variety of plastic waste to be recovered for industrial reuse with a quality that is ‘indistinguishable from virgin plastics’. In the Counter Current process, waste material enters an extruder and is rotated in the opposing direction to the ﬂow of the extruder screw. This allows for more waste material to be processed at faster rates than previously possible and at lower temperatures. The technology, based on an idea ﬁrst quickly sketched out by Feichtinger, is a crucial part of the inventors’ recycling machines and is protected by several European patents.
and thermoset materials with antifouling and antibite properties.
‘Counter Current’ technology singled out for praise
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World News Top 10 dominate USA’s ‘Top 100’ injection list
A STUDY by the publication Plastics News in the USA made some interesting ﬁndings about the injection moulding sector in North America: set out to list the top 100 injection moulding businesses in the region, the researchers found that the businesses had combined moulding sales of $29,1-billion (R415-billion) and, surprisingly, that the top 10 make up 34% of the revenue. The average sales per ﬁrm is $284.7-million (R4,062billion), holding steady compared with last year. The general trend in automotive was down, although a few ﬁrms managed to grow. Medical moulders also grew. For those ﬁrms reporting growth at the top 100, the average increase was 15 percent. The ﬁgure rises to 23% if acquisition-related growth is included. Six percent of the top 100 executives in this list are women.
Ineos invests £1bn in UK vinyl acetate plant
UNITED Kingdom energy company Ineos will invest £1-billion in its UK operations, of which £150-million will be allocated to a new vinyl acetate monomer (VAM) plant. The company is planning to build a 300 kiloton per annum plant in Hull, England, to ‘bring production of an important raw material back to the UK’. VAM is a key component in a wide range of high-end products including laminated windshields, toughened glass, adhesives, coatings, ﬁlms, textiles and carbon ﬁbre.
BASF to cut 6 000 jobs
Chemical giant BASF will launch an ‘organizational realignment’ through 2021 which will see it cut up to 6 000 jobs, largely come from the administrative division. As part of the changes, about 29 000 employees around the world will be tasked with working in cross-functional service units, billed as global engineering services, global digital services and global procurement. The company expects annual savings of €300 million ($338.6 million) upon completion of the project, which will result in a €2 billion ($2.26 billion) increase of anticipated earnings from the end of 2021.
Additive manufacturing is not only changing the way companies think about products, Rietzel said, but also how they create their business models. A prime example of this is BMW’s Mini Yours Customised project, where consumers are able to customise and personalise various components, such as side scuttles and cockpit fascias, that are then 3D printed by the automaker
BMW sees potential of
3D printing in new business models Additive manufacturing might change way cars or components are produced AS additive manufacturing matures, improvements in the technology can help companies to create economies of scale, but only if material costs are low. That was a point made by Dominik Rietzel, head of additive manufacturing in the non-metals division at BMW Group, during a keynote presentation at the Rapid + TCT trade show, held in May in Detroit. The German automaker identiﬁed eight important topics that are transforming automotive production such as smart data and analytics, automation, lightweight construction, electriﬁed powertrains and additive manufacturing. “We believe that additive manufacturing might change the way that we could produce our cars or components in the future in a dramatic way,” Rietzel said. BMW has been innovating in the ﬁeld of prototyping for decades and is using 3D printing to produce foam-like prototype parts that mimic the real foam parts used in seats and dashboards. But for series production, especially in automotive, reliability is key. That’s part of the reason why BMW developed its own additive manufacturing readiness levels, which is
essentially a generic approach to using the technology and validating 3D printed parts. It’s also something BMW openly shares with its suppliers. Changing the process Additive manufacturing is not only changing the way companies think about products, Rietzel said, but also how they create their business models. A prime example of this is BMW’s Mini Yours Customised project, where consumers are able to customise and personalise various components, such as side scuttles and cockpit fascias, that are then 3D printed by the automaker. For the project, Rietzel said BMW is using an automated production cell with two robots and two M2 printers from Carbon. With automation, the company can produce 504 pieces per week on each machine vs 120 pieces in a manual production setup. The research that went into automating that process is part of a big-picture view for how BMW is working to improve additive manufacturing for applications in the future. Rietzel said the automaker has started an initiative on additive manufacturing across the whole group, including production, design, engineering and IT departments.
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Will the EU miss its 2025 PET recycling target? Study reveals challenges with PET bottle collection
THE European recycling industry will miss a 2025 target for recycling PET bottles unless there is a reversal of the slowing growth rate in recycling, according to a new study by ICIS. In March, the European Parliament adopted the Commission-proposed Single-Use Plastics (SUP) Directive to increase the recycling of PET. The ICIS study on the 2018 market, looked at the supply chain: collection, recycling and end-use of PET. It concluded that the PET bottle collection rate in Western Europe rose from 58% in 2016 to 63% in 2018 and is projected to reach 65% in 2019. Under the SUP Directive, the industry must reach recovery rates of 77% by 2025 and 90% by 2029, but the collection volume growth rate is currently falling. ICIS estimates that the volume of collected material will need to increase by 7% per annum if the
2029 target is to be met. Helen McGeough, ICIS senior analyst, explained the dynamics. “The rise in demand for rPET began early in 2018 as supply issues for virgin PET resin carried over from the end of 2017. This pushed up demand from sectors that could easily use either feedstock. This in turn pushed up prices as supply was constrained, since collection activity did not increase in line with demand. The drive for foodgrade rPET came later in 2018, once the SUP Directive was passed. “Despite the boost in demand for rPET, collection failed to match those growth rates, reaching 2.1 million tons in 2018 – just a 2.4% growth on 2017 volumes. Tight supply saw PET bale prices rise 20% in 2018, compounded by the growth in reclamation capacity during the year that expanded to meet the downstream demand for rPET products.
“The reclamation industry increased production of rPET products by 17% to 1.4 million tons and packaging applications absorbed two-thirds of that total. The capacity of food-grade rPET barely had time to build prior to the rush of supply enquires following the signing of the SUP Directive. As a result of the Directive, there was an increase of 13% in food grade rPET prices, which were generally accepted as these prices sat only 7% higher (on average) than virgin PET prices. However, this has changed considerably in 2019, with premiums of over 30% on average, peaking at near 50% so far this year.” Looking ahead, collection volumes are projected to grow by less than 4% per annum over 2019-2020. If this growth rate is sustained in the longer term, the SUP Directive recovery targets will not be met. AUG / SEPT 2019
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World News East Timor to become world’s ﬁrst plasticneutral country
EAST Timor is set to become the world’s ﬁrst country to recycle all its plastic waste after it teamed up with Australia to build a revolutionary recycling plant. The US$40-million plant will ensure that no plastic, once used in the Southeast Asian nation, would become waste, but would instead be turned into new products. Australia’s Mura Technology have established a non-proﬁt called RESPECT that will run the plastic recycling plant, expected to commence by the end of 2020. In many parts of Asia, fast-growing economies and populations, coupled with huge coastlines and densely populated cities, have ﬁlled local seas with trash and plastic waste. The new plant will use chemical technology that quickly turns plastic waste into liquid or gas without adding mineral oil, which no other recycler can do as well. Run at no cost to Asia’s youngest democracy, all proﬁts will go toward supporting community projects and waste collectors in East Timor, which must ﬁrst ﬁnd funding to build the recycling facility. The same technology is currently planned for other recycling plants in Canada, Australia and Britain. If successful, RESPECT will be used as a model for other developing countries suffocating in plastic waste.
Engel posts higher sales despite auto slowdown
AUSTRIAN injection moulding machinery maker Engel Holding GmbH has seen its sales rise 6% year-overyear to €1.6-billion for the ﬁscal year to end-March, but it warned of a global slowdown in its biggest end market. The company said it had noticed a worldwide decline in production since last summer. “It is difﬁcult to gauge the impacts of punitive tariffs and sanctions, Brexit and the debate around regulatory limits and bans on diesel, which has resulted globally in feelings of uncertainty and a reluctance to buy,” Engel said. In China, the automotive slowdown accounted for ‘a signiﬁcant share of the decrease’ in economic growth, according to Gero Willmeroth, president for East Asia and Oceania at Engel. “Overall, we’re expecting a sideways movement for Asia for the current ﬁscal year,” Willmeroth added. Europe remains Engel’s largest overall sales region, accounting for 54% of sales. Asia accounted for 21% and the Americas another 24%.
Berry of USA completes
purchase of RPC 290 locations, 48,000 employees
BERRY Global Group completed its acquisition of RPC Group Plc for a purchase price of approximately $6,5-billion, which includes approximately $4,3-billion cash paid for the equity interest in RPC and $2,2-billion of net debt and estimated transaction related costs, subject to closing adjustments. The combination of Berry and RPC creates a leading global supplier of valued-added protective solutions and one of the world’s largest plastic packaging companies. Berry’s combined global footprint will consist of over 290 locations worldwide, including locations in North and South America, Europe, Asia, Africa and Australia. The combined business will employ over 48 000 people across six continents with sales of approximately $13-billion based on the latest published ﬁnancial statements of Berry and RPC. The acquisition of RPC was ﬁnanced with a portion of the proceeds of Berry’s sale (in May) of $1,25-billion of 4.875% ﬁrst priority senior secured notes due 2026 and $500-million; of 5,625% second priority senior secured notes due 2026; as well as a $4,25-billion incremental term loan and a €1,075-billion incremental term loan, which also served to reﬁnance an existing Berry term loan. www.berryglobal.com
Colgate recyclable toothpaste tube COLGATE has ﬁnalised the design for a ﬁrst-of-its kind recyclable toothpaste tube that sets a new standard in the industry. Most toothpaste tubes are made from sheets of plastic laminate sandwiched around a thin layer of aluminium that protects the toothpaste’s ﬂavour and ﬂuoride, but is impossible to recycle through conventional methods. To make a recyclable tube, Colgate chose HDPE. But because HDPE is rigid, it isn’t well suited for ultra-thin laminate sheets and soft, squeezable tubes. Colgate’s ‘eureka moment’ came when their packaging engineers recognised that they could use more than one grade of HDPE in their designs. The team then tested a dozen different combinations – using from 6 to 20 layers – to ﬁnd the recipe that allows people to comfortably squeeze out all the toothpaste, protects the integrity of the product, and meets the demands of high-speed production.
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– innovative and sustainable BASF, Borealis, Südpack, Zott prototypes of food packaging made from 100% recycled material MULTILAYER packaging is sustainable: it does not require much material and can now also be produced from chemically recycled material. “Today’s high-tech ﬁlm packaging solutions consist of multiple materials and layers with different properties, such as an oxygen barrier. And thanks to the optimized use of materials, we were able to reduce the packaging volume to a minimum,” said Johannes Remmele, MD of Südpack. “Within the ChemCycling project, BASF is working on advancing the chemical recycling of plastic waste, because this will make it possible to process and reuse previously non-recyclable plastics such as mixed plastics. In collaboration with our partners, we have now for the ﬁrst time produced a prototype packaging made of chemically recycled polyamide and polyethylene. This goes to show that the recycling of multilayer packaging could soon come full circle,” explained Christoph Gahn, who is responsible for the polyamide business at BASF. This pilot project was made possible thanks to the collaboration between the four partners BASF, Borealis, Südpack and Zott. BASF supplies chemically recycled polyamide, while Borealis provides sustainably produced polyethylene. Südpack, one of Europe’s leading producers of ﬁlm packaging for food products, uses these materials to produce multilayer ﬁlm for a specially sealed Mozzarella packaging for Zott Gourmet Dairy. In addition, the collaboration between the companies involved made it possible for the ﬁrst time to consistently certify each step up from the raw material to the ﬁnished packaging. The raw materials for polyamide and polyethylene were produced in very small quantities as part of the ChemCycling project. The pyrolysis oil derived from plastic waste was supplied by a partner and fed into BASF’s Verbund production site in Ludwigshafen as feedstock. According to the certiﬁed mass balance method, both plastics have an allocated 100% share of recycled materials.
SILICON Valley based company Carbon has developed Digital Light Synthesis™ (DLS™) technology, which can accelerate the production of parts up to a hundredfold compared to previous processes. After years of R&D, Carbon developed a novel polyurethane liquid resin suitable for production parts. Covestro is a key partner in the scale-up and high-volume production of this material. The company invested a signiﬁcant sum to enable the production in commercial quantity. “Our biggest challenge in the upscaling of additive manufacturing until series production lies in the supply of suitable materials in the required quality and quantity,” explains Patrick Rosso, global head of additive manufacturing at Covestro. “By partnering with companies like Carbon, we are pushing existing scale boundaries and supporting various industries along the value chain on their way to digital mass production.” www.covestro.com
3D printing on the road to mass production
Hillenbrand to buy Milacron in $2 billion deal HILLENBRAND Inc, the Batesville-based parent company of compounding extruder maker Coperion and auxiliary equipment ﬁrms K-Tron and Rotex, is buying Milacron Holdings Corp in a cash and stock deal valued at about $2 billion. Executives of both companies said one key area will be in extruders, making a combined, stronger and more diversiﬁed company. Both companies also generate about one-third of their machinery-related sales from aftermarket spare parts and service – so-called ‘consumables’, or business that brings in steadier sales than capital machinery. Only about 35% of the total Milacron portfolio is sensitive to cycles thanks to the Mold-Masters hot runner, DME mould-component and metal-cutting ﬂuids businesses.
Milacron sells Uniloy
MILACRON Holdings Corp, one of the most widely diversiﬁed USA machinery manufacturing groups, sold its Uniloy blow moulding machinery business to two private equity ﬁrms in July, for $51,9-million. The deal so far involved only the Uniloy’s US and European operations, with the businesses in Mexico and India expected to follow. The new owners are to transfer Uniloy’s US production from Milacron’s factory in Ohio to Uniloy’s global headquarters in Michigan where the manufacturing will join Uniloy’s mould making operations. JUNE / JULY 20137777 AUG / SEPT 2019
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World News Multi-layered material can self-heal
NASA researchers have reportedly developed a multi-layered self-healing material that can mitigate the impact from ballistic or hypervelocity events such as micrometeoroids or orbital debris. The system is constructed in a tri-layered structure, comprising a solid plastic front and back layers sandwiching a viscous, reactive liquid middle layer. Self-healing in the front and back layers occurs when the puncture event creates a melt state in the polymer materials and the materials melt elasticity snaps back and closes the hole. The viscous middle layer can increase the self-healing properties of the other layers by ﬂowing into the gap created by a ballistic puncture and concurrently solidifying due to the presence of oxygen. Thus, this innovation has two tiers of self-healing: a puncturehealing mechanism triggered by the projectile and a second mechanism triggered by the presence of oxygen, NASA says. While developed with space exploration in mind, the innovation has many other applications, such as fuel tanks and hydraulic insulation, NASA adds. According to the organization, the material has selfhealing capability over a wide range of temperatures and could be tailored for use in structural load-bearing applications.
Plastics machinery shipments decline in ﬁrst quarter
THE shipments value of primary plastics machinery in North America declined in the ﬁrst quarter of 2019, according to the statistics compiled and reported by the Plastics Industry Association’s Committee on Equipment Statistics. While 2018 ended with strong plastics machinery shipments, 2019 has started soft, with the preliminary estimate of the shipments value from reporting companies totalling $273 million, 27.6% lower than the fourth quarter of 2018. Injection moulding shipments fell 26.3% and single and twin extrusion shipments decreased 24.8% and 46.2% respectively. Year over year, the value of shipments for single and twin screw extrusion equipment rose 19.8% and 8.3% respectively. 78 JULY 2019 2013 78 JUNE AUG // SEPT
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ExxonMobil, SABIC in
massive project in Texas EXXONMOBIL and SABIC are undertaking the construction of a chemical facility and 1,8 million tons p/a ethane cracker in San Patricio County, Texas, in what is reputed to be the world’s largest steam cracker, the partners said in a statement on 13 June. “Building the world’s largest steam cracker, with state-of-the-art technology, on the doorstep of rapidly growing Permian production gives this project signiﬁcant scale and feedstock advantages,” said Darren Woods, chairman and chief executive ofﬁcer of ExxonMobil. “It is one of several key projects that provide the foundation for signiﬁcantly increasing the company’s earnings potential.” The joint-venture between ExxonMobil and SABIC, called Gulf Coast Growth Ventures, received ﬁnal environmental regulatory approval in June to build an ethane steam cracker, two polyethylene units and a monoethylene glycol unit. Construction will begin in the third quarter of 2019 and startup is anticipated by 2022. “SABIC is very pleased to move forward on this third joint venture with ExxonMobil, the ﬁrst to be operated outside of Saudi Arabia,” said SABIC vice chairman and CEO Yousef AlBenyan. “This project will not only increase global diversiﬁcation for our company, but will also continue to create value within our new home of San Patricio County through creating jobs and supporting economic growth. With this project, we look forward to further building our business presence in the US and serving the communities and customers in the North and South American markets even more effectively.” www.corporate.exxonmobil.com
The project is expected to create more than 600 permanent jobs with average annual salaries of $90,000 per year. An additional 6,000 high-paying jobs will be created during construction. A preliminary independent study, conducted by Impact DataSource, estimates the project will generate more than $22-billion in economic output during construction and $50 billion in economic beneﬁts during the ﬁrst six years of operation. The facility will produce materials used in the manufacturing of various consumer products including automotive coolants, packaging, agricultural ﬁlm and building, construction materials and clothing. Project construction will be led by four primary engineering, procurement and construction companies: The Wood Group, McDermott & Turner Industries Group, Chiyoda & Kiewit and Mitsubishi Heavy Industries & Zachry Group. Gulf Coast Growth Ventures is a unique opportunity created by the abundance of low-cost US natural gas and is part of ExxonMobil’s Growing the Gulf initiative initiative, which outlined plans to build and expand manufacturing facilities along the US Gulf Coast, creating more than 45,000 high-paying jobs across the region. The project is part of SABIC’s growth strategy to build new petrochemical facilities in key markets, including the Americas, to address industry demand and achieve the company’s 2025 strategy. Ownership interests in the Gulf Coast Growth Ventures project is 50% ExxonMobil and 50% SABIC, with ExxonMobil as site operator. www.sabic.com
Unilever committed to using 25% PCR in all packaging by 2025 By Jim Johnson, PlasticsNews.com
SUSTAINABILITY can require compromise. For global consumer goods maker Unilever, that’s just ﬁne. “Our goal is 100% recyclability and we’re working hard on it every single day. If that means that we need to change a packaging type, we will be changing a packaging type,” said Melissa Craig, senior manager of packaging sustainability for Unilever in North America. “We know that ﬂexibles are a big problem. We use ﬂexibles. We are working on it every single day. That’s probably 80% of my job right now,” she said. Unilever recently made headlines through news that its Hellmann’s brand mayonnaise containers in the United States are transitioning to 100% recycled PET by the end of this year. “We’re compromising all the time with all of our products that have postconsumer resin,” she said. Compromise could mean a slightly different tint to plastic packaging or maybe some black specks in the resin. One way the company assures that compromise does not go too far is by
working with packaging suppliers to set guidelines about how much variation is acceptable, Craig said. Packaging makers know that if a run of bottles ends up being too dark, for example, they just will not send those along. This is really no different than working with packaging suppliers using virgin resin: There are guidelines that must be followed. Unilever has committed to using 25% PCR in its overall packaging by 2025 around the world. “I’m happy to say that we’ve accelerated that in North America and by the end of this year, 50% in North America will be PCR,” Craig said. Switching to PCR for mayonnaise containers was especially challenging because of the white colour of the product. The company also wanted to make sure that the bottle colour did not make the product look unappealing to consumers. “We believe that businesses and brands can play a part,” she said. “We have a very simple purpose and that’s to make sustainable living commonplace,” Craig added. www.unilever.com
World’s ﬁrst facility converting plastic waste to wax in Ireland THE world’s ﬁrst facility to convert plastic waste into wax has opened in County Laois in Ireland following a €12 million investment by backers. The company, Trifol, produces ecofriendly wax from 100% plastic waste. It can be used across a variety of industries, from personal cosmetics to candles and chewing gum. The company can also produce wax ingredients for the production of synthetic lubricants. The company can process more than 50% of all plastic waste including polyethylene and polypropylene. The product, EnviroWax, removes up to two tons of plastic waste for each ton of wax produced. The plant has the capacity to produce up to 3 500 tons of wax in its ﬁrst phase and hopes to double that after the ﬁrst quarter of 2020. Trifol’s patented processes follow research at Queen’s University Belfast and subsequent testing at the University of Limerick. The company has been awarded three patents by the UK patent ofﬁce for its process. Patents have been ﬁled and are awaiting grant approval by the EU and US patent ofﬁces.
Cambodia to send plastic waste back to US & Canada
CAMBODIA says it will send 1 600 tons of plastic waste found in shipping containers back to the US and Canada, as Southeast Asian countries revolt against an onslaught of rubbish shipments. Eighty-three shipping containers full of rubbish were found at Sihanoukville, Cambodia’s main port: 70 of the containers were shipped from the US and 13 came from Canada. Both countries are major exporters of such waste. “Cambodia is not a dustbin where foreign countries can dispose of out-of-date e-waste, and the government also opposes any import of plastic waste and lubricants to be recycled in this country,” said a spokesman for the country’s environment minister. A government committee established to look into the matter will investigate how and why the containers ended up in Cambodia. Any company found to be involved in bringing in the waste would be ﬁned and brought to court.
Covestro products in a new light
THE new Covestro Solution Centre is online: a key component of Covestro’s digitalization strategy. In the new Covestro Solution Centre, more than 2 000 Covestro products can be accessed via an intelligent search, which also includes numerous technical product features. Customers can ﬁlter by product characteristics or application areas and compare products side by side, as well as application examples. The new website www. solutions.covestro.com is strictly focused on the needs of the customers and supports them in all phases – from the initial idea to ordering the product. In the Covestro Solution Centre, customers can see all product features and examples of applications, download data sheets, compare products, make service requests, inquire samples, ﬁnd the right contact persons and contact Covestro directly. AUG / SEPT 2019
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Unilever says sustainability needs some compromise Unilever’s Hellmann’s mayonaisse is its ﬁrst brand to move to all recycled packaging for its bottles
It makes no sense to pay good money for bad products Enforced certiﬁcation will condemn nonconforming polymers in thermoplastic pipes By MIKE SMART, Pr. Eng., B.Sc. (Hons) Civ. Eng.,
50-year minimum design life requirement – certainly not 100 years’ service life. Construction industry contracts contain FIFTY years ago, 1969 was an eventful clauses that address the issues of latent year which included the Apollo 11 and patent defects and a ‘maintenance moon landing, LGBT Stonewall riots, period’, usually one year, during which Woodstock Music Festival … and my time retention money is withheld to graduation. The Woodstock organisers meet any corrective action expenses estimated a maximum of about 200 incurred by the client. Therefore, the 000 people would attend; 186 000 standard of the work is measured with tickets had been sold. In the end, over 1 respect to time and any unacceptably million people tried to get there! As one rapid deterioration is condemned and reporter wrote, “It’s like watching God penalised. Contractors, faced with claims perform the Creation”. Who can ever and costs under these circumstances, forget Crosby, Stills, Nash and Young are increasingly turning to their suppliers opening with ‘Suit Judy Blue Eyes’ – we for compensation (money) to meet these thought we’d died and gone to heaven! costs, which are often substantial. Which brings me to my point – quality A supplier’s recourse when caught lasts! between an irate contractor and an Fifty years is the minimum design life unscrupulous manufacturer is to of all thermoplastic pipes and ensure conformance of the ﬁttings as speciﬁed by ISO “There material to the applicable (International Standards will always SANS (South African Organisation) protocol. be somebody who National Standard), by This notwithstanding, can make something demanding test data customers now demand cheaper and worse from the manufacturer a service life of not less than somebody else and, if necessary, having than 100 years for their tests conducted at a substantial investment – the fool is this competent test laboratory. in infrastructural assets – man’s fair Quality is driven by the maybe ISO needs to revise game.” customer and whomever pays its protocol. Every polymer for the material decides the quality has a unique ﬁngerprint, called of what they buy – it makes no sense to the ‘Creep Rupture Regression Curves’ pay good money for bad products. (CRRC), based on many thousands of Furthermore, the addition of outsourced tests to failure over thousands of hours recycled scrap material of unknown origin for a range of temperatures. Fifty years carries with it another risk – contamination ago, we designed for ‘one generation’, of the potable water conveyed by the pipe. deﬁned as 40 years! This risk has the potential to be severe The CRRC for the latest polymers when, for example, the origin of the scrap prove they will achieve 100-years’ service recycled HDPE pipe is an old slurry life - and more. However, if the quality of pipeline from a gold mining operation the polymer is compromised in any way, that used cyanide solution techniques to for example with the addition of a cheaper extract the gold from the reef rock. nonconforming polymer or nonconforming Policing the use of recycled material recycled material, the performance in thermoplastic pipe extrusion requirements will not be achieved, resulting in premature failure before the manufacturing operations is difﬁcult.
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However, just as the ‘cheat-police’ in sport take time to catch-up with and apprehend the cheaters; likewise the plastics industry has caught-up with cheaters and now has a detection mechanism at its disposal that will identify, condemn and preclude any dangerous material in products that is detrimental to the health of the consumer. SAPPMA (Southern African Plastic Pipe Manufacturers Association) has forged a relationship with NSF International, a global, independent, public health and safety organisation that has become a member a SAPPMA member. NSF’s mission is “protecting and improving human health” through various mechanisms, including certiﬁcation in 168 countries. Since its inception, SAPPMA, whose fundamental premise is the improvement and maintenance of quality, has sort to detect and condemn nonconforming polymers in thermoplastic pipes – a ongoing process. Since 1988, NSF 61 Certiﬁcation for a product “assures that no harmful chemicals are leached from the products into the drinking water”, by checking “the toxicity and health effects evaluation” of anything that comes into contact with drinking water. Herein lies a mechanism to detect, identify and expose unscrupulous manufacturers who consider proﬁt above consumers’ health. And maybe, following litigation and conviction, possibly for extremely serious offences such as manslaughter, manufacturers who wilfully endanger the lives of unwitting users of their products in the pursuit of proﬁt will reconsider the true cost of their ill-gotten gains. With enforced certiﬁcation for all manufacturers of products that come into contact with the drinking water that comes into your home, it will be truly potable. Then you’ll be able to listen to Jimi Hendrix belting out ‘Purple Haze’ for another 50 years – well, some of you will.
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Diary INTERNATIONAL CONFERENCE ON COMPOSITES IN MELBOURNE
THE 22nd International Conference on Composites Materials (ICCM22) will be held in Melbourne, Australia, from 11-16 August. ICCM is the premier international conference in the ﬁeld of composite materials, and covers polymer matrix composites, metal matrix composites, ceramic matrix composites, natural ﬁbre composites, ﬁbre metal laminates, ﬁbres and resins and all the other classes of composites. ICCM22 provides a forum for the presentation, exchange and discussion of the latest research into composite materials and their applications. The conference theme for the ICCM22 is ‘Advanced Composites: Research to Impact’, with the objective of exploring the latest research into composite materials and how they will be used in the future covering multiple applications including aerospace, construction, wind energy, automotive, electronics and so on. ICCM22 includes plenary talks, keynote lectures, oral and poster presentations, site visits, and an entertaining social programme for delegates from around the world. Melbourne, an international gateway to the rest of Australia, is a fantastic, vibrant, safe and clean city and welcomes you warmly to ICCM22. https://iccm22.com/
COMPOSITES IN CONSTRUCTION CONFERENCE ADVANCED Composites in Construction returns for its ninth edition in 2019 at the University of Birmingham, England, from 3-5 September focusing on current topics within the construction industry with the purpose of highlighting the use of ﬁbre reinforced polymer (FRP) composite materials in new and existing all-FRP structures as well as strengthening, refurbishment and reinforcement applications in traditional infrastructure. This three-day event attracts practicing engineers, asset managers, researchers and representatives of regulatory bodies and promotes an active exchange of scientiﬁc and technical information on the rapidly changing scene of advanced composites in construction. https://acic-conference.com/
INT’L FORUM FOR MASTERBATCH INDUSTRY IN VIENNA THE 32nd edition of AMI’s Masterbatch Conference will take place at the Austria Trend Hotel Savoyen in Vienna, Austria, from 10-12 September. Despite volatility and increased maturity, the masterbatch business in Europe continues to be one of the most innovative and dynamic in the whole plastics market. The conference will also focus on business issues including the circular economy and sustainability issues impacting demand as well as the way in which changing customer needs will inﬂuence strategy. Trends in new resin formulations, downgauging and recycling all require clever additives and pigments to maintain performance and aesthetics – which convertors increasingly look to the masterbatch industry to deliver in a cost-effective way. The conference includes speakers from Gabriel-Chemie, Venator, Orion Engineered Carbons, Kunststoff Kemi, Hayat Kimya and Euroﬁns Consumer Product Testing. www.ami.international
SAPPMA’S PIPES XII Two days packed with back-to-back presentations about industry
THE biennial PIPES Conference, hosted by the Southern African Plastic Pipe Manufacturer’s Association (SAPPMA) plays an important role in ensuring that the South African plastic pipe industry is kept up to date with the latest international developments and best in class methods when it comes to pipe manufacturing, pipeline design and installation. This year’s PIPES XII Conference takes place from 27-28 August at the Altron Business Park in Midrand. As with previous years, it once again promises to give delegates exposure to local and international speakers who were invited to share their expertise around the conference theme, ‘Not all plastics are alike’. “It is part of SAPPMA’s mandate to share knowledge and to ensure that all industry role-players have access to the latest information when it comes to quality standards that govern
the manufacturing and installation of high-performance plastic pipes and pipe systems, as well as about new product development, advancements made in production and installation methods, research ﬁndings and case studies,” says Jan Venter, CEO of SAPPMA
Manufacturing – an event for Africans,
THE Manufacturing Indaba held in June in Sandton – just one of three conference and exhibitions held around the country – saw 75 speakers, 17 technical workshops, over 2600 visitors and 112 exhibition stands. The Manufacturing Indaba is the leading
manufacturing event in Sub-Saharan Africa. The two-day event has shown impressive growth year-on-year and has proved its value in catalysing business connections and helping manufacturers to innovate and grow their potential. The exhibition provides an opportunity for
John McEwan and Liza du Plessis answered questions from interested parties on the PtSA operation
Robert Bosch was on the Rubbernano Products stand
82 AUG / SEPT 2019
Conference 2019 expertise, innovation and case studies
Thinking Ian Venter (SAPPMA): Thermoplastic materials for pipes and ﬁttings for pressure applications – classiﬁcation and designation; overall service (design) coefﬁcient • Mike Smart (Genesis Consulting): PVC-O Pipe Fittings Developments • Jacques van Eck (Avesco): Ensuring Quality Thermoplastic Piping Systems • Anders Nystrand (Uponor Infra Oy): A Weholite Journey • George Diliyannis (Safripol): Post-consumer recycled material – the effects on key performance characteristics of HDPE pressure pipe • Alaster Goyns (Pipes cc): Combined effect of internal pressures and external loads on low-pressure pipelines • Marco Camarda (Trenchless Technologies): Hammanskraal Pipe Reaming “According to the results of the latest merSETA Plastics Chamber
little development and innovation and being slow in adopting new technologies’. “For this reason, we are encouraging our industry role-players and other interested parties to attend this year’s conference, actively take part in the lively question and answer sessions after each presentation, visit the stands and make use of this opportunity to network, build contacts and learn from the best in the ﬁeld. Development, innovation and adapting to new technologies is vital to the future of our industry,” concludes Venter. Main sponsors for the conference include PipeFlo, Sizabanto Piping Systems, Rare Plastics, Sun Ace SA and NSF International. www.sappma.co.za
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This year’s PIPES XII speaker line-up has been chosen to cover exactly these topics and more, with speakers including • Dr Roelof Botha: Economist • Stefan Schiesser (Borealis): Polyoleﬁns in pipe: More than 50 years innovation track record • Marco van Dijk (University of Pretoria): Hydraulic capacity – the inﬂuencing factors • Onno Fortuin (Onno Fortuin Consulting): Vryburg Outfall Sewer – Practical solutions for a challenging environment • Albert Lueghamer (Agru): Advanced technologies in large diameter piping systems for offshore and onshore installations • Renier Snyman (Sun Ace): Advancements in impact modiﬁcation of PVC pipes • Antoine Walter (GF Piping Systems): Applied NDT – How an algorithmic quality assessment provides grid owners with absolute certainty on their piping system life-time expectancy. • Kirtida Bhana (Plastics SA): Design
Development, innovation and adapting to new Research 2018/19, technologies is vital the South African pipe-manufacturing/ to the future of sub-sector is facing our industry. criticism for ‘having
Indaba by Africans
manufacturers to showcase their expertise, network with industry peers and meet business suppliers. Share your product or service with an industry relevant audience of decision-makers. Several plastics industry representatives exhibited. www.manufacturingindaba.co.za Jason de Bock Technical Applications of Multitrade Distributors advising on total tooling solutions PHOTO’S by Lowrie Sharp CONSULTING (Pty) Ltd.
Representative in Africa
+27 (0)82-651 3315 firstname.lastname@example.org www.labotek.com
PROPAK WEST AFRICA 2019 IN LAGOS IN SEPT PROPAK West Africa will be held at the Landmark Centre in Lagos, Nigeria, from 17-19 September, this region’s largest gathering for everyone in the printing, packaging and plastics industry. Propak West Africa provides those that visit the opportunity see ﬁrst-hand the products and solutions available on the global market place and with 32 countries represented in 2018 and many more expected in 2019. The free-to-attend conference will once more take place alongside the main exhibition. Be prepared to hear senior representatives from a number of the industry’s leading brands and businesses as they unveil exclusive market insights, technology trends and crucial advice on how to take your business to the next level. Exhibiting will be companies within the packaging, plastics, manufacturing and processing sectors. With the intricate cross over between the different sectors, having them all represented under one roof provides the perfect opportunity for you to procure your supply chain requirements for the year in one go. www.propakwestafrica.com
LIVE DEMOS AT LABELEXPO EUROPE For the ﬁrst time at Labelexpo Europe (Brussels, 24-27 September), delegates will be able to witness two live press lines – one conventional and one digital – producing indirect food contact ﬂexible packaging to the latest GMP standards at a special feature Flexible Packaging Arena. www.labelexpo-europe.com 84
AUG / SEPT 2019
Inaugural Africa Wire, Cable & Tube Conference THE inaugural Africa Wire, Cable & Tube Conference will be held on 11-13 November at the Emperors Palace, Johannesburg, South Africa. Metallic wire, cable, tube and pipe products are crucial to industries that are key pillars of economic development across Africa; such as mining, power supply and construction. For the ﬁrst time, a conference is being held to bring together local stakeholders and international experts to discuss how to boost production and trade in these products throughout the continent. Co-organised by CRU and The Southern African-German Chamber of Commerce and Industry (AHK), and sponsored by Wire and Tube Düsseldorf, this unique partnership is the basis for creating an event in which the international wire, cable, tube and pipe supply chain will meet and make new trade partnerships with key African stakeholders. Discussions at the conference will explore the main trends impacting the global steel, copper and aluminium wire, cable and tube products and what this means for Africa. Delegates will also
be brought up-to-date on the expected consumption trends within Africa for these products in mining, utilities, oil and gas, construction and infrastructure. Attendees will gain insights into the current political and investment climates across the continent from local experts and international organisations with real case studies. Investors will also have the chance to assess greenﬁeld and brownﬁeld project showcase presentations. In other sessions, industry experts will discuss the latest global technological advances in wire, cable, tube and pipe manufacturing, and how this can be applied to African operations. • Visit http://bit.ly/CRUAWCTPR for more details and to book your place.
First sanitation in Jo’burg in Oct
THE Association of Mobile & Portable Sanitation Africa (AMPS Africa) will hold its ﬁrst conference, on 23 October at the Zulu Nyala Contry Manor in Fourways, Johannesburg. The theme of the conference will be ‘Growing our Industry’. A number of plastics and composites processing technologies are involved in the sanitation sector, including roto moulding, injection moulding and vacuum forming, according to AMPS Africa chairman, Gary Bolt, MD of Sanitation for Africa. The primary purpose of the initiative, according to Bolt, who was formerly at roto moulder Atlas Plastics in Klerksdorp, is to improve the perceptions regarding the sanitation industry. The Association of Mobile and Portable Sanitation Africa was only recently established by a group of people and businesses in the mobile and portable sanitation industry, to regulate the industry and bring about change. Its current involvement is to get a better understanding of the size and opportunities within the industry. It aims to invite subject matter experts to increase knowledge about the sanitation industry. Members include suppliers, manufacturers, distributers, importers, chemical suppliers, councils and the general public involved in the industry. Other chief objectives for the association include to: • be a point of reference for suppliers, manufacturers and councils; • improve corporate governance and the environmental
Local expo showcased SA’s manufacturing capabilities Over 3000 exhibitors from more than 60 countries
THE Local Southern African Manufacturing Expo (LME), held during May, received over 3 700 pre-registrations. Showcasing South Africa’s manufacturing capabilities across a range of industry sectors, the signiﬁcance of the inaugural expo was providing local manufacturers with an
opportunity to demonstrate their export potential. It also facilitated collaboration between the private and public sectors, while promoting and showcasing local manufacturing across all industry sectors. The biennial event will be held next from 25-27 May 2021 at the Johannesburg Expo Centre.
Dipti Kang and Demona Pillay proudly display the paint buckets incorporating a built-in paint tray, developed for Olympic Paints PHOTO’S by Lowrie Sharp
Pumeza Duru and Phumeza Ceshemba of Afriwaste Group, and Linda Lubengu from ECDC . AfriWaste strive to actively participate in the collection, sorting, washing, drying, bailing and pelletising scrap plastics. They deal with HDPE, LDPE and PP and are based in Fort Jackson
Gerhard Vermaerke and Geo De Matos of Envisoneers promoted their ‘Products of Imagination’ operation manufactured mainly from plastics
conference • • •
impact of our industry; implement standards and best practice guidelines for our industry; make available training standards and facilitators to members; protect and grow our industry including our network.
For more info about the conference and AMPS, email email@example.com The steering committee for the Association of Mobile & Portable Sanitation Africa’s (AMPS Africa) ﬁrst conference includes Gary Bolt, chairman of AMPS Africa and MD of Sanitation Africa, Marcel Malkic, Bev Miller, Lugelo Twalo and Gary Wiid of Pioneer Plastics
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• Official Distributor in Southern Africa for BASF
on TPU Elastollan® Thermoplastic Polyurethane
• Official Distributor in Southern Africa for Elastron on TPE, TPV Elastron® SEBS and EPDM/PP
• Official Distributor in Southern Africa for CGFSE on FSE® Fluoroelastomers and Perfluoroelastomers
• Distributor for Weifang on Weipren CPE • Suppliers of EPS, Various Grades • Engineering Polymers • Polyolefins • Reworked and Repaletised Materials • Official distributor for Politem on PA6, PA66 ®
unfilled and filled compounds
PLANS FOR OZPIPE XIX IN FULL SWING THE Plastic Pipes Conference Association’s spin-off event in Australasia, OzPipeE XIX, will showcase signiﬁcant developments in the ﬁeld of plastic pipe technology and industry. OzPipe XIX will be hosted late this year in Australia on 7-8 November at Dockside on Cockle Bay in Sydney. Zoran Davidovski, chair of the PPCA Organizing Committee comments: “OzPipe XIX is shaping up to be an exciting technical event on the Australasian calendar for 2019. The world market for plastic pipes continues to grow exponentially by volume and by application. Signiﬁcant technical and commercial developments are set to transform the global plastic pipe industry and these will have particular consequences for the Australasian region.” Speakers from the UK, USA, Belgium, China and Austria have already conﬁrmed their attendance. The conference and exhibition will be hosted by the Plastics Industry Pipe Association of Australia (PIPA). Main corporate sponsors are Rollepaal and Baerlocher. Rollepaal is one of the world’s leading suppliers of pipe extrusion equipment and Baerlocher is a global supplier of additives to the plastic pipe industry. www.pipa.com.au
POLYOLEFIN ADDITIVES RETURNS TO VIENNA FOR 12TH EDITION THE programme for the 12th edition of the Polyoleﬁn Additives conference, taking place from 12-14 November, at the Imperial Riding School Renaissance Hotel in Vienna, Austria, has been released. Polyoleﬁns lead the global plastics market in terms of production volumes and the diversity of their applications. The industry is not alone in feeling the pressure to create a circular economy and understand the changing regulations effecting their products. This three-day event is the leading event for senior executives in the polyoleﬁns industry to meet and discuss the technical and business issues impacting the growth and development of the industry. Featuring presentations from Graham Packaging, Borealis, Norner, Milliken and more … key industry topics, such as recycling and the circular economy are addressed through presentations and an interactive panel discussion. The event also looks to discover the new market trends and opportunities for growth in this vast market. Attendees can also learn how to enhance and optimise the performance of polyoleﬁns. www.ami.international
WEAR-RESISTANT PLASTICS 2019 The second edition of Wear-Resistant Plastics in Düsseldorf taking place from 12-13 December provides a unique forum to evaluate and debate the latest advancements in polymer tribology, and explore how they can open new applications, particularly in metal replacement. Industry experts will discuss innovative methods for optimising the wear and friction properties of plastics components, such as gears, bearings, conveyors wheels and seals. www.ami.international
Optical 3D metrology Passing on process and measurement technology knowledge
Peter Macrae (QA manager) from Volkswagen South Africa, spoke on how GOM equipment has sped-up and improved Volkswagen’s operation internationally
HellermannTyton’s Chantelle Phillips (tech projects manager) spoke about ‘Tooling in Plastics’ - discipline, design, quality
RGC Engineering hosted the highly successful ‘GOM Plastics Knowledge Days 2019’ in July, at the Plastics/ SA ofﬁces in Midrand – part of a global event that brings together specialists from the plastics industry and experts in optical metrology in a free one-day event. GOM sets international standards in optical 3D metrology, and with this international series of events, the GOM network passes on process and measurement technology knowledge to designers, model, mould and toolmakers as well as production and quality assurance experts. The Midrand event took the form of a plastic injection moulding workshop with RGC Engineering’s CEO, Aurelio Grech-Cumbo, welcoming delegates. The ‘knowledge tracks’ taught practical applications, such as the handling of GD&T and the use of optical measurement technology in toolmaking, an introduction to optical metrology, and digital assembly. Delegates were also able to hear presentations by Volkswagen South Africa’s, Peter Macrae (QA manager) on ‘Optical Measurement Strategy & Experience’; HellermannTyton’s Chantelle Phillips (tech projects manager) on ‘Tooling in Plastics’; RGC Engineering’s, Gerhard du Plooy (GOM application engineer) on ‘Prerequisites for Successful QA Control Industry 4.0–Injection Moulding’.
COMPOSITES EUROPE 2019 Digital process chain makes ﬁbre composites competitive
COMPOSITES Europe from 10-12 September will present the trends and advances in the production and processing of ﬁbre-reinforced plastics in Stuttgart. The trade fair will be accompanied by the International Composites Conference and the Lightweight Technologies Forum. Also held in parallel at the Messe Stuttgart premises will be Foam Expo Europe. Trade fair visitors will meet with over 300 exhibitors from 30 nations who will be displaying materials, technical solutions and innovative application examples in Stuttgart. Apart from novel products the trade fair will place special emphasis on innovative process engineering. Visitors will learn about the state of play in serial production and new applications in the composites industry in the exhibition area as well as on numerous special areas, on themed guided tours, at the accompanying International Composites Conference and at the Lightweight Technologies Forum, which is dedicated to the trends in multi-material lightweight construction.
Perfectly coordinated processing and manufacturing processes will be centre stage at the ‘Process live’ event. On shared exhibition space machinery and equipment manufacturers will exhibit their technologies in concert and – what’s more – in operation so as to show the different individual processes in a real context. 5th International Composites Conference (ICC) Serial production, stable processes, new markets – the International Composites Conference (ICC) is set to inject a fresh breeze for innovations into the market and to this end brings together processors and users of ﬁbre-reinforced plastics from all over Europe. For the ﬁrst time, this renowned Conference will be held in parallel with Composites Europe. The lecture programme put together by the trade association Composites Germany and the trade fair will also move closer in terms of content. One of tomorrow’s cross-cutting
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‘made simple’ at Knowledge Day Gerhard du Plooy (GOM application engineer) addressed delegates about ‘Prerequisites for Successful QA Control Industry 4.0–Injection Moulding’ and the latest GOM CT system PHOTO’S by Lowrie Sharp During the ‘meet the experts network Q&A’ session, Amos Makgoba gave delegates useful info about additive manufacturing with regards to material testing and failure
themes keeping the entire industry on its toes are multi-material solutions in nearly all industrial applications. In the construction sector the conference also deals with the rising use of carbon concrete. Process engineering will focus on processing thermoplastic materials for serial production and stable processes for thermoset plastic processing. Guided tours and hands-on demonstrations in the exhibition halls complement the conference programme. Themed guided tours revolving around composites application, materials and markets guide trade fair visitors and congress delegates right to the stands of
CHINAPLAS 2019 closed with tremendous success
CHINAPLAS 2019 attracted 3 622 exhibitors and 163 314 professional visitors from around the globe. Just a handful of the highlights included: High/low-dielectric constant modiﬁed plastics and other high-performance materials for future 5G communication; lightweight materials designed to enhance new energy vehicles and future travel solutions; along with ﬁbre-reinforced composite materials, graphenebased electrically conductive plastics, high-performance thermoplastic elastomers, additives to reduce unwanted VOC emissions and to change both the colour and brightness of ﬁnal products, plus liquid silicone and other high-tech materials. In the fair’s machinery exhibition area, digital smart manufacturing solutions showcased the implementation of various intelligent manufacturing options, while exhibitors also introduced a large number of high-performance, high-precision advanced equipment and a wealth of advanced moulding processes. Visitors also got to see cost-effective, high-quality, small-batch, diversiﬁed production processes, in-mould decorating techniques, as well as polyurethane (PU) in-mould coating and ﬂexible manufacturing technologies, multilayer injection moulding and co-extrusion technologies, and automated all-in-one machines, among other high-end sophisticated technologies. Chinaplas 2020 will return to Shanghai in the National Exhibition and Convention Centre (NECC), in Hongqiao, Shanghai, from 21-24 April 2020.
selected exhibitors, who will share with visitors their innovations in the ﬁelds of digitalisation of composites production, automotive manufacturing, building and construction, ﬁbreglass, new mobility, thermoplastic materials and wind power.
resource-efﬁcient manner. The forum in pools lightweight construction projects from automotive manufacturing, aviation and aerospace and mechanical engineering, to name but a few industries that serve as a driving force for many sectors with high demands made on materials, security and reliability. This year’s keynote speakers include Airbus Innovation Manager Peter Pirklbauer, lightweight construction expert Prof. Jörg Wellnitz (TU Ingolstadt), Dutch racing driver Jeroen Bleekemolen and lightweight construction, aviation and aerospace specialist Claus Georg Bayreuther (AMC). In their talks they will provide an overview of reference projects and novel manufacturing and joining technologies. The aerospace industry has always served as a pioneer for ultra-lightweight construction pushing many disciplines to their limits as a driver of innovation. The latest technical trends are currently under scrutiny via a market study carried out by consultancy Automotive Management Consulting (AMC) in cooperation with the Luxembourg-based aerospace OEM GRADEL. The results will be presented for the ﬁrst time at the LTF in Stuttgart on 10 September.
AUG / SEPT 2019 87
New ideas on special areas and joint stands “Material and Production Technology” is the name of the new special area set up, placing manufacturing technology centre stage at the trade fair. In particular, the special area will trace the path from scientiﬁc development to practical, industrial implementation. Tomorrow’s automotive experts will also be given a separate forum: under the heading “Formula Student” students and trainees will present to visitors racing cars and bikes they have engineered. The Lightweight Technologies Forum (LTF) held as part of Composites Europe makes it clear how lightweight construction can be achieved in an economical and
Diary KJELT VAN RIJSWIJK TO HOST ‘THINK COMPOSITES’ COURSE DR Kjelt van Rijswijk – now based at the Delft University of Technology (TU Delft) – will be in South Africa from 26-29 November to host the hugely useful ‘Think Composites’ course in Johannesburg and Port Elizabeth, where the presentation will coincide with the African Advanced Manufacturing and Composites Show. Clear your diaries and make travel plans – as all roads lead to Nelson Mandela Bay in November. Course attendees will get free access to the show. www.mandelabaycompositescluster.co.za
PACPROCESS MIDDLE EAST AFRICA 2019 PACPROCESS Middle East Africa 2019, the international exhibition for processing & packaging in the Middle East and Africa, takes place in Egypt, from 9-11 December at the Egypt International Exhibition Centre. The event addresses the requirements of the food, beverage, confectionery, bakery, pharmaceutical, cosmetics, non-food, and industrial goods sectors in the region. It brings together local and international industry stakeholders from across the entire value chain to highlight cutting-edge technologies and forge lucrative partnerships. Pacprocess 2019 features a specialised conference called ‘innovationparc’ that brings together international experts from the packaging business to address the latest innovations, technologies, and trends in this industry. The exhibition also presents the Save Food Initiative, which aims to reduce food waste by examining optimal solutions. www.pacprocess-mea.com
COMPLAST AT GALLAGHER IN MARCH 2020 THE Complast show, run by Smart Expos of India, returns to SA next year with the presentation of Complast South Africa from 3-5 March 2020 at Gallagher Estate in Midrand. Referred to as the ‘Complete Plastics Exhibition,’ this will be the third staging of increasingly popular event in the country. The previous editions were in November 2017 in Sandton and November 2018, also at Gallagher. A new feature of the 2020 show will be the concurrent WOPS – World of Products – event for ﬁnished, semi-ﬁnished products, including products made from recycled materials. Complast events have been held widely over the past few years, in nations where plastics shows have not been staged frequently, including in Kenya (six editions), Sri Lanka (ﬁve shows), Vietnam (three), Myanmar (ﬁve) and Nigeria (one show). “The size of the next Complast South Africa exhibition will be much bigger, with larger participation from India, China and other countries, including sizeable numbers from South-East Asia, Europe, the Middle East, Turkey and homeland South Africa,” a Smart Expos spokesman said. www.smartexpos.in 88
Guill shines at Interwire
INTERWIRE, the largest and longest-running wire and cable show, from 13-16 May at the World Congress Centre in Atlanta, USA, Guill Tooling & Engineering showcased its in-line 5-layer extrusion crosshead Series 800, singlepoint concentricity extrusion crosshead and Bullet II extrusion head (pictured here). Guill’s 800 Series is designed to produce the highest quality, highest material-efﬁcient OD tubing for automotive, medical, appliance and industrial applications. This series produces smooth extrusion and layer deﬁnition of ﬂuropolymer and other materials for all multi-layer, multilumen medical tubing, as well as fuel line constructions, multi-layer PEX pipe and drip irrigation applications. The single-point concentricity crosshead uses micro-ﬁne adjustment screws for precise concentricity.
Zerma at IFAT
ZERMA Africa participated in the recent IFAT Exhibition at Gallagher Estate in Midrand. IFAT is the world’s leading trade fair for refuse, recycling, water and sewage and provided a unique platform for Zerma to showcase their machinery for the size reduction of different materials in preparation for downstream recycling processes in the plastic, rubber, wood, paper and MSW sectors. Zerma Africa’s Chantal Shaw, ready to engage visitors with a smile, is seen here with a cuttingchamber from one of Zerma’s heavyduty GSH series granulators.
www.zerma.co.za 2019 ICCM22 11-16 Aug Melbourne, Australia firstname.lastname@example.org KZN Manufacturing Indaba 2019 14-15 Aug ICC, Durban www.manufacturingindaba.co.za SAPPMA Pipes XII 27-28 Aug Altron Business Park, Midrand www.sappma.co.za ACIC 2019 3-5 Sept University of Birmingham, UK email@example.com Masterbatch 2019 10-12 Sept Vienna, Austria www.ami.international/events Composites Europe 10-12 Sept Messe Stuttgart, Germany www.composites-europe.com ARMO Global (hosted by ARMSA) 16-18 Sept Sun City www.armsa.co.za EMO Hannover 16-21 Sept Hannover, Germany www.emo-hannover.de Propak West Africa 17-19 Sept Landmark Centre, Lagos, Nigeria www.propakwestafrica.com RubberTech China 2019 18-20 Sept Shanghai New Int’l Expo Centre www.rubbertech-expo.com
Label Expo Europe Brussels, Belgium
24-27 Sept www.labelexpo-europe.com
FachPack 2019 Nuremberg, Germany
25 Sept www.fachpack.de
EFIBCA Open Meeting Amsterdam, Holland
15 Oct www.eﬁbca.com
K2019 Düsseldorf, Germany Sanitation for Africa Johannesburg
16-23 Oct www.k-online.com 23 Oct www.sanitationforafrica.co.za
IPSA Gold Pack Awards Inanda Club, Sandton
30 Oct www.goldpack.org.za
SAPRO Recycled Product of Year 6 Nov Johannesburg www.plasticrecyclingsa.co.za OzPipe XIX Sydney, Australia
7-8 Nov www.pipa.com.au
Africa Wire, Cable & Tube Conference 11-13 Nov Emperors Palace, Kempton Park www.crugroup.com/events Polyoleﬁn Additives Vienna, Austria PPS Europe-Africa CSIR Convention Centre, Pretoria
12-14 Nov www.ami.international 16-21 Nov www.pps2019.com
AUG / SEPT 2019
Domo’s PAs with post-production scrap for auto, aerospace applications WITH a focus on the use of composites and new materials in the aeronautic and automotive sectors, Domo Engineering Plastics presented its portfolio of Econamid® polyamides based on valuable post-production feedstock at the Aerocar show in Spain in July. The Econamid Air range of carbon ﬁbre-reinforced PA6, PA66 and PA66/6 compounds provides enhanced sustainability and comparable performance over conventional virgin countertypes materials .With a carbon ﬁbre content of up to 50%, Electrical component housing Econamid Air combines outstanding stiffness with low density moulded in Econamid Air PA66/6 for a wide range of cost-effective and lightweighting designs in for superior con-ductivity, low demanding application areas, including automotive, industrial density and high ﬂame retardancy in and sports uses. line with VW TL 1011 (class V0) • Domo is represented by Chemipol Solutions www. www.domochemicals.com starlinger.com
Starlinger: New sack collection for woven plastic fabric The new Starlinger sack collection: AD*STAR *ultra, IC*STAR *liner and AD*STAR *easy, which Starlinger presented at the textile machinery exhibition ITMA 2019 in Barcelona. Now customers can choose from an even broader and more individual product range on Starlinger machinery: from an automatically inserted PE ﬁlm liner and an easy-open feature up to ultra-light sacks. With its patented easy-open feature, the AD*STAR *easy, this new feature allows for quick and easy emptying without the use of mechanical tools: The new easy-open feature is available on the Starlinger sack conversion line ad*starKON HX, which covers a sack capacity from 5 litres up to 100 litres.
TPU insoles and more
AUG / SEPT 2019
PORCHER Sport unveiled new thermoplastic insoles for customised footwear at Outdoor by ISPO 2019 in Munich at the end of June. Porcher Sport’s thermoplastic insoles are thermoformable at 80ºC and become extremely pliable when immersed in boiling water to form to the shape of the shoe it’s being used in. The thin and lightweight product offers advanced comfort and cushioning.
www.porcher-ind.com Polymers in Footwear Conference Soﬁtel Hotel Kurfürstendamm, Berlin, Germany
19-20 Nov www.ami.international
Think Composites (training course) 26-29 Nov Johannesburg & Port Elizabeth www.mandelabaycompositescluster.co.za African Adv Manf & Comp Nelson Mandela Bay Stadium, PE
27-29 Nov www.mandelabaycompositescluster.co.za
pacprocess Middle East Africa 2019 Egypt
9-11 Dec www.pacprocess-mea.com 2020
Complast South Africa Gallagher Estate, Johannesburg Plastics Regulations Cologne, Germany
11-12 Marh www.ami.international/events
Machine Tools Africa 2020 Expo Centre, Nasrec, Johannesburg
12-15 May www.machinetoolsafrica.co.za
Electra Mining Africa 2020 Expo Centre, Nasrec, Johannesburg
7-11 Sept www.electramining.co.za
OzPipe XIX Hotel Okura, Amsterdam, Holland IMPC 2020 Cape Town
3-5 Mar www.smartexpos.in
21-23 Sept www.pipa.com.au 18-22 Oct www.impc2020.com
Masterbatch industry shows solid growth globally
THE masterbatch industry is showing strong growth on the back of growing polymer demand and its ability to replace alternative methods of polymer modiﬁcation, according to an The global market for thermoplastic authoritative new report just published by leading industry masterbatch 2019. Startlingly, Asia consultants in the ﬁeld, AMI Consulting, Thermoplastic accounts for 46% of global Masterbatch – The Global Market 2019. demand; Africa falls The global masterbatch industry continues to outperform under ‘Other’ Largest 10 both GDP and polymer demand growth with all regions global producers many of these companies are active of the world and all product types beneﬁting from these in packaging applications (almost trends. The result will be a growth rate in excess of 5% account for two-thirds of colour masterbatch per annum for the medium term. around one-third demand) there will be challenges These ﬁndings are the bedrock of the new analysis as the ‘circular economy’ debate of masterbatch just produced by AMI. Building on an unequalled inﬂuences the market in all the corners experience derived from over 30 years of investigating industry of the world. this global market, the report details not just supply and The market is intrinsically linked to the demand but also comments on the changing nature of size, growth and relative maturity of demand the industry structure. The emergence of global players for polymers around the world. Thus China, as the world’s combined with the active role played by private equity are largest consumer of polymer, is also the largest individual driving a revised business structure in all markets. Currently country market and in total Asia accounted for46% of the largest 10 global producers of masterbatch account global masterbatch demand 2018, compared with 26% in for around one-third of the industry, given the pace of this the Americas and 18% in Europe. The markets of Asia will change in the world this share is forecast to accelerate in the continue to be key drivers for the masterbatch industry going medium-term future. forward driven by the markets of China and India. However, grasping the opportunity is not easy. Growing Thermoplastic Masterbatch – The Global Market 2019 competitive intensity, raw material supply and pricing volatility, provides current and forecast information and is intended increased speciﬁcations and heightened customer service to support the strategic decisions that are required of requirements all demand that participants think carefully participants to ensure they keep abreast of developments about the sectors that they engage in. It is already clear that within this fast-changing industry. It will assist in anticipating missteps are costly to company development and proﬁtability. change, formulating strategies, directing R&D investment, The report quantiﬁes, in detail, masterbatch demand for and proactively managing threats and opportunities. each world region according to masterbatch type (black, AMI Consulting has published several multi-client studies in white, colour and additive) as well as providing an analysis of the Masterbatch ﬁeld including individual very detailed reports the industry’s supply structure and up-to-date information on on each geographic region of the world. the end use application demand for each variety. It is clear • For further information, contact Andrew Reynolds at that the over 130,000 injection moulders in the world account firstname.lastname@example.org for the largest customer group for masterbatch, however, as www.ami.international
AUG / SEPT 2019
Impact of tethered cap regulations SUSTAINABILITY is the key driver in the European plastic caps and closures industry; the three pillars of sustainability, whereby environmental gains are commercially viable and socially accepted, have so far supported market development initiatives. The current regulatory context concerning the single use plastics directive shifts the pillars, creating uncertainty in the value chain. A new report from industry consultants, AMI Consulting, contextualises the new industry challenges and quantiﬁes the impact of the changing regulations over demand.
The European closures industry has been proactive for well over a decade to reduce the use of virgin material in both neck ﬁnish and closures. Lightweighting has been the most important driver of change. The last industry step-change within beverage closures was the shift towards 1-piece beverages caps and away from 2-piece caps, coinciding with the adoption of the PCO1881 bottle neck standard. Concomitant with raw material reduction are savings in energy, lower CO2 emissions in logistics and consequently - cost savings. Now the focus of the European sustainability agenda is single use plastics (SUP), which includes the handling of caps in a circular economy and promoting anti-
littering solutions. Because of the single use plastics directive drafted in 2018 (2018/0172 COD), of which Article 6 dictates a new norm to enforce closures to be connected/tethered with the bottle, has been voted in by the European Parliament in March 2019. The European plastic caps & closures industry is about to undergo another major step-change. The tethered cap regulation will affect plastic beverage bottles under 3-litres, including composite containers (i.e. carton). By 2024, all beverage closures will have to be tethered by law. The industry needs to work collectively to reduce the economic impact of the coming step-change and search for value creating opportunities to maximise the gains – environmental, commercial and consumer focussed. www.ami.international
All assets and property included
Due to retirement, our client is selling the operational business manufacturing plastic injection and blow moulded products. To be sold as a going concern, features of the Johannesburg-based converting operation include:
• Established for over 33 years, the business also conducts secondary processes in-house;
• Good relations with customers built up over this period, consistent client base and leverage;
• Company conducts its own in-house tooling, tool room and printing; • Long-serving, skilled and reliable team from management to sales, technical to production operators; • Company has maintained capex investment over the years and all machines are well maintained and fully operational; • Sales are well established, products are generic and custom-
• • • • •
made under own brand names and white label; Scope to diversify business into other sectors Company has 3rd party accreditation and validation for a variety of customers; Company works 5 day week with some shifts but has potential of working 24/ 7 Company has its own land and buildings and there is room to acquire adjacent land and buildings; All assets as well as the buildings and property (7,000m²) are for sale;
Next step and contact details
Potential investors interested in receiving further information should contact PREA Ltd in total conﬁdence, which has the global exclusivity in selling this business: Pravin S Mistry, Global CEO PREA Ltd, Manchester, UK; Tel +44 161 207 8007, mobile +44 7810 882 339; email@example.com . We are available 7 days a week.
Prea is a global manufacturing consultancy focussing on:
• Mergers & Acquisitions • Joint Ventures • Buying and Selling companies • Investment & Private Equity Funding • • Recruitment • Plastics, Composites, Rubber, Chemical Technical Consultancy • • Chairman Guidance / Non-Executive Directorship •
To place a classiﬁed advert please
Injection moulding machines, and household moulds For details contact
Fax: 086 519 6089 or Tel: 021 712 1408 or Email: firstname.lastname@example.org
THERMOFORMING, SHEET EXTRUSION, AND MATERIALS THERMOFORMING TECHNOLOGY
SAVE 90% of your electricity use with GN! • GN (Canada): machines for reduced waste and reduced energy • Thermoforming Moulds for GN and other thermoformers • ToolVu technology for productivity and NEW quality improvement on thermoforming machines • Complete lines for EPS foam trays and EPS cup moulding NEW
For sale: Johannesburg Plastic injection/blow moulding business
EXTRUSION TECHNOLOGY FROM AGRIPAK OF ITALY Mono & multi-layer extrusion lines for the production of: • ‘Cartonplast’ (twinwall/hollow profile sheet) • Multilayer sheet for packaging • Semi-foamed sheet for thermoforming Technical Drawing
MATERIALS FOR THERMOFORMED PACKAGING
• Sealing films for trays and top web for FFS machines • OPS, PP, PET sheet for general packaging • PP/EVOH/PP for high barrier containers
BRE INNOVATIONS Contact: Tim Forshaw (083 381 5253) or Phil Hopkinson (083 408 5253) or 021 671 5253 or mail to email@example.com Blade Sharpening
INDUSTRIAL BLADE SPECIALISTS BRANCHES: KZN, GAUTENG & WESTERN CAPE
Contact: Brett Allan - 083 2844 873
Contact: 011 894 3520 or firstname.lastname@example.org www.jcl.co.za
LUMPS - OFF-CUTS - REJECTS - OFF SPEC - REDUNDANT - EXPIRED - TRIMMINGS SKELETAL - TOPS/TAILS Contact: 011 894 3520 or email@example.com www.jcl.co.za
Classifieds Aug/Sept'19.indd 91
51 35 IFC 09 81 13 59 85 89 29 24 83 71 31 03 43 19 01 47 23 25 61
Meraxis Messe Dusseldorf MGMW Trading Nissei ASB Orion Engineered Carbons PacProcess Performance Colour Systems Plastic & Chemical Trading Plastics/SA Plastomark Rawmac Relloy Relloy – EREMA Safripol SAPY Colours SAVA Skyland Masterbatch & Polymers Taigan M-Stretch West African Group Zerma Africa
15 37 67 39 11 84 65 17 49 53,55 75 69 41 05 IBC 30 22 21 27 OBC
AUG / SEPT 2019 91
WE BUY PRODUCTION WASTE
LUMPS – OFF-CUTS - REJECTS - OFF SPEC - REDUNDANT - EXPIRED T - ITRIMMINGS WE BUY PRODUC ON SKELETAL - TOPS/TAILSWASTE
Advertisers: – August / September 2019 ACD RotoFlo BMS Brenntag SA Cabletech Marketing Carst & Walker CTP Flexibles DemaPlastech DH Polymers Eder Design ‘Bunting’ ExxonMobil FdB Consulting FdB Consulting (Labotek) FdB Consulting (Rapid Granulator) Ferro South Africa GPS Plastics GreenTech Machinery Habitat Industries Hestico Inkulu Plastic Pipes Ipex Machinery Jenowill Masterbatch SA
Covestro offers ﬂameretardant and optimised plastics for electromobility – including electric surfboards
Riding the waves with
electric surfboards PC+ABS blend makes batteries safe, durable and waterproof ELECTROMOBILITY is on the rise around the world. With a wide range of ﬂame-retardant PC + ABS blends, Covestro provides optimal materials for this ﬁeld of application; for instance, for the production of injection-moulded battery casings. This can be seen in exciting leisure products, such as Onean electric surfboards from the Bilbao-based Aquilaboards. The boards come with a plug & play battery, which can be replaced after a charging time of just 2.5 hours. The impact-resistant, durable and ﬂame-retardant casings are all made of Bayblend FR3010, a high-performance PC+ABS blend from Covestro. The unreinforced injection mould type features improved heat resistance (Vicat/B 120 = 110°C), phenomenal impact resistance and outstanding stress cracking behaviour. At a wall thickness of 1.5mm, Bayblend FR3010 achieves the category UL 94 V-0 in the ﬂame retardance test of the Underwriters Laboratories, and Class V-1 at 1.2mm. The blend’s high resistance to 92 AUGUST / SEPTEMBER 2019
chemicals is another advantage; for example, in contact with sunscreen and insect repellents. The ﬂame retardant systems in Bayblend FR3010 are compatible with the requirements of various environmental seals of approval, such as the Blue Angel (Germany) or the TCO label,
which identiﬁes materials that are designed for recycling.
SAPY Advert 2018.indd 86
The Home of Size Reduction
Classifieds Feb/Mar'18.indd 92
SA Polymer Technology (previously SA Plastics, Composites & Rubber) magazine launched in 2002 by Summit Publishing based in Cape Town and ow...
Published on Aug 7, 2019
SA Polymer Technology (previously SA Plastics, Composites & Rubber) magazine launched in 2002 by Summit Publishing based in Cape Town and ow...